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WP-5012-005-00 DC Troubleshooting Manual - Off

1. WHISPERG EN Personal Power Station Model PPS16 12MD and Model PPS16 24MD Part Number WP 5012 005 00 For Authorised Personnel Only Whisper Tech reserves the right to revise or change product specifications at any time This publication describes the state of this product at the time of its publication and may not reflect the product at all times in the future Patents granted and pending worldwide Whisper Tech WhisperGen Personal Power Station and WhisperGen Personal Power Station are registered trademarks of Whisper Tech Limited Title Part No Application Troubleshooting Manual Models PPS16 12MD PPS16 24MD WP 5012 005 00 WhisperGen PPS16 12MD Diesel fired 12 V DC output Marine WhisperGen PPS16 24MD Diesel fired 24 V DC output Marine WhisperGen is designed and manufactured by Whisper Tech 224 Armagh St P O Box 13 705 Christchurch New Zealand www whispergen com Copyright 2005 Whisper Tech Limited All Rights Reserved Printed in New Zealand Conditions of use Read this manual completely before commissioning the WhisperGen The WhisperGen must be commissioned only by an authorised WhisperGen representative Whisper Tech accepts no liability for personal injury or property damage resulting from incorrect or unauthorised installation commissioning and servicing of the WhisperGen Unapproved installations may be dangerous result in poor pe
2. 67 Stop Button Non Warning or Non Fault Code Problems Stop Button Possible Causes Possible Fixes Whenever the stop button is pushed and the WhisperGen goes into Standby it tries to start again The WhisperGen is receiving a signal from other than the start button telling it to start This signal could be an Auto charge start signal or an Ext Control start signal If you don t want the WhisperGen to try and start again then either turn the Auto charge and the Ext Control function off in the User Menu or set Enable Starts in the Installation Menu to 0 or 1 68 Non Warning or Non Fault Code Problems Control panel LED s Control panel LED s The LED s on the control panel are flashing 1 The Enable Starts function in the Installation Menu is switch to 0 or 1 to Possible Causes prevent the WhisperGen starting to enable maintenance to be carried out 1 Ensure that it is safe for the WhisperGen to start and then Set Possible Fixes Enable Starts to 1 or 2 69 No automatic start Non Warning or Non Fault Code Problems No automatic start Possible Causes Possible Fixes The WhisperGen will not automatically start and charge the battery when it is discharged The Auto charge function in the User Menu has not been turned on The battery parameters have not been set correctly in the hidden Service Menu The battery current shunt in the negative battery cable has been wired inc
3. Non Warning or Non Fault Code Problems Battery not fully charging Battery not fully charging Possible Causes Possible Fixes The battery is not getting fully charged When Auto charge is turned on the battery goes flat before the WhisperGen starts The battery voltage sense wires are not connected to the battery terminals The battery parameters have not been set correctly in the hidden Service Menu The battery current shunt in the negative battery cable has been wired incorrectly The load on the battery and the WhisperGen is greater than the output of the WhisperGen Ensure that the battery voltage sense wires are connected to the battery terminals and not anywhere else Ensure that the battery parameters are correctly set Ensure that the battery current shunt is correctly wire into the battery cable Reduce the load on the system 73 No automatic stop Non Warning or Non Fault Code Problems No automatic stop WhisperGen starts automatically but will not stop a by itself 1 The battery is very flat or the load on the battery and the Possible Causes WhisperGen is so high that the battery is only being charged very slowly 2 Heat Manage is turned on and Max Run Hours is set to 25 1 Reduce the load on the system Possible Fixes 2 Turn Heat Manage off or set the Max Run Hours to less than 25 74 Non Warning or Non Fault Code Problems Exhaust howling noise Exhaust how
4. Warning Codes numbered from 102 to 199 Warning Codes numbered from 102 to 199 One Warning is shown per page in the following format The Warning number and message displayed The definition of the Warning as the WhisperGen microprocessor sees it During which Mode this Warning can be produced A further clarification of the Warning condition if needed Possible causes of the Warning Possible ways to fix the cause of the Warning All Warnings are conditions that are registered by the WhisperGen microprocessor and are described in this section as is the action to take to correct the Warning The possible causes of the Warning s are listed in order of likelihood All variables used by the WhisperGen microprocessor are written spelt as they are in the variable screen of Micromon 11 102 Texhaust Warning Codes numbered from 102 to 199 102 Texhaust Possible Causes Possible Fixes Texhaust has been greater than ExhaustAlarm 15 for at least 1 second Warning occurs anytime during engine operation Although the WhisperGen microprocessor will always try and keep Texhaust below the ExhaustSetpt under certain abnormal conditions it will not be able to back the burner fan off fast enough to stop the exhaust temperature reaching the alarm level The ExhaustAlarm is currently set at 545 C giving a warning at 530 C 1 Low nitrogen gas pressure 2 Oxygen sensor reading may have drifted giving a very
5. 2 The exhaust pipe is blocked and fresh air cannot flow through the exhaust system when the fan is on at low speed 3 The oxygen sensor has failed 1 Turn on the air bleed function in the installation menu to try and dry out any diesel Also remove the oxygen sensor and place in fresh air while still plugged in caution the end gets to about 250 degree s Celsius While the WhisperGen is powered up with any of the bleed functions the oxygen sensor will also be turned on Check the oxygen sensor reading after being in the fresh air for at least 5 minute to see if it is within limits If it is not then replace it 2 Check that there is air flowing through the exhaust system during the heat up period If there is no airflow then remove the obstruction Also check that the fan is operating during the heat up period 3 Remove the oxygen sensor and place in fresh air while still plugged in caution the end gets to about 250 degree s Celsius Power up the WhisperGen and the oxygen sensor by turning on the coolant 1 bleed function Check the oxygen sensor reading after being in the fresh air for at least 5 minute to see if it is within limits If it is not then replace it 47 58 Ignition failure Fault Codes numbered from 2 to 99 58 Ignition failure Possible Causes The FlDcurrent has not been above 0 125 for 10 consecutive second s 2 minutes after the fuel was first turned on Fault occurs during Flame detect Mode
6. it 2 9 gt 3 4 71 Bu J aA a a i BR dxaz E 3333 te BK RD 1234 E m si GN 16 r gt 71 82 ENGINE CONTROL PCB p BK 9 191 RD 65432 J3 gt J EEEE PHASE 1 BKO 91 EA PHASE 7 BKO 07 ala PHASE 3 BK 6 93 ps 2 PREE y gt BK 5 Spal od dea BUO pwM AUX gq 199 IND pw O aux qaqa RD gt gt gt Es a Se SI 3333 009 DAW OXYGEN SENSOR OWER MODULE PCB 1 718K BATTERY BU 2 Bu len BK BATTERY SLANE 3 LBK BLOCK TEMP RK Bo camp vi BLOck TEMP y 5 Lan EXHAUST TEMP i BK 7 a o g WH EXHAUST TEMP pe BATTERY E gt CHASSIS daaa T py RD_ FUEL POWER TO THERMAL Sw 2333 2 BN FUEL POWER FROM THERMAL sw Eee 45 5 OR FUEL SHUTOFF sass lt lt 7 GLOWPLUG 559433 Bk FUEL SHUTOFF 333353 aw J z uw 1 253885 N Jel ar PK A 123456 3 GLOWPLUG i N BO BATTERY O Pe ef 3 3 z f 5 0 S g H A 3 3 2 BUS He a a Ly Ss 3 2 3 ES a 3 3 3 i EXHAUST HX F 4 4 THERMAL a gt A o A ol FUSE p 1 m N m FLOW aS af I i oes BLOCK INTERNAL SHUTOFF TEMPERATURE EXHAUST HX DL AMBIENT 1 T SOLENOID SWITCH 95 C THERMAL gpeg amec THERMAL SWITCH T WATER FLAME CYLINDER K TYPE VALVE A s AWITEH FLAW SWITEH IONISATION BLOCK EXHAUST 0 DETECTOR TEMP THERMOCOUPLE d al 3 3 IFIDI SENSOR lt gt MAIN LOOM CONDUIT 77 www whispergen com
7. 1 6 7 The secondary coolant pump is not pumping enough water maybe because the intake or circuit is blocked or partially obstructed or it maybe air locked The secondary coolant water intake is not submerged The secondary coolant pump has not primed after the intake was out of the water The primary or secondary coolant sides of the marine heat exchanger are partially or fully obstructed Note that both the primary and secondary sides of the marine heat exchanger can be 2 3rds blocked but still have a large amount of coolant flowing through them This is because there are 3 parallel paths through the marine heat exchanger for both the primary and secondary coolant and two of them could be blocked The wires to the primary or secondary coolant pump are broken or disconnected The secondary coolant intake water is above 40 C Faulty temperature sensor The above may apply along with 8 9 10 11 1 11 The radiator air passages are blocked The fan is not working The fan and or radiator is too small The ambient air temperature is above 40 C Check the flow rate through the secondary coolant circuit It should be greater than 4 liters per minute Make sure that the inlet is submerged when the error occurs Make sure that the pump is self priming or that any air that collects in the intake to the pump can escape If the flow rate through both the primary greater than 4 liters per minute and the
8. a cooler location 4 Replace the battery 5 Reduce charging rate It is unlikely that the WhisperGen charging the battery by its self could charge it at to higher rate 6 Reduce the discharge rate of the battery 62 Fault Codes numbered from 2 to 99 84 Clamp failed Off 84 Clamp failed Off Possible causes Possible Fixes Vbus is greater than Vclamp 0 35 for 12 V WhisperGen s and Vclamp 0 7 for 24 V WhisperGen s for more than 25 consecutive seconds Fault occurs during BULK Mode 2 1 Failure of the clamp element open circuit Connection problem between the clamp element and electronics board loose wire Electronic failure Replace clamp element Check wiring and repair defects Replace electronics 63 85 High batt volts Fault Codes numbered from 2 to 99 85 High batt volts Vbattery is greater than temperature compensated Absorb voltage 0 5 for 12V WhisperGen s for more than 5 seconds and Vbattery is greater than temperature compensated Absorb voltage 1 0 for 24V WhisperGen Ys for more than 5 seconds Fault occurs at any time during engine operation Mode 2 or higher 1 Low electrical load high heat load and high engine power leading to Possible causes clamp trying to dissipate more power than is possible for it leading to battery voltage rise 2 Electronic fault 1 Add electrical load or change engine settings Possible fixes 2 Repl
9. burner is burning well but there is no FID Possible Fixes reading then remove the FID and check its height setting Also check the continuity of the FID wire back to the electronics and that it is not shorting to earth Also check that the FID is not shorting through to earth because of a carbon build up on its end 2 See 58 Ignition failure 50 Fault Codes numbered from 2 to 99 60 Flame failure 60 Flame failure The FlDcurrent has been less than 0 2 for more than 10 consecutive seconds Fault occurs during Heatup Mode 3 9 1 The FID is set too high or too low Possible causes 2 See 58 Ignition failure 1 If you can hear that the burner is burning well but there is no FID Possible fixes reading then remove the FID and check its height setting Also check the continuity of the FID wire back to the electronics and that it is not shorting to earth Also check that the FID is not shorting through to earth because of a carbon build up on its end 2 See 58 Ignition failure 51 61 Flame failure Fault Codes numbered from 2 to 99 61 Flame failure The FlDcurrent has been less than 0 4 for more than 10 consecutive seconds Fault occurs during CRANK Mode 4 1 The FID is set too high or too low Possible Causes 2 See 58 Ignition failure 1 If you can hear that the burner is burning well but there is no FID Possible Fixes reading then remove the FID and check its height setting Also check th
10. charge function 2 Reduce the electrical load if the WhisperGen is never going to keep up and the batteries are just going to go flat or start up another battery charger 3 Start WhisperGen and or another battery charger 20 Fault Codes numbered from 2 to 99 Fault Codes numbered from 2 to 99 One Fault is shown per page in the following format The Fault number and the message displayed on the WhisperGen control panel The definition of the Fault as the WhisperGen microprocessor sees it During what Mode this Fault can be produced A further clarification of the Fault condition if needed Possible causes of the Fault Possible ways to fix the cause of the Fault All Faults are conditions that are registered by the WhisperGen microprocessor and are described in this section as is the action to take to correct the Fault The possible causes of the Fault s are listed in order of likelihood All variables used by the WhisperGen microprocessor are written spelt as they are in the variable screen of Micromon and are shown in Italics Note that in a lot of cases a loose wire to a sensor may be the cause of a fault and the wiring in all cases should be considered as a possible cause of the fault Most alarm conditions have to be present for at least 5 seconds before they register as alarms and cause engine shutdown Exceptions are some checks made at a specific point in the startup sequenc
11. electronics 60 Fault Codes numbered from 2 to 99 82 Excess volt drop 82 Excess volt drop Vdrop voltage drop between WhisperGen and battery is greater than 2V for more than 5 seconds Fault occurs during any time during charging Mode 2 or higher 1 Very high resistance in the battery cables from the WhisperGen to Possible Causes the battery poor connections or battery cables too thin or too long 2 Faulty battery voltage sensing 1 Check for battery cable connections switches fuses for poor Possible Fixes connections Also check battery cable size is large enough 2 Check battery voltage sensing wire to WhisperGen or replace electronics 61 83 Battery overtemp Fault Codes numbered from 2 to 99 83 Battery overtemp Possible causes Possible fixes Tbattery is greater than 55 for more than 5 seconds Fault occurs at any time during engine operation Mode 2 or higher 1 The battery temperature sensor is faulty 2 The battery is hotter than 55 degrees Celsius 3 The battery is located in a place with a very high ambient temperature and is over heating 4 There is an internal fault in the battery 5 The battery is being charged at to higher rate 6 The battery is being discharged at to higher rate 1 Replace the battery temperature sensor 2 Reduce the temperature of the battery 3 Provide some form of cooling to the area that the battery is located or place the battery in
12. ic a DI EHER ee 51 61 Flame tall ica aa 52 62 Flame Talle tit da a tii 53 04 HeatuptalUrO iii ido 54 66 Crank fallecida nn HIN ii dain 55 68 Engine Sluggish ci ie a 56 12 Drive bridge Tall aiii ranas 57 FA LOW CNGING POWER Agente ade ei ER TERRA 58 OFA INAO EEA A einer iia gs 59 80 Clamp failed Oni iii A dee ar A a ee a sariari 60 82 Excess volt Aa o PEE EEE E Rd este de dee ena eee eect aardehe dernier ele 61 83 Battery Over Mica oli iia 62 84 Glamptaled iia ici 63 S5 High Datt Mo iia a oe Seaview 64 90 Clamp control liura a Ei ae a 65 92 ParGhg Vito0 high a a 66 Non Warning or Non Fault Code Problems cccseceseeseeeeeseesseeeeeeeeeneneesseeeaseeeseeaeaseesaeeesaseasseeesaseaeneaeaseeseeeeaseeeeeneenes 67 TEMPS e a denis aaiaehs T A fase caaeiata len AAT 67 Stop Buttons ay tiie ad e 68 Gontrolipanel EED S 4 u mn ati alada 69 No automalic Start su see n 70 NORSE IKAN oo 1 10 NOPEEEPRRRPERFFRLFPETFFERRELEPTELFERFFEFRBERSFETLERTREFERTRERSELEERTEPEPRFPEEFFEFTERERETEFFLEETTETEFETFFIFERTELFERFETFESFLERTELFERFERFFFFFTER 71 NN 72 Battery not f lly charging 2 2 2822 ee A lt ce oe 73 No AUtO0MatiC S OP Cinta ee en eee lad 74 Exhaust howling noise ici dol 75 Wiring Diagram for PSS16 12MD PSS16 24MD neuuunsnssnannnnannnnannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 76 Introduction Introduction Whisper Tech Ltd reserves the right to revise and improve it
13. is no fuel in the burner before the fuel pump is turned on 2 Check the FID current reading while the glow plug is on and is pre heating the burner before the fuel is turned on The actual FID reading should be between 0 00 and 0 05 If it is dancing around and is sometimes above 0 05 then it is likely receiving interference from something Check electrical and electronic equipment in the area such as a radio transmitter and turn off if necessary 3 Check the FID current reading while the glow plug is on and is pre heating the burner before the fuel is turned on If there is a constant reading above 0 05 then it is likely that there is a fault with the electronic circuit and if this condition can be repeated then the electronics module should be replaced 46 Fault Codes numbered from 2 to 99 56 O2 sensor fail 56 O2 sensor fail Possible Causes Possible Fixes O2value is not between 1300 and 2500 for more than 1 second Fault occurs during No flame check Mode 3 5 The fresh air reading of the oxygen sensor is outside the above limits During the pre heat period when the glow plug is on the burner fan is also on ata low speed blowing fresh air through the burner and over the oxygen sensor Just before the fuel is turned on the oxygen sensor is checked and calibrated 1 There is a built up of fuel in the burner from previous failed starts and this is causing an out of limits reading when the oxygen sensor is checked
14. of the 4 microprocessor independent thermal cut out switches that are used to cut off the fuel supply by disconnecting the electrical supply to the fuel pump should an over temperature situation occur Fan Tacho The Fan tacho measures the speed of the burner fan The fan tacho is used by the microprocessor to determine that the burner fan is rotating Battery temperature sensor The Battery temperature sensor measures the battery temperature to compensate the absorption voltage with regard to temperature when the battery is being charged Battery current shunt The current shunt measures the current going into and coming out of the battery This measurement is used to keep track of the state of charge of the battery Controlled Components Controlled Components 1 Burner Fan 2 Fuel Pump 3 Flushing Valve 4 Primary Coolant Pump The burner fan is a Pulse Width Modulation PWM speed controlled fan Its speed of operation is controlled by the WhisperGen microprocessor When the WhisperGen is required to produce more power the speed of the burner fan is increased If the WhisperGen Mis required to produce less power or the exhaust temperature is going to exceed the exhaust temperature set point then the speed of the burner fan is decreased Normal operation range is 10 to 100 as required to meet the above conditions The fuel pump is a piston solenoid type positive displacement pump Its speed of operation is co
15. rich mixture 3 Faulty exhaust temperature sensor 4 The top burner ceramic rope is leaking 1 Top up with nitrogen gas to the recommended filling pressure for that series of WhisperGen 2 Check oxygen sensor fresh air reading and if below 1300 or above 2500 then replace If fresh air reading nitrogen gas pressure and exhaust temperature sensor are ok and problem still exists then replace any way After the WhisperGen has been running for at least 20 minutes and if you have a combustion analyzer then check that the excess air reading is around 9 5 O2 This is equivalent to an 80 10 excess air reading The mixture can be adjusted to a limited extent by adjusting the O2Runfact in the hidden menu on the control panel A smaller number makes the mixture richer 3 Replace exhaust sensor 4 Remove the burner and check the seal Note that any time the burner is removed the top burner ceramic rope seal must be replaced 12 Warning Codes numbered from 102 to 199 104 Tblock 104 Tblock Possible Causes Air cooled systems Possible Causes Possible Fixes Air cooled systems Possible Fixes Tblock has been greater than BlockAlarm 3 for more than 1 second Warning occurs anytime during engine operation Tblock is actually the temperature of the coolant measured just after it exits the engine block and before it enters the exhaust cooler The BlockAlarm is currently set at 84 C giving a Warning at 81 C
16. secondary are sufficient then remove the marine plate heat exchanger from inside the WhisperGen and disassemble and check for blockage Check wires for continuity and or voltage Make sure that the secondary coolant outlet is not feeding back into the inlet Replace coolant temperature sensor Clean air passages Make sure that the fan has power to it and that it working order Make sure that the fan and radiator combination are rated to transfer 6 Kw of heat into the air with a coolant temperature of 70 C and an air temperature of 40 C If running the WhisperGen in ambient air temperatures greater than 40 C then a larger fan and radiator combination may be needed 13 107 Tpcb Warning Codes numbered from 102 to 199 107 Tpcb Possible Causes Possible Fixes Tpcb has been greater than 75 for more than 1 second Warning occurs anytime during engine operation Tpcb is the temperature measured on the main electronics board by a small temperature sensing integrated circuit 1 The air ducts on the back of the heat sink on the back of the WhisperGen electronics module is blocked or partially blocked 2 The air inlet holes on the bottom of the WhisperGen electronics module are blocked or partially blocked 3 The WhisperGen is being run at ambient air temperatures that are too high Rated to 40 C 4 The airflow under the bottom of the WhisperGen is obstructed 5 The WhisperGen has been r
17. starting of the burner the air rate and the fuel rate remain constant until the end of the Stabilize period It is only used to control the mixture from the end of the Stabilize period through to the shut down sequence being activated FID Sensor The FID Flame lonization Detector is an insulated electrode that protrudes into the flame and detects when the flame is present It is mounted to the evaporator on the top of the burner The FID is used by the microprocessor to Determine no flame is present prior to ignition Determine that ignition has taken place and that a flame is present during start up and operation of the burner Coolant Temperature Sensor The coolant temperature sensor is a small potted temperature sensing integrated circuit which is mounted into the coolant circuit where the coolant exits the engine block The coolant temperature sensor is used by the microprocessor to Control the coolant temperature to close to the Temp Setpoint Shut the WhisperGen down if the coolant temperature reaches the over temperature alarm set point Currently 84 C Turn on all pumps and the fan when the coolant temperature is higher than the over temperature alarm set point Coolant Temperature Switch The coolant temperature switch is a self resetting normally closed 95 C thermal switch which is mounted into the coolant circuit where the coolant enters the engine block The coolant temperature switch is one
18. 3 6 1 10 11 12 13 14 The evaporator is blocked The exhaust pipe is blocked The exhaust cooler is blocked The FID is set too high or too low There is no fuel flowing through the evaporator into the burner There is no fuel in the fuel tank and or an air bubble in the fuel line The fuel line is blocked or has a kink in it The fuel filters are blocked The fuel pump has failed The wrong type of fuel is being used The fuel has been contaminated The centre hole in the bottom of the evaporator close to the bottom of the glow plug is blocked or obstructed The air supply to the WhisperGen is blocked It is possible that very strong winds may blow the flame out 48 Fault Codes numbered from 2 to 99 58 Ignition failure Possible Fixes 10 11 12 13 14 Remove the fuel line from the evaporator and turn on the fuel bleed function and check that the fuel flow rate is about 10 cc 1 5 per minute If the fuel flows when the evaporator is disconnected but does not flow when the evaporator connected then the evaporator is blocked Replace the evaporator Check that the exhaust pipe is not blocked or obstructed Listen for gurgling noises when the WhisperGen is trying to start and when it is cooling down with the fan on at 100 Remove any obstructions Remove the top plate from the exhaust cooler and check to see if it is blocked Clean flush if necessary can switch on f
19. Daisy Chain circuit can be checked by removing the J5 connector in the electronics enclosure and checking the continuity between pin 1 red wire and pin 2 brown wire on the yellow plug An electrical fuse has blown The self resetting thermal switch on the engine block has opened or is defective Opens at about 95 C and closes at about 91 C The self resetting thermal switch on the burner fan has opened or is defective Opens at about 100 C and closes at about 96 C The self resetting thermal switch in the thermal switch fuse block on the bottom of the exhaust cooler has opened or is defective Opens at about 100 C and closes at about 96 C The one time only thermal fuse in the thermal switch fuse block on the bottom of the exhaust cooler has blown Blows at about 150 C There is a loose or bad connection in the Daisy Chain circuit Ensure that none of the electrical fuses have blown Ensure that both the primary and secondary coolant circuits are flowing and that the heat exchanger is not partially blocked Replace thermal switch if defective Ensure that both the primary and secondary coolant circuits are flowing and that the heat exchanger is not partially blocked Replace thermal switch if defective Check that the red silicon rubber burner seal is in place and is not leaking Check that no high temperature exhaust gases are leaking from the around the Evaporator and exhaust cooler Check that the ambient air temperatur
20. MO ae eta heen een en ieee eee read A ede 19 O NO 20 Fault Codes numbered from 2 to 99 uuuuursannnannsnnannnnnnsnnnnnnnnnennnnnnnnnennnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnsnnnnsnnnnnnernnnnnnnnennnnnnnn 21 2 EX OVER MP an ee reden Heerlen 22 4 Blok over EMD A ON 23 6 Heaisink OVEreMp oi A A Ae A Rs te aei ay 25 7 ElSctronics t00 Not socia ds 26 12 Air supply T lled 2 42 2 2er ale as 27 14 O2 sensor li ica 28 6 FUsO Dais Clic een 29 18 Low battery VOS usan bh Ra ER A eee les 30 19 High batt Voltcts cic ia a ee een 31 20 BUS NOU charger o do ed ds 32 NN 33 30 Low battery Vol a 34 32 BUS not charged t cita 24 2 8 taa pd Maven ee 35 34 ISOlatorStUCK O it ae re na ieee dida led eA debo aa 36 35 Low of 11K 0 AA 0 1L SPPRRETEETPERLPELEFERSLERTFEFELFELTERPEIFFEFFPFTTIFFEFEIFFEETPELTTEBERTRTTEPETERLTERRFTEEEFETEFFELFTERFFESFFEERLLTFEREFSTEFFPERETTEPEL TREFFEN 37 IOGlOWPlUA Ko o ia i 38 38 Bus not CO AO 4 win alee en Roan ee einer ne ln sein en Irene 39 40 Isolator ope miracle aa 40 44 Fuel sense f lle euere ie ine nel li 41 44 Fuensalida da 42 46 Flame sensetalliuticsi id o td 43 48 Drive bridge fall ai ai da 44 52 Fuelsupply Tallada al iia A 45 54 Flame sense fall c cccsssesscesarcccuscaseseuscecsveccuccauscanapacdsesascaiosauadasasseanobauecauarenapanasccasseareansoauseasarccanecauscarseecnaaats 46 56 O2 SONSOL Tall iii da td aha da 47 DS lgnition TaN UNG tit He Dee A is 48 SM OT 50 GO Flame failure
21. NAL VALVE EXTERNA COOLING PUMP Y OR FAN NOTES NSTALL FUSE RATED BETWEEN 1 AND SA IN THE BATTERY POSITIVE SENCE 2 USE BLUE SEAS MODEL 7103 3 OPTIONAL TEMPERATURE SENSOR TO BE BOLTED DIRECTLY TO WATER PUMP BATTERY NEGATIVE TERMINAL POST PERMANEN MAGNET BRUSHL ALTER S DAD CLAMP RESISTOR BATTERY p BATTERY BKo CHASSIS NGINE MOUNT STUD rh BURNER SHELL EARTH STUD a T BK F DYNAMIC DXYGEN wH SENSOR oc 76 Wiring Diagram for PSS16 12MD PSS16 24MD ELECTRONICS BOX 100M 1 BATTERY SENSE LOOM 4 EXTERNAL CONTROL ERRE adaa Hz a areal da SSdda gg 33998 Xe 33d a So mama a LAWL Rx 38 3uU8 gt PH 50 12345 6 ep ae A a za An COMMS LOOM 11 BLOWER 7 a KT Lor a LEA sh mH Ll aa la vi DISPLAY EERE
22. WhisperGen will throttle up and down to meet the minimum requirements of both the battery voltage and Heat Management The Coolant Temperature will only ever be held at close to the Temp Setpoint and may be up to 5 to 14 C above it depending on operating conditions Sensor Operation Sensor Operation Exhaust Temperature Sensor The exhaust temperature sensor is a K type thermocouple mounted in the exhaust gas stream after the burner and just before it goes into the exhaust cooler it is not the temperature of the exhaust exiting the WhisperGen enclosure The temperature of the exhaust exiting the WhisperGen enclosure is usually about 5 to 10 C hotter than the coolant temperature The exhaust temperature sensor is used by the microprocessor to Determine when to crank the engine during Heatup Determine when to produce an over temperature warning and or fault at any time Determine when to switch the WhisperGen to Standby during Cool Down Determine how long the glow plug needs to be on before turning on the fuel to the burner Determine when to switch off the glow plug after the burner has successfully started Determine how much air needs to go through the burner when igniting the burner Control the maximum exhaust temperature to not more than the ExhaustSetpt exhaust temperature set point currently 480 C 480 C is not the normal maximum running temperature and most systems run well below about 400 to 460 C t
23. ace electronics 64 Fault Codes numbered from 2 to 99 90 Clamp contro flt 90 Clamp control flt Possible causes Possible fixes Verror is greater than 0 25 for 12 Volt WhisperGen s or 0 5 for 24 Volt WhisperGen s for more than 3 minutes Fault occurs during VOLTCONTROL Mode 3 Verror is the difference between Vbattery and Vcontrol which is the set point for the battery voltage If this error gets to big then this is because the clamp controller is not capable of controlling the battery voltage 1 High power WhisperGen running at full power due to high heat demand but very low electrical demand and clamp element is not able to dump all the electrical power at the set float voltage 2 Faulty clamp element 3 Faulty control electronics 1 Reduce the power the WhisperGen by setting a leaner fuel mixture or add some DC load 2 Replace clamp element 3 Replace the electronics 65 92 ParChg V too high Fault Codes numbered from 2 to 99 92 ParChg V too high Possible causes Possible fixes Vcontrol is greater than Vabs_comp 0 5 for 12 Volt WhisperGen s or Vabs_comp 1 0 for 24 Volt WhisperGen s for more than 30 Seconds Fault occurs during VOLTCONTROL parallel charge Mode 3 4 When A parallel charger is detected the Control voltage is slowly increased until the Clamp Current is less than or equal to the Alternator Current to make sure not to much current goes thro
24. ad connection in the battery cables between the battery and the WhisperGen 1 Charge the battery 2 Reduce the electrical load and or charge the battery 3 Fix the broken or poor connection 4 Replace the fuse and check the sense wire for chaffing between the fuse and the WhisperGen 5 Fix the bad connection 37 36 Glowplug cct fit Fault Codes numbered from 2 to 99 36 Glowplug cct flt Vbus has not dropped below 7V within 30 seconds of the Glowplug being turned on Fault occurs during STARTUP Mode 3 1 i 1 The glow plug has burnt out Possible Causes 2 The glow plug fuse has blown 3 There is a bad connection between the electronics and the glow plug 4 There is an electronic failure 1 Replace the glow plug and check the glow plug fuse for failure Possible Fixes 2 Replace the glow plug fuse and check the glowplug for failure 3 Check the continuity from the connection at the electronics through to the glowplug gt Replace the electronics 38 Fault Codes numbered from 2 to 99 38 Bus not charged 38 Bus not charged Vbus has not reached Vbattery 1 75v within 30 seconds of the glowplug being turned off after it had been turned on for a few seconds to discharge the bus Fault occurs during WAKEUP Mode 3 1 1 The clamp element has a low resistance path to earth Possible Causes 2 The glow plug relay is stuck on 1 When the WhisperGen is in Standby and all
25. al is monitored for the presence of a flame Mode 3 6 then after a waiting period for flame stabilization Mode 3 8 the lambda control system is turned on to adjust the fuel level based on exhaust oxygen concentration From this point on Mode 3 9 the burner runs at a gradually increasing firing rate increasing air value until the engine is hot enough to crank Part of the startup sequence is a software routine that modifies the starting fuel value slightly to improve future starts This learning function will cause the initial StartFuel1 value to move slowly away from its initial value toward a more optimum value for the engine Once the engine is hot enough it is cranked Mode 4 1 then the power output checked over the next short period Mode 4 2 to ensure it is operating correctly Once the engine has commenced running the heat exchanger washer is turned on Mode 5 1 in a few short bursts then stopped Mode 5 2 The wash function is repeated every 10 hours During the engine run time burner power level and generator output voltage are controlled to meet heat management and battery charging requirements At any stage after startup a shutdown sequence will be initiated if a shutdown signal is received This signal may come form the Stop button from completion of a battery charging cycle from an external control signal from expiry of a maximum engine run time or from detection of a parallel charger operating at a high
26. an 27 14 02 sensor failure Fault Codes numbered from 2 to 99 14 02 sensor failure O2value not between 200 and 2500 for at least 120 seconds Fault occurs anytime during engine operation The reading from the oxygen sensor is outside its normal operating 1 The exhaust pipe has been obstructed while the burner is operating Possible Causes causing a very rich mixture in the burner 2 A large air vapor bubble has passed through the fuel pump or burner 3 The oxygen sensor is defective 1 Remove or stop obstruction from occurring during burner operation Possible Fixes 2 Use the correct size of fuel line to ensure that bubbles do not collect in it 3 Replace the oxygen sensor 28 Fault Codes numbered from 2 to 99 16 Fuse DaisyCh fail 16 Fuse DaisyCh fail Possible Cause Possible Fixes Fault occurs anytime during engine operation This fault occurs when either the Daisy Chain safety circuit has been cut or an electrical fuse has blown after a delay of 5 seconds Note The Daisy Chain is a safety back up system that is independent of the WhisperGen s microprocessor control system and on no account should the thermal switches or thermal fuses be bypassed That if this fault occurs while the WhisperGen is running but is not present after the WhisperGen has cooled down then it is most likely to be a self resetting thermal switch opened and then closed again The continuity of the whole
27. attery voltage during absorption and float charging If this error gets too big then this is because the clamp controller is not capable of controlling the battery voltage 1 High power WhisperGen running at full power due to high heat demand but very low electrical demand and clamp element is not able to dump all the electrical power at the set float voltage 2 Faulty clamp element 3 Faulty control electronics 1 Reduce the power the WhisperGen by setting a leaner fuel mixture or add some DC load 2 Replace clamp element 3 Replace the electronics 19 195 Ah Warning Codes numbered from 102 to 199 195 Ah Possible Causes Possible Fixes Ah is more negative than MaxDisch 0 15 Battsize for more than 1 second ie the battery has been discharged 15 more than the commissioner set auto charge level Warning occurs at anytime 1 The Auto charge function is not turned on and the WhisperGen was not manually started before the alarm level was reached 2 The WhisperGen has started but the current draw from the batteries is higher than what the WhisperGen can produce This may be normal operation for some systems 3 The WhisperGen may have failed to start for some other reason and during the time that the WhisperGen has not been running the battery has discharged enough to trigger the alarm When the original fault is cleared this warning immediately comes up 1 Turn on the Auto
28. ble Fixes Vbattery is higher than 18 volts for 12 Volt WhisperGen Mis and 36 volts for 24 Volt WhisperGen s at power up 1 Incorrectly wired battery bank giving higher than 18 Volts Faulty battery voltage sensing 12V WhisperGen connected to 24V battery Correctly wire battery bank Check battery voltage sensing wire to WhisperGen or replace electronics Connect 24V WhisperGen to 24V battery 31 20 Bus not charged Fault Codes numbered from 2 to 99 20 Bus not charged Possible Causes Possible Fixes Vbus has not reached Vbattery 1 75V Fault occurs during WAKEUP Mode 1 3 when the engine is hot and attempts to power up in order to cool down 1 The clamp element has a low resistance path to earth The glow plug relay is stuck on The Power relay is stuck on When the WhisperGen is in Standby and all other loads disconnected from the battery Vbus Bus Voltage should always be about 0 6V less than Vbattery With the WhisperGen in Standby note the Bus Voltage Remove both Clamp Element wires from the terminals in the Electronic Module and then note the Bus Voltage If the bus voltage rises more than 0 5V then the Clamp Element has a low resistance path to earth and should be replaced Check the above a few times and make certain that it is the problem When the WhisperGen is in Standby and all other loads disconnected Vbus Bus Voltage should always be about 0 6V less than Vbatt
29. bout 10 cc 1 5 per minute 2 Check that the air intake to the WhisperGen is not obstructed 3 Check that the exhaust pipe is not blocked or obstructed Listen for gurgling noises when the WhisperGen is trying to start and when it is cooling down with the fan on at 100 Remove any obstructions Remove the top plate from the exhaust cooler and check to see if it is blocked Clean flush if necessary If blocked also check flushing nozzle for blockage Clean replace if necessary 4 Check that exhaust temperature reading looks right Replace if in any doubt 5 Check replace the oxygen sensor If the oxygen sensor is faulty and causes the burner to run with a very lean mixture then the temperature of the exhaust will not rise quick enough 54 Fault Codes numbered from 2 to 99 66 Crank failure 66 Crank failure Possible causes Possible fixes The BridgeRunning signal is not present 6 seconds after an attempt to crank was made Fault occurs during CRANK Mode 4 2 1 There is a fault in the electronics 2 The electronics have just been replaced and the 3 phases from the alternator to the electronics have been wired incorrectly 3 Nitrogen gas pressure is too high 4 Internal mechanical failure of WhisperGen 5 Open circuit or short circuit of an alternator phase to ground 1 Replace the electronics 2 Change the positions of any 2 wires from the alternator at the electronics 3 Check and red
30. charging voltage that interacts adversely with the WhisperGen When a shutdown signal is received fuel is turned off immediately and a message displayed on the LCD either Normal Shutdown or an error message Mode 6 1 Air is increased to 100 Mode 6 3 to assist with burner cooling and the engine is brought to a stop over several minutes Mode 6 4 After the engine is stopped another cooling period Mode 6 5 allows the engine exhaust and water circuit to cool down further before the fan and water pump are stopped At completion of Shutdown the engine returns to the Idle condition and is available for restart If several faults have occurred with no fault free runs between the system enters a Lockout mode Mode 7 1 which requires manual reset of the fault condition before the engine reverts the Idle condition and can restart Battery Charging Operation Battery Charging Operation At any time that the WhisperGen is started for any reason a battery charging cycle i is commenced and continued until complete or until the WhisperGen is stopped for any reason 1 The WhisperGen runs at full power in Bulk Charge mode until the battery voltage is lifted to the Absorb Voltage as set in the Hidden Service Menu If the Battery Temperature Sensor is fitted then the Absorb Voltage will vary a little depending on the temperature of the Battery Temperature Sensor 2 When the battery has been lifted to the Absorb Voltage t
31. crease the nitrogen pressure to the recommended value if necessary Check replace the oxygen sensor If the oxygen sensor is faulty and causes the burner to run with a very lean mixture then the temperature of the heater heads may not be stay hot enough Remove the burner and check the burner seal The ceramic rope burner seal must always be replaced whenever the burner is removed Replace the core engine or whole WhisperGen 58 Fault Codes numbered from 2 to 99 76 O2 sensor OOL 76 02 sensor OOL ABS O2value O2run 1050 is greater than 300 for more than 1 second i e the fresh air reading at the end of a run is such as to indicate that the sensor is no longer operating correctly Fault occurs during Cooloff Mode 6 5 1 The oxygen sensor characteristic has drifted substantially Possible causes 2 The oxygen sensor has failed 1 Check exhaust excess air and re calibrate the O2run value Possible fixes 2 Replace the oxygen sensor 59 80 Clamp failed On Fault Codes numbered from 2 to 99 80 Clamp failed On Possible Causes Possible Fixes The clamp current is greater than 5 amps for a 12 Volt WhisperGen or 2 5 amps for a 24 Volt WhisperGen when there should be no clamp current and the condition persists for 25 seconds Fault can occur any time 1 The clamp element is shorting to earth 2 Faulty electronics 1 Check the resistance of the clamp element to earth 2 Replace
32. d Remove all three wires and check insulation to ground Replace WhisperGen if there is an internal phase to earth contact 57 74 Low engine power Fault Codes numbered from 2 to 99 74 Low engine power Possible Causes Possible Fixes PowerOutput is less than Air 2 100 for more than 5 seconds Fault occurs at anytime during engine operation Mode 5 Exhaust flow from the burner is restricted Air flow to the burner is restricted Fuel flow to the burner is restricted Low nitrogen pressure Faulty oxygen sensor The burner has been lifted or the ceramic rope burner seal has been damage and is allowing the hot gasses from the burner to by pass the heater head and go directly into the exhaust reducing the power output of he WhisperGen Internal mechanical failure of WhisperGen Check that the exhaust pipe is not blocked or obstructed Listen for gurgling noises when the WhisperGen is trying to start and when it is cooling down with the fan on at 100 Remove any obstructions Remove the top plate from the exhaust cooler and check to see if it is blocked Clean flush if necessary If blocked also check flushing nozzle for blockage Clean replace if necessary Check that the air intake to the WhisperGen is not obstructed Remove the evaporator and with the fuel line connected to it turn on the fuel bleed function and check that the fuel flow rate is about 10 cc 1 5 per minute Check and in
33. e eg the no flame check of the FID signal before fuel is started Once the engine is running however no abnormal conditions of less than 5 seconds duration will be registered 21 2 Exh overtemp Fault Codes numbered from 2 to 99 2 Exh overtemp Possible Causes Possible Fixes Texhaust has been greater than ExhaustAlarm for gt 5 seconds Fault occurs anytime during engine operation Although the WhisperGen microprocessor will always try and keep Texhaust below the ExhaustSetpt under certain abnormal conditions it will not be able to back the burner fan off fast enough to stop the exhaust temperature reaching the alarm level The ExhaustAlarm is currently set at 545 C giving a warning at 530 C 1 Low nitrogen gas pressure 2 Oxygen sensor reading may have drifted giving a very rich mixture 3 Faulty exhaust temperature sensor 4 The burner may have been lifted off its inner burner seal 1 Top up with nitrogen gas to the recommended filling pressure for that series of WhisperGen 2 Check oxygen sensor fresh air reading and if below 1300 or above 2500 then replace If fresh air reading nitrogen gas pressure and exhaust temperature sensor are ok and problem still exists then replace any way After the WhisperGen has been running for at least 20 minutes and if you have a combustion analyzer then check that the excess air reading is around 9 5 O2 This is equivalent to an 80 10 excess air reading The m
34. e around the WhisperGen is below 40 C Ensure that both the primary and secondary coolant circuits are flowing and that the heat exchanger is not partially blocked Replace thermal switch fuse block if defective Ensure that both the primary and secondary coolant circuits are flowing and that the heat exchanger is not partially blocked Replace thermal switch fuse block if defective Ensure that there are no bad connections in the Daisy Chain 29 18 Low battery volts Fault Codes numbered from 2 to 99 18 Low battery volts Possible Causes Possible Fixes Vbattery is less than 8 volts for 12 Volt WhisperGen s and 16 volts for 24 Volt WhisperGen s at power up 1 The battery is flat 2 There is a very large load being applied to the battery which is causing the battery voltage to drop below the allowed limit 3 The battery voltage sense wires have a bad or no connection to the battery 4 The fuse in the battery voltage sense wire has blown 5 There is a very bad connection in the battery cables between the battery and the WhisperGen 1 Charge the battery 2 Reduce the electrical load and or charge the battery 3 Fix the broken or poor connection 4 Replace the fuse and check the sense wire for chaffing between the fuse and the WhisperGen 5 Fix the bad connection 30 Fault Codes numbered from 2 to 99 19 High batt volt 19 High batt volt Possible Causes Possi
35. e continuity of the FID wire back to the electronics and that it is not shorting to earth Also check that the FID is not shorting through to earth because of a carbon build up on its end 2 See 58 Ignition failure 52 Fault Codes numbered from 2 to 99 62 Flame failure 62 Flame failure The FlDcurrent has been less than 0 6 for more than 10 consecutive seconds Fault occurs anytime during engine operation Mode 5 1 The FID is set too high or too low Possible Causes 2 See 58 Ignition failure 1 If you can hear that the burner is burning well but there is no FID Possible Fixes reading then remove the FID and check its height setting Also check the continuity of the FID wire back to the electronics and that it is not shorting to earth Also check that the FID is not shorting through to earth because of a carbon build up on its end 2 See 58 Ignition failure 53 64 Heatup failure Fault Codes numbered from 2 to 99 64 Heatup failure Possible Causes Possible Fixes Texhaust has failed to reach the crank temperature in 500 seconds Fault occurs during Heatup Mode 3 9 1 Fuel flow to the burner is restricted 2 Air flow to the burner is restricted 3 Exhaust flow from the burner is restricted 4 Faulty exhaust temperature sensor 5 Faulty oxygen sensor 1 Remove the evaporator and with the fuel line connected to it turn on the fuel bleed function and check that the fuel flow rate is a
36. erGen is in Standby and all other loads disconnected Vbus Bus Voltage should always be about 0 6V less than Vbattery With the WhisperGen in Standby note the Bus Voltage and then remove the Glow Plug wire from the glow plug If the Bus Voltage increases by more than 0 5V then it is likely that the Glow Plug relay is stuck on Try tapping the relays in the electronics module until the Bus Voltage does not drop when the Glow Plug wire is connected 35 34 Isolator stuck on Fault Codes numbered from 2 to 99 34 Isolator stuck on Vbus has not dropped below 7V within 30 seconds of turning the Glowplug and the Power relay on Fault occurs during STARTUP Mode 3 1 1 The Isolator relay is stuck in the closed position Possible Causes 1 Try tapping relay with screwdriver handle or replace the electronics Possible Fixes 36 Fault Codes numbered from 2 to 99 35 Low battery volts 35 Low battery volts Possible Causes Possible Fixes Vbattery is less than 8V for 12 Volt WhisperGen s or less than 16V for 24 Volt WhisperGen s for more than 1 second Fault occurs during STARTUP Mode 3 1 1 The battery is flat 2 There is a very large load being applied to the battery which is causing the battery voltage to drop below the allowed limit 3 The battery voltage sense wires have a bad or no connection to the battery 4 The fuse in the battery voltage sense wire has blown 5 There is a very b
37. ery With the WhisperGen in Standby note the Bus Voltage and then remove the Glow Plug wire from the glow plug If the Bus Voltage increases by more than 0 5V then it is likely that the Glow Plug relay is stuck on Try tapping the relays in the electronics module until the Bus Voltage does not drop when the Glow Plug wire is connected Check for a stuck power relay by measuring the DC voltage at the auxiliary DC output If it is the same as the bus voltage when the WhisperGen is in the Idle state it is likely that the Power relay is stuck on Try tapping the relays in the electronics module 32 Fault Codes numbered from 2 to 99 24 Isolator open 24 Isolator open Vbus has not reached Vbattery 0 35V 2 seconds after turning on the Isolator Fault occurs during WAKEUP Mode 1 3 when the engine is hot at power up and is attempting to cool down 1 Isolate relay is not operating Possible Causes 4 1 Try tapping relay with screwdriver handle or replace the electronics Possible Fixes 33 30 Low battery volts Fault Codes numbered from 2 to 99 30 Low battery volts Possible Causes Possible Fixes Vbattery is less than 8V for 12 Volt WhisperGen systems or less than 16V for 24 Volt WhisperGen systems for more than 5 seconds Fault occurs during STARTUP Mode 3 1 The battery is flat There is a very large load being applied to the battery which is causing the battery voltage to drop bel
38. fications of its products or the information in this manual without necessarily notifying its users Variations in installation and operating conditions may affect the WhisperGen s performance Whisper Tech has no control over each installation s unique operating environment Hence Whisper Tech makes no representations or warranties concerning the performance of the WhisperGen under the actual operating conditions prevailing at the installation All operating parameters for each application should be validated by a technical expert of the user s choosing Whisper Tech has made every effort to explain all installation commissioning operating maintenance troubleshooting procedures warnings and safety precautions as clearly and completely as possible However due to the range of operating environments it is not possible to anticipate every issue that may arise Therefore Whisper Tech is not able to guarantee that this manual will address every issue that may arise This manual is intended to provide general guidance For specific guidance and technical support contact your authorised WhisperGen supplier Information in this manual shall not be deemed a warranty representation or guarantee For warranty provisions applicable to your WhisperGen please refer to the warranty provided by the supplier of your WhisperGen Unless otherwise noted reference to brand names product names or trademarks constitute the intellectua
39. g STARTUP Mode 3 3 1 Fuel pump relay is stuck in the closed position Possible Cause 2 Electronics failure 1 Try tapping relay with screwdriver handle or replace the electronics Possible Fixes 2 Replace electronics 41 44 Fuel sense fail Fault Codes numbered from 2 to 99 44 Fuel sense fail The supply voltage to the fuel pump is on when it should not be Fault occurs during STARTUP Mode 3 3 1 Fuel pump relay is stuck in the closed position Possible Causes 2 Electronics failure 1 Try tapping relay with screwdriver handle or replace the electronics Possible Fixes 2 Replace electronics 42 Fault Codes numbered from 2 to 99 46 Flame sense fail 46 Flame sense fail FlDcurrent is greater than 0 05 for more than 1 sec Fault occurs during STARTUP Mode 3 3 1 There is a flame present in the burner before the fuel has been turned Possible Causes on 2 The FID circuit is receiving some interference from something 3 The FID circuit has failed in the electronics 1 Ensure that there is no fuel in the burner before the fuel pump is turned Possible Fixes on 2 Check the FID current reading while the glow plug is on and is pre heating the burner before the fuel is turned on The actual FID reading should be between 0 00 and 0 05 If it is dancing around and is sometimes above 0 05 then it is likely receiving interference from something Check electrical and electronic equipme
40. he WhisperGen will then run in Absorption Charge mode holding the battery at the Absorb Voltage by reducing the current going into the battery until the current going into the battery has reduced to the Tail Current set point as set in the Hidden Service Menu If the Heat Management requirements are met then the WhisperGen will also slowly throttle down 3 When the battery is held at the Absorb Voltage and the current going into it has reduced to the Tail Current then the battery cycle is deemed to be complete and depending on the heat management settings the WhisperGen will do one of two things 1 Shuts down and goes to Standby 2 continue running to meet the Heat Management requirements while holding the battery voltage at the Float Voltage as set in the Hidden Service Menu until a stop signal is received During this time The WhisperGen will throttle up and down to meet the minimum requirements of both the battery voltage and Heat Management Heat Management Operation At any time that the WhisperGen is started for any reason a the WhisperGen M will try and maintain the Coolant Temperature at close to the Temp Setpoint as set in the User Menu When the Heat Manage function is turned On the WhisperGen will continue to run after the battery charging cycle is completed and continued to run maintaining the Coolant Temperature at close to the Temp Setpoint until the WhisperGen is stopped for any reason During this time The
41. his when the fan is on 100 Exhaust Heat Exchanger Thermal Switch Block The exhaust heat exchanger thermal switch block contains both a self resetting normally closed 100 C thermal switch and a 150 C thermal fuse It is mounted on the bottom left hand side of the exhaust heat exchanger The exhaust heat exchanger thermal switch block is one ofthe 4 microprocessor independent thermal cut out switches that are used to cut off the fuel supply by removing the supply voltage to the fuel pump should an over temperature situation occur Should the thermal fuse blow then the exhaust heat exchanger thermal switch block must be replaced Fan Thermal Switch Internal Ambient Thermal Switch The fan thermal switch is a self resetting normally closed 100 C thermal switch and is mounted on the burner fan guard The fan thermal switch is one of the 4 microprocessor independent thermal cut out switches that are used to cut off the fuel supply by removing the supply voltage to the fuel pump should an over temperature situation occur Sensor Operation 10 Oxygen Sensor O2 Sensor The oxygen sensor measures the amount of oxygen in the exhaust gas stream and is mounted on the top of the exhaust cooler from the left hand side The oxygen sensor is used by the microprocessor to control the air to fuel ratio mixture in the burner The oxygen sensor plays no part in the initial ignition of the burner during start up During the initial
42. hisperGen in ambient air temperatures greater than 40 C then a larger fan and radiator combination may be needed 24 Fault Codes numbered from 2 to 99 6 Heatsink overtemp 6 Heatsink overtemp Possible Causes Possible Fixes HeatsinkTemp is greater than 95 C for gt 5 seconds Fault occurs anytime during engine operation 1 The air ducts on the back of the heat sink on the back of the WhisperGen electronics module are blocked 2 The air ducts into the electronics module are blocked 3 The WhisperGen is operating in an ambient air temperature of greater that 40 C 4 The airflow under the bottom of the WhisperGen is obstructed 5 The WhisperGen has been running with the enclosure lid off 6 The enclosure lid rubber seal is badly damaged 7 Faulty temperature sensor 8 Some electronic components attached to the heat sink have failed creating heat 1 Unblock the air ducts to the heat sink 2 Unblock the air ducts to the electronics module 3 Reduce the ambient air temperature 4 Remove the obstruction from under WhisperGen 5 Re fit the enclosure lid 6 Re place the rubber seal 7 Replace the electronics module 8 Replace the electronics module 25 7 Electronics too hot Fault Codes numbered from 2 to 99 7 Electronics too hot Possible Causes Possible Fixes Tpcb is greater than 80 C for gt 5 seconds Fault occurs anytime during engine operation Tpcb is the
43. ixture can be adjusted to a limited extent by adjusting the O2Runfact in the hidden menu on the control panel A smaller number makes the mixture richer 3 Replace exhaust sensor 4 Remove the burner and replace the braded rope ceramic burner seal This must always be replaced when removing the burner 22 Fault Codes numbered from 2 to 99 4 Block overtemp 4 Block overtemp Possible Causes Air cooled systems Possible Causes Possible Fixes Tblock has been greater than BlockAlarm for more than 5 seconds Fault occurs anytime during engine operation Tblock is actually the temperature of the coolant measured just after it exits the engine block and before it enters the exhaust cooler The BlockAlarm is currently set at 84 C giving a Warning at 81 C 1 The secondary coolant pump is not pumping enough water maybe because the intake or circuit is blocked or partially obstructed or it may be air locked The secondary coolant water intake is not submerged The secondary coolant pump has not primed after the intake was out of the water The primary or secondary coolant sides of the marine heat exchanger are partially or fully obstructed Note that both the primary and secondary sides of the marine heat exchanger can be 2 3rds blocked but still have a large amount of coolant flowing through them This is because there are 3 parallel paths through the marine heat exchanger for both the primary and secondary coola
44. l property of the owner thereof Subject to your right to use the WhisperGen Whisper Tech does not convey any right title or interest in its intellectual property including without limitation its patents copyrights and know how No part of this manual may be reproduced or transmitted in any form or by any means without the express written permission of Whisper Tech Every effort has been made to ensure the accuracy of this document however it may contain technical inaccuracies or typographical errors Whisper Tech assumes no responsibility for and disclaims all liability of such inaccuracies errors or omissions in this publication Use of the WhisperGen shall constitute your acceptance of the conditions above Contents Introduction ivonne a De a anna 4 Engine Numbering eeaeee ae aara raan earar er 4 Sequence of Operator iii a 4 Battery Charging Operation iii 6 Heat Management Operation scssccssseesseesseeeseeeesseeesseeeeneneesseeeseneseeeeesenaseneesaseasseeesaseasneesaeesaseesaseaeaseesaseeeaseesaseeeaseess 6 sensor OPS rath ON ii ii ita 7 Controlled CoM ponents aoeeoe nenene ii 9 Warning Codes numbered from 102 to 199 ssssssnssennsnnnnnnnnnnnnunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnannnnnnnnn nunn nnn nenna annen 11 102 TEXHaUst ete iii a a A 12 104 Toluca er een een 13 MOT TPC a AE A A adidas 14 t26 HORES ji A Le a ee 15 130 dor LLS 97 va iia 16 A a NO 17 A ves ETETETT E asses 18 LIO
45. l to stop Controlled Components 5 Secondary Coolant Pump or Heat Dump Fan 6 Auxiliary Heater if fitted Marine systems The secondary coolant pump marine water is usually a small centrifugal circulation pump or a membrane positive displacement pump which pumps marine water r through one side of the marine heat exchanger inside the WhisperGen enclosure and then back out into the marine water The secondary coolant pump s speed i is Pulse Width Modulation PWM speed controlled by the WhisperGen microprocessor to maintain the coolant temperature close to the coolant temperature set point Mobile or land based systems The heat dump fan is usually an automotive type electrical radiator fan bolted to an appropriately sized radiator The heat dump fan s speed is a Pulse Width Modulation PWM speed controlled by the WhisperGen microprocessor to maintain the coolant temperature close to the coolant temperature set point Either the secondary coolant pump or the heat dump fan is connected to the same terminal on the side of the WhisperGen electronic enclosure There is no selection of the fan or the pump to be made when commissioning the WhisperGen The WhisperGen controls a set of contacts that can be used to control an ancillary water heater connected in series with the WhisperGen The ancillary heater is only turned on if the heat management option has been selected on and if only if it is required 10
46. ling noise The Exhaust is making a howling noise 1 The mixture is not set correctly Possible causes 2 A combination of the burner and the exhaust system is causing a resonance to occur 1 Try adjusting the mixture after the WhisperGen has been running for Possible fixes at least 20 minutes and if you have a combustion analyzer then check that the excess air reading is around 9 5 O2 This is equivalent to an 80 10 excess air reading The mixture can be adjusted to a limited extent by adjusting the O2Runfact in the hidden menu on the control panel A smaller number makes the mixture richer 2 Fita muffler to the exhaust system The muffler should be a flow through type This means that when you look into one end of the exhaust pipe you should be able to see straight through it 75 Wiring Diagram for PSS16 12MD PSS16 24MD Wiring Diagram for PSS16 12MD PSS16 24MD SERVICING amp DIAGNOSTICS PERSONAL COMPUTER EXTERNAL EQUIP XT TEMP EXT TEMP at EXT DIGITAL OUT 31 DIGITA Em DIGITAL IN XT DIGITAL IN z 6 GN CURRENT f7 77 z gt 3 FISE G NOTE 7 BATTERY POSITIVE DISTRIBU L B THERMAL C B ane SA 30V 24 N BA TE2 MIN 200Ah OPTIONAL TEMPER Ls SHUNT GIDA SImV BATTERY NEGATIVE DISTRIBU z a 8 T A o ETERING u 5 OPTIO
47. lushing nozzle from control panel Also check flushing nozzle for blockage Remove and clean if necessary If you can hear that the burner is burning well but there is no FID reading then remove the FID and check its height setting Also check the continuity of the FID wire back to the electronics and that it is not shorting to earth Also check that the FID is not shorting through to earth because of a carbon build up on its end This is general to the others shown below Remove the evaporator and with the fuel line connected to it turn on the fuel bleed function and check that the fuel flow rate is about 10 cc 1 5 per minute Check the fuel level in the fuel tank is high enough Check that all connections in the fuel line are tight Remove the kink or replace the fuel line Clean and or replace fuel filters Clean fuel tank if necessary Check pulse signal to fuel pump when turned on If signal is present but fuel pump does not work then replace fuel pump Use correct fuel Clean out the fuel system The evaporator may also need to be replaced Remove obstruction Remove obstruction Try restarting 49 59 Flame failure Fault Codes numbered from 2 to 99 59 Flame failure The FlDcurrent has been less than 0 075 for more than 10 consecutive seconds Fault occurs during Stabilizing Mode 3 8 1 The FID is set too high or too low Possible Causes 2 See 58 Ignition failure i 1 If you can hear that the
48. nt and two of them could be blocked The wires to the primary or secondary coolant pump are broken or disconnected The secondary coolant intake water is above 40 C Faulty temperature sensor The above may apply along with 8 9 10 11 N The radiator air passages are blocked The fan is not working The fan and or radiator is to small The ambient air temperature is above 40 C Check the flow rate through the secondary coolant circuit lt should be greater than 4 litres per minute Make sure that the inlet is submerged when the error occurs Make sure that the pump is self priming or that any air that collects in the intake to the pump can escape If the flow rate through both the primary greater than 4 liters per minute and the secondary are sufficient then remove the marine plate heat exchanger from inside the WhisperGen and disassemble and check for blockage Check wires for continuity and or voltage Make sure that the secondary coolant outlet is not feeding back into the inlet Replace coolant temperature sensor 23 4 Block overtemp Fault Codes numbered from 2 to 99 Air cooled sytems Possible Fixes 10 11 Clean air passages Make sure that the fan has power to it and that it working order Make sure that the fan and radiator combination are rated to transfer 6 Kw of heat into the air with a coolant temperature of 70 C and an air temperature of 40 C If running the W
49. nt in the area such as radio transmitters and turn off if necessary 3 Check the FID current reading while the glow plug is on and is pre heating the burner before the fuel is turned on If there is a constant reading above 0 05 then it is likely that there is a fault with the electronic circuit and if this condition can be repeated then the electronics module should be replaced 43 48 Drive bridge fail Fault Codes numbered from 2 to 99 48 Drive bridge fail The BridgeRunning signal is present before the WhisperGen has been cranked Fault occurs during STARTUP Mode 3 3 1 Electronic failure Possible Causes 1 Replace electronics Possible Fixes 44 Fault Codes numbered from 2 to 99 52 Fuel supply fail 52 Fuel supply fail The supply voltage to the fuel pump has not been sensed 3 seconds after it was turned on Fault occurs during No flame check Mode 3 5 1 The electronics are faulty Possible Causes 1 Replace the electronics Possible Fixes 45 54 Flame sense fail Fault Codes numbered from 2 to 99 54 Flame sense fail Possible Causes Possible Fixes FIDcurrent is greater than 0 05 for more than 1 sec Fault occurs during No flame check Mode 3 5 1 There is a flame present in the burner before the fuel has been turned on 2 The FID circuit is receiving some interference from something 3 The FID circuit has failed in the electronics 1 Ensure that there
50. ntrolled by the WhisperGen microprocessor When the oxygen content in the exhaust increases above the set point the speed of the fuel pump is increased When the oxygen content in the exhaust decreases below the set point the speed of the fuel pump is decreased Normal operating frequency is between 2 and 16 Hz If the fuel pump is ever required to operate above 15Hz then the speed of the burner fan will begin to decrease until the fuel pump frequency is below 15 Hz The flushing valve is a solenoid operated on off water valve and is used to control the flow of fresh water to the flushing nozzle i iin the top of the exhaust cooler It is controlled by the WhisperGen microprocessor and opened and closed e For 10 seconds just after the WhisperGen has cranked e For 10 seconds 1 minute after the WhisperGen has cranked Repeated once every 10 hours if the WhisperGen is running continuously The primary coolant circulation pump is usually a small centrifugal type circulation pump The power supply to this pump is from the battery but it also a has a diode feed directly from the WhisperGen M alternator so that even if the WhisperGen i is disconnected from the battery while it is running the pump will continue to run while the WhisperGen is rotating The primary coolant pump is turned on as the WhisperGen powers up after receiving a signal to start It is turned off when the WhisperGen goes into standby after receiving a signa
51. oing into Standby after the stop button has been pushed Sequence of Operation IDLE mode Mode 2 1 STARTUP mode Mode 3 1 to 3 9 CRANK mode Mode 4 1 amp 4 2 RUN mode Mode 5 1 amp 5 2 SHUTDOWN mode Mode 6 1 to 6 5 The WhisperGen is in the Standby condition awaiting a Start signal and monitoring the battery condition A Start signal might come from the Start button or from the WhisperGen s measurements on battery state of charge or from an external control line Whilst in the IDLE mode it also possible to initiate the bleed sequences for air water and fuel Mode 2 2 to 2 6 The WhisperGen has received a Start signal All LEDs on the control panel are flashed on momentarily A sequence is begun Mode 3 1 to power up the bus so the isolate relay can be closed Battery power is then available for the water pump fan glowplug etc Part of this sequence involves a test to ensure the glowplug is not burned out Once the bus is powered up a pre check is carried out Mode 3 3 to ensure that electrical conditions are normal then the glowplug is turned on to pre heat the burner evaporator Mode 3 4 When the glowplug has been on long enough a final no flame electrical check is carried out then the air and fuel supply to the burner is turned on Mode 3 5 Fuel is supplied at maximum rate for a second or so then dropped back to the standard rate in order to fill the evaporator reservoir space The FID sign
52. orrectly The Enable Starts function in the Installation Menu is switch to 0 or 1 to prevent the WhisperGen starting to enable maintenance to be carried out Turn the Auto charge function on Ensure that the battery parameters are correctly set Ensure that the battery current shunt is correctly wire into the battery cable Also check that the battery current sense wires are connected correctly to the WhisperGen and to the current shunt Ensure that it is safe for the WhisperGen to start and then Set Enable Starts to 1 or 2 70 Non Warning or Non Fault Code Problems No start No bleed No start No bleed Possible Causes Possible Fixes The WhisperGen will not attempt to start when the start button is pushed When first installed the WhisperGen s bleed functions will not operate Enable Starts in the Installation Menu is switched to 0 The start button is faulty Ensure that it is safe for the WhisperGen to start and then Set Enable Starts to 1 or 2 Replace the control panel 71 No standby Non Warning or Non Fault Code Problems No standby After receiving a stop signal the WhisperGen will not go to standby 1 The Coolant Temp or the Exhaust Temp is still too high Possible Causes 2 The Coolant Temperature sensor or the Exhaust Temperature sensor is faulty 1 Ensure that the WhisperGen is receiving adequate cooling Possible Fixes 2 Replace the faulty sensor 72
53. other loads Possible Fixes disconnected from the battery Vbus Bus Voltage should always be about 0 6V less than Vbattery With the WhisperGen in Standby note the Bus Voltage Remove both Clamp Element wires from the terminals in the Electronic Module and then note the Bus Voltage If the bus voltage rises more than 0 5V then the Clamp Element has a low resistance path to earth and should be replaced Check the above a few times and make certain that it is the problem 2 When the WhisperGen is in Standby and all other loads disconnected Vbus Bus Voltage should always be about 0 6V less than Vbattery With the WhisperGen in Standby note the Bus Voltage and then remove the Glow Plug wire from the glow plug If the Bus Voltage increases by more than 0 5V then it is likely that the Glow Plug relay is stuck on Try tapping the relays in the electronics module until the Bus Voltage does not drop when the Glow Plug wire is connected 39 40 Isolator open Fault Codes numbered from 2 to 99 40 Isolator open Vbus has dropped below 7V after the Glowplug is turned on for the preheating of the evaporator Fault occurs during Preheat Mode 3 4 1 Isolate relay has malfunctioned Possible Causes 1 Replace electronics if this fault recurs Possible Fixes 40 Fault Codes numbered from 2 to 99 44 Fuel sense fail 44 Fuel sense fail The supply voltage to the fuel pump is on when it should not be Fault occurs durin
54. ow the allowed limit The battery voltage sense wires have a bad or no connection to the battery The fuse in the battery voltage sense wire has blown There is a very bad connection in the battery cables between the battery and the WhisperGen Charge the battery Reduce the electrical load and or charge the battery Fix the broken or poor connection Replace the fuse and check the sense wire for chaffing between the fuse and the WhisperGen Fix the bad connection 34 Fault Codes numbered from 2 to 99 32 Bus not charged 32 Bus not charged Vbus has not reached 7 2V for a 12V system or 14 4V for a 24V system within 30 seconds of the glowplug being turned off after it had been turned on for a few seconds to discharge the bus Fault occurs during STARTUP Mode 3 1 1 The clamp element has a low resistance path to earth Possible Causes 2 The glow plug relay is stuck on 1 When the WhisperGen is in Standby and all other loads Possible Fixes disconnected from the battery Vbus Bus Voltage should always be about 0 6V less than Vbattery With the WhisperGen in Standby note the Bus Voltage Remove both Clamp Element wires from the terminals in the Electronic Module and then note the Bus Voltage If the bus voltage rises more than 0 5V then the Clamp Element has a low resistance path to earth and should be replaced Check the above a few times and make certain that it is the problem 2 When the Whisp
55. rformance and void any WhisperGen warranty Along with any warnings instructions and procedures in this manual the user should also observe any such other common sense procedures generally applicable to equipment of this type Failure by the user to comply with any warnings instructions procedures or any such other common sense procedures may result in injury equipment damage property damage or poor performance of the WhisperGen The major hazards involved with operating the WhisperGen include explosion fire carbon monoxide fumes and electrical shock These hazards can be avoided if the user adheres to the procedures in this manual and exercises all due care Whisper Tech accepts no liability for direct indirect incidental special or consequential damages resulting from failure by the user installer or service technician to follow any warnings instructions and procedures in this manual or any such other common sense procedures generally applicable to equipment of this type The foregoing limitation extends to damages to person or property caused by the WhisperGen or damages resulting from the inability to use the WhisperGen including loss of profits loss of products loss of power supply the cost of arranging an alternative power supply and loss of time whether incurred by the user its employees the installer a service technician or any third party Whisper Tech reserves the right to change the speci
56. s products as it sees fit This publication describes the state of this product at the time of its publication and may not reflect the product at all times in the future This manual applies to the following WhisperGen systems manufactured by Whisper Tech Ltd New Zealand 5000 3000 and 7000 series WhisperGen PPS16 12MD and PPS16 24MD This Manual should be used in conjunction with the User s Manual and the Installation and Commissioning Manual Engine Numbering Engine Serial Numbers 12 and 24V 5000 to 5034 12V 3000 onwards 24V 7000 onwards Engine number coding The full engine number is stamped on the front right hand side of the engine block All of the 5000 series and the early 3000 and 7000 series have the full engine number stamped on the back left had side of the engine block Based on the following example the engine code is M 4 08 5005 01 5 M Marine system R RAPS C MCHP 4 24VDC 2 12VDC 3 230VAC 1 110VAC 08 u Month August 5005 Engine Serial Number 01 Year 2001 5 Batch No M5 Occasionally you may encounter an R1 01 00 as an example stamped below the main engine stamp In this case it indicates the first rebuild R1 occurred first month 01 of the year 2000 2000 Sequence of Operation This section details the sequence of events that the WhisperGen goes through during a normal start run and stop from the push of the start button through to the WhisperGen g
57. sperGen is not obstructed 4 Check that the exhaust pipe is not blocked or obstructed Listen for gurgling noises when the WhisperGen is trying to start and when it is cooling down with the fan on at 100 Remove any obstructions Remove the top plate from the exhaust cooler and check to see if it is blocked Clean flush if necessary If blocked also check flushing nozzle for blockage Clean replace if necessary 5 Check that exhaust temperature reading looks right Replace if in any doubt 6 Check replace the oxygen sensor If the oxygen sensor is faulty and causes the burner to run with a very lean mixture then the temperature of the exhaust will not rise quick enough 7 Remove the burner and check the burner seal The ceramic rope burner seal must always be replaced whenever the burner is removed 8 Replace the core engine or whole WhisperGen 56 Fault Codes numbered from 2 to 99 72 Drive bridge fail 72 Drive bridge fail The BridgeRunning signal indicates that the generator is not rotating while in RUN Fault occurs anytime during engine operation Mode 5 1 Failure of the electronics Possible Causes 2 Internal mechanical failure of WhisperGen 3 Open circuit or short circuit of an alternator phase to ground 1 Replace the electronics module Possible Fixes 2 Replace the core engine or whole WhisperGen 3 Check the connections of the alternator phase wires to the electronics boar
58. temperature measured on the main electronics board by a small temperature sensing integrated circuit 1 The air ducts on the back of the heat sink on the back of the WhisperGen electronics module are blocked 2 The air ducts into the electronics module are blocked 3 The WhisperGen is operating in an ambient air temperature of greater than 40 C 4 The airflow under the bottom of the WhisperGen is obstructed 5 The WhisperGen has been running with the enclosure lid off 6 The enclosure lid rubber seal is badly damaged 7 Faulty temperature sensor 8 Some electronic components in the electronics module failed creating heat 1 Unblock the air ducts to the heat sink 2 Unblock the air ducts to the electronics module 3 Reduce the ambient air temperature 4 Remove the obstruction from under WhisperGen 5 Re fit the enclosure lid 6 Re place the rubber seal 7 Replace the electronics module 8 Replace the electronics module 26 Fault Codes numbered from 2 to 99 12 Air supply failed 12 Air supply failed Possible Causes Possible Fixes BlowerTaco not between 4 and 150 for gt 5 seconds Fault occurs anytime during engine operation During normal operation of the burner fan there is a signal from it to indicate that it is going around 1 There is something obstructing the burner fan from going around 2 The burner fan is defective 1 Remove obstruction N Replace burner f
59. tery is measured at the battery using the battery voltage sense leads 1 The battery is flat There is a very large load being applied to the battery which is causing the battery voltage to drop below the allowed limit The battery voltage sense wires have a bad or no connection to the battery The fuse in the battery voltage sense wire has blown There is a very bad connection in the battery cables between the battery and the WhisperGen Charge the battery Reduce the electrical load and or charge the battery Fix the broken or poor connection Replace the fuse and check the sense wire for chaffing between the fuse and the WhisperGen Fix the bad connection 16 Warning Codes numbered from 102 to 199 182 Vbattery 182 Vbattery Possible Causes Possible Fixes Vbattery is more than 0 55Volts less than Vbus for more than 1 second Warning occurs during Charging Mode 2 and higher This results in electrical energy being lost and wasted gt 30W and may also result in the WhisperGen not being able to lift the battery right up to the Absorption voltage 1 Bad connections on the battery cables between the terminals on the inside of the WhisperGen electronics enclosure and the batteries 2 Bad connection in the battery voltage sense wire 3 Use of battery cables that are too long or too small in cross sectional area 1 Check the voltage drop across all connections and switches etc 2 Fi
60. uce the nitrogen pressure to the recommended value if necessary 4 Replace the core engine or whole WhisperGen 5 Check the connections of the alternator phase wires to the electronics board Remove all three wires and check insulation to ground Replace WhisperGen if there is an internal phase to earth contact 55 68 Engine sluggish Fault Codes numbered from 2 to 99 68 Engine sluggish Possible Causes Possible Fixes lalt is less than 25 or PowerOutput is less than elapsed time 3 300 where elapsed time is in seconds and starts counting up from zero when the WhisperGen cranks Fault occurs during Runup Mode 4 2 1 Low nitrogen pressure 2 Fuel flow to the burner is restricted 3 Air flow to the burner is restricted 4 Exhaust flow from the burner is restricted 5 Faulty exhaust temperature sensor 6 Faulty oxygen sensor 7 The burner has been lifted or the ceramic rope burner seal has been damage and is allowing the hot gasses from the burner to by pass the heater head and go directly into the exhaust reducing the power output of he WhisperGen 8 Internal mechanical failure of WhisperGen 1 Check and increase the nitrogen pressure to the recommended value if necessary 2 Remove the evaporator and with the fuel line connected to it turn on the fuel bleed function and check that the fuel flow rate is about 10 cc 1 5 per minute 3 Check that the air intake to the Whi
61. ugh the clamp If however the same Control voltage Vcontrol goes up too high because of this then error 92 is raised 1 The external charger has its charging voltage set substantially higher than the WhisperGen Absorption voltage 1 Reduce the charging voltage of the external charger or do not operate it and WhisperGen simultaneously 66 Non Warning or Non Fault Code Problems Temp Setpoint Non Warning or Non Fault Code Problems Temp Setpoint The Temp Setpoint is set at 60 but the Coolant Temp runs at 68 while the WhisperGen is running 1 To ensure that the control system remains stable when using a large Possible causes range of different secondary coolant pumps or different heat dump fans the WhisperGen modulates the pump or fan in the following way When the Coolant Temp reaches the Temp Setpoint 3 the WhisperGen turns the pump or fan to 30 RMS of the battery voltage The RMS voltage to the pump or the fan is then proportionally increased relative to the Coolant Temp so that it will be at 100 when the Coolant Temp is atthe Temp Setpoint 14 This results in there always being an error between the Coolant Temp and the Temp Setpoint while the WhisperGen is running Any time the pump of fan are turned on it is turned on to 100 RMS of the battery voltage for 1 second to ensure that the pump has started and is not stalled 1 There is no fix for this it s just the way it is Possible fixes
62. unning with the enclosure lid off 6 The enclosure lid rubber seal is badly damaged 7 Faulty temperature sensor 8 Some electronic components in the electronics module failed creating heat 1 Unscrew electronics module mounts and then clean fins and passageway to fins 2 Unscrew electronics module mounts and then clean holes and passageway to holes 3 Reduce the ambient air temperature 4 Remove the obstruction from under WhisperGen 5 Re fit the enclosure lid 6 Re place the rubber seal 7 Replace the electronics module 8 Replace the electronics module 14 Warning Codes numbered from 102 to 199 126 Hot Reset 126 Hot Reset Possible causes Possible fixes Engine is hot and might be running Warning occurs when the controller is restarted and the engine temperatures are already high exhaust temperature higher than TopCool block temperature is higher then BlockAlarm or the engine actually running Controller reset under these conditions is abnormal 1 Abad connection in comms cable between control panel and controller 1 Replace comms cable between control panel and controller 15 135 Vbattery Warning Codes numbered from 102 to 199 135 Vbattery Possible Causes Possible Fixes Vbattery is less than 10 Volts for 12 Volt WhisperGen s or 20 Volts for 24 Volt WhisperGen s for more than 1 second Warning occurs during STARTUP Mode 3 1 The battery voltage Vbat
63. x the broken or bad connection 3 Use the recommended minimum cable size and maximum length for battery cables 17 183 Tbattery Warning Codes numbered from 102 to 199 183 Tbattery Possible Causes Possible Fixes Tbattery is greater than 48 C Warning occurs during Charging Mode 2 and higher The battery temperature sensor which is fitted to the negative battery terminal registers that the battery temperature is getting close to the maximum normally recommended maximum temperature for batteries 1 There is an internal fault with the battery 2 There is not enough fresh air circulating around the batteries 3 The batteries are being operated in an environment that is just too hot 4 The batteries are being charged or discharged to rapidly for there size 5 The sensor is reading incorrectly 1 Replace the battery 2 Increase the air circulation around the batteries 3 Cool the batteries down some how or stop charging or discharging them 4 Reduce the current going into or out of the batteries 5 Replace the sensor 18 Warning Codes numbered from 102 to 199 190 V_error 190 V_error Possible Causes Possible Fixes V_error is greater than 0 2 for 12 Volt WhisperGen s or 0 4 Volts for 24 Volt WhisperGen s for more than 1 second Warning occurs during VOLTCONTROL Mode 3 Verror is a time averaged difference between Vbattery and Vcontrol which is the set point for the b

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