Section 3 Technical Information

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Eunice Stevenson
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1 Section 3 Technical Information In this Module: Engine identification Modes of operation Battery charging and heat manage operation Service and repair procedures Maintenance requirements

2 Engine Identification Engine number coding The full engine number is stamped on the front right hand side of the engine block behind the Filling and Pressure Relief Valves All of the 5000 series and the early 3000 and 7000 series have the full engine number stamped on the back left hand side of the engine block below the Burner Fan.

3 Engine Identification Based on the following example, if the engine code is; M Z M = Marine system 4 = 24VDC, (2 = 12VDC) 08 = Month (August) 7156 = Engine Serial Number 05 = Year (2005) 09 = Batch No. (M10) Z = Factory rebuilt engine.

4 FID (Flame Ionization detector) Location: Within the evaporator/burner assembly. Description: Ceramic tube enclosed Pylomax wire. Function: Flame detection within the burner. Transmits ma value to MPU to record flame presence or absence.

5 Glow Plug Location: Within fuel evaporator Description: Kanthal wire wound ceramic rod, 7/8 screwed ferrule with electrical terminal post. Function: Preheater; heats evaporator to fuel flash temperature. Remains on after ignition is present until flame is stabilised.

6 Evaporator Location: Top of Burner Description: Two part, Stainless Steel tube with internal S/S mesh wick. Internal fuel delivery gallery. Function: After preheat by Glow plug, remains hot from reflected heat from burner. Fuel is evaporated and mixed with incoming air before flowing into the burner.

7 Oxygen Sensor Location: Top left of Exhaust Heat Exchanger. Description: Honeywell heated sensor, sintered sampling tip. Function: Samples exhaust gas for oxygen content and transmits the information to the MPU. Essential for accurate setting and monitoring of Air/Fuel ratio

8 The oxygen sensor plays no part in the initial ignition of the burner during start up. During the initial 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

Burner Shell Assembly Location: On top of Core Engine/Power-Head. Description: Stainless Steel. Series of shells within shells (six in total), acting as heat shields and air preheating galleries.

9 Burner Shell Assembly Location: On top of Core Engine/Power-Head. Description: Stainless Steel. Series of shells within shells (six in total), acting as heat shields and air preheating galleries. Function: Receives the air/fuel mixture and contains the flame within the combustion chamber. Heat is directed down and around the heater heads, back up via a separate gallery and exits into the Exhaust Heat Exchanger.

Burner Fan Blower Location: Upper left of Burner Description: A Pulse Width Modulation (PWM) speed controlled fan. Function: The speed of operation is controlled by the WhisperGen microprocessor.

10 Burner Fan Blower Location: Upper left of Burner Description: A Pulse Width Modulation (PWM) speed controlled fan. Function: The 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 (along with a linear increase in fuel). If the WhisperGen is 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.

11 Fan Tachometer The Fan Tachometer measures the speed of the burner fan. The Fan Tachometer is used by the microprocessor to determine that the burner fan is rotating and at what rate.

12 Exhaust Temperature Sensor Probe Location: In exhaust gas stream between the burner outlet and the exhaust HX inlet. Description: K Type Thermocouple. Function: measures the exhaust gas temperature and signal is inputted to the MPU. See next slide to see how this temperature reading is used:

13 Determines when to crank the engine during Heatup. Determines when to produce an over temperature warning and/or fault at any time. Determines when to switch the WhisperGen to Standby during Cool Down. Determines how long the glow plug needs to be on before turning on the fuel to the burner. Determines when to switch off the glow plug after the burner has successfully started. Determines how much air needs to go through the burner when igniting the burner. Controls the maximum exhaust temperature to not more than the ExhaustSetpt (exhaust temperature set point currently 480 C).

14 Fuel Pump Location: In fuel line, (exact position will differ slightly with every installation). Description: Piston / solenoid type positive displacement, metering pump. Function: Supplies metered fuel flow to the evaporator/burner. The fuel pump s speed of operation is controlled by the WhisperGen microprocessor.

15 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.

16 Daisy Chain Components 1. Exhaust Heat Exchanger Thermal Block Switch Location: Mounted on the bottom left hand side of the exhaust heat exchanger. Description: A self-resetting normally closed 100 C thermal switch. Function: 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.

Daisy Chain Components 2. Thermal Cut Out Fuse Location: Within Thermal Switch Block on the bottom left hand side of the exhaust heat exchanger. Description: 150 C thermal fuse.

17 Daisy Chain Components 2. Thermal Cut Out Fuse Location: Within Thermal Switch Block on the bottom left hand side of the exhaust heat exchanger. Description: 150 C thermal fuse. Function: 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. Note: Should the thermal fuse blow then the Exhaust Heat Exchanger Thermal Switch Block must be replaced.

18 Daisy Chain Components 3. Fan Thermal Switch (Internal Ambient Thermal Switch) Location: Mounted on the burner fan guard. Description: Self-resetting normally closed 100 C thermal switch Function: 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.

19 Daisy Chain Components 4. Coolant Temperature Switch Location: Mounted into the coolant circuit where the coolant enters the engine block. Description: Self-resetting normally closed 95 C thermal switch Function: One 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

Coolant Temperature Sensor Location: Mounted into the

Description: Small potted temperature sensing integrated

Function: Controls the coolant temperature to close to the

Shuts the WhisperGen down if the coolant temperature

20 Coolant Temperature Sensor Location: Mounted into the coolant circuit where the coolant exits the engine block. Description: Small potted temperature sensing integrated circuit. Function: Controls the coolant temperature to close to the Temp Setpoint. Shuts the WhisperGen down if the coolant temperature reaches the over temperature alarm set point (84 C) Turns on all pumps and the fan when the coolant temperature is higher than the over temperature alarm set point.

21 Battery temperature sensor Location: On the main earth terminal of the Battery Bank. Description: Simple heat sensing thermocouple. Function: Measures the battery temperature to compensate the absorption voltage with regard to temperature when the battery is being charged.

22 Battery Current Shunt Location: Earth side of Battery, as close to the battery as possible. Description: 500A, 50mV Function: 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.

Flushing Valve Assembly Location: Lower rear of enclosure.

flow of fresh water to the flushing nozzle.

10 seconds just after the WhisperGen has cranked -For 10 seconds 1

23 Flushing Valve Assembly Location: Lower rear of enclosure. Description: Solenoid operated on/off water valve Function: Controls the flow of fresh water to the flushing nozzle. Controlled by the WhisperGen microprocessor and opened and closed: -For 10 seconds just after the WhisperGen has cranked -For 10 seconds 1 minute after the WhisperGen has cranked -This is repeated once every 10 hours if the WhisperGen is running continuously

Exhaust Heat Exchanger Flushing Assembly.

Function: When Flush Valve is activated, fresh water

24 Exhaust Heat Exchanger Flushing Assembly. Location: Top of Exhaust Heat Exchanger. Description: Spray nozzle positioned over HX plates, connected by hose to the Flushing Valve. Function: When Flush Valve is activated, fresh water is sprayed through a nozzle and onto the Exhaust HX plates, cleaning off any combustion residue.

25 Primary Coolant Pump Location: In the Primary Coolant Circuit usually just downstream of the Header Tank. Description: Centrifugal type circulation pump. Function: Circulates Coolant around the Primary Coolant Circuit. Not supplied with WhisperGen TM

26 Primary Coolant Pump (Cont) The power supply to this pump is from the battery via the MPU but it also a has a diode feed directly from the WhisperGen alternator so that even if the WhisperGen 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 signal to stop.

27 Secondary Coolant Pump Description: Self priming, positive displacement, raw water pump. Function: Pumps raw water through one side of the marine heat exchanger inside the WhisperGen enclosure and then back out into the raw water. The secondary coolant pump is Pulse Width Modulation (PWM) speed controlled by the WhisperGen MPU to maintain the coolant temperature close to the coolant temperature set point. Not supplied with WhisperGen TM

28 Mobile or land based systems A heat dump radiator and fan is used instead of the raw water cooling. 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.

29 Auxiliary Heater (If Fitted) 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.

30 Modes of Operation 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 going into Standby after the stop button has been pushed. Each part of the sequence is called a Mode.

31 Modes of Operation IDLE mode [Mode=2.1] The WhisperGen TM 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 TM 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]

32 Modes of Operation STARTUP mode [Mode=3.1 to 3.9] The WhisperGen TM 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 isolator 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.

33 Modes of Operation 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.

34 Modes of Operation The FID signal 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/fuel values), until the engine is hot enough to crank

35 Modes of Operation 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.

36 Modes of Operation CRANK mode [Mode=4.1 & 4.2] 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.

37 Modes of Operation RUN mode [Mode=5.1 & 5.2] Once the engine has commenced running, the heat exchanger washer is turned on [Mode=5.1] for 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.

38 Modes of Operation At any stage after startup, a shutdown sequence will be initiated if a shutdown signal is received. This signal may come from 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 charging voltage that interacts adversely with the WhisperGen TM.

39 Modes of Operation SHUTDOWN mode [Mode=6.1 to 6.5] 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 Stand-By 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 to the Idle or Stand-By condition and can restart.

40 Battery Charging Operation At any time that the WhisperGen is started for any reason a battery charging cycle is commenced and continued until complete or until the WhisperGen is stopped for any reason. 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.

41 Battery Charging Operation When the battery has been lifted to the Absorb Voltage the 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

42 Battery Charging Operation Battery Charging 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. Shut 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.

43 Heat Management Operation Heat Management At any time that the WhisperGen is started for any reason a the WhisperGen 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 continue to run maintaining the Coolant Temperature at close to the Temp Setpoint until the WhisperGen is stopped for any reason. During this time The 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.

44 Service and Maintenance Service A Minor Service Interval Service A Schedule: 500 hours use (12 months since installed) 1,500 hours use (36 months since installed) 2,500 hours use (60 months since installed) 3,500 hours use (84 months since installed) 4,500 hours use (108 months since installed) 5,500 hours use (132 months since installed) etc.

45 Service and Maintenance What to check after each 500 hours of use: Service A Tasks: 1. Check all coolant levels and flow rates. Bleed the system as required check for signs of leakage. 2. Check the condition of all hoses. 3. Check the seawater filter and inlet for debris and build up. 4. Inspect the fuel filter and fuel pump. Clean and replace the fuel filter and fuel pump as required. 5. Check the condensate drain is working correctly. 6. Check the FID and reset FID height. 7. Change the Evaporator wick. 8. Check the condition of all battery cables. Check all the battery cable connections. 9. Remove the electronics cover and check the wiring, loom and elements cables. 10. Check and reset variables using Micromon. 11. Check the user display is working correctly. 12. Carry out a test run 13. Check exhaust with a gas analyzer for 9% O Check for any exhaust gas leakage.

46 Service and Maintenance Service B Intermediate Service Interval Service B Schedule: 1,000 hours use (24 months since installed) 3,000 hours use (72 months since installed) 5,000 hours use (120 months since installed) etc

47 Service and Maintenance What to check after each 1000 hours of use: Service B includes Service A plus the tasks below: 1. Change the primary coolant and reverse flush the system. 2. Check the FID and glow plug. Change the FID and glow plug as needed. 3. Replace the fuel filter element. 4. Remove the heat exchanger top plate and check for any blockage. 5. Clear any blockage as needed. 6. Check the flushing nozzle for blockage and wear. 7. Clear blockage or replace the flushing nozzle. 8. Strip and clean the seawater heat exchanger. 9. Carry out a test run 10. Check exhaust with a gas analyzer for 9% O Check for any exhaust gas leakage.

48 Service and Maintenance Service C Major Service Interval Service C Schedule: 2,000 hours use (48 months since installed) 4,000 hours use (96 months since installed) 6,000 hours use (144 months since installed) etc.

49 Service and Maintenance What to check after each 2000 hours of use: Service C includes Service B plus the tasks below: 1. Remove the top burner ceramic and check its condition. 2. Replace the ceramic as needed. 3. Replace the ceramic rope and heater head seals. 4. Carry out a test run 5. Check exhaust with a gas analyzer for 9% O2. 6. Check for any exhaust gas leakage.

50 Service and Maintenance Trouble shooting Refer to the User Manual for fault diagnosis Refer to the Trouble Shooting Guide

Operation of the FFBH is enabled and disabled by the Automatic Temperature Control Module (ATCM).

Operation of the FFBH is enabled and disabled by the Automatic Temperature Control Module (ATCM). Page 1 of 8 Published : Apr 22, 2004 Auxiliary Heater COMPONENT LOCATIONS Item Part Number Description 1 - Fuel line connection with fuel tank 2 - Auxiliary fuel pump 3 - Fuel fired booster heater GENERAL