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Silent Power Series Generator Operator Manual · Operator Manual Models WSP25 - WSP40 with DSE7320...

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  • Silent Power Series Generator

    Operator Manual

    Models WSP25 - WSP40 with DSE7320 Controller

    PN: 221228

  • Thank you for purchasing a Wanco Silent Power Series three-phase diesel generator set. This manual

    contains important safety and operating information - please read the complete manual before attempting

    to operate the generator.

    All information in this publication is based on the latest product information available at the time of approval

    for printing. We reserve the right to make changes at any time without notice.

    No part of this publication may be reproduced without written permission.

    Throughout this manual pay special attention to statements preceded by the following signal words:

    Failure to properly follow these precautions is likely to result in property damage,

    serious injury or death

    Failure to properly follow these precautions can result in property damage,

    serious injury or death

    Indicates a possibility of personal injury or equipment damage if instructions are

    not followed

    Gives helpful information.

    If you need assistance with your generator set, please contact our service department using the following

    information:

    Wanco Inc.

    5870 Tennyson Street

    Arvada, Colorado 80003

    303-427-5700

    fax 303-427-5725

    www.wanco.com

    [email protected]

    If you need technical assistance with the alternator, please contact Mecc Alte directly:

    Visit: www/meccalte.com Support Service Network North America to locate a qualified service center

    or contact the US office directly at:

    MECC ALTE INC.

    1229 ADAMS DRIVE - 60051

    MCHENRY - ILLINOIS

    USA

    Tel. 815/344-0530 Fax 815/344-0535 email: [email protected]

    If you need technical assistance with the Perkins engine, please contact your local Perkins Distributor or

    call Wanco Inc.

  • Page | 3

    CONTENTS

    1. SAFETY INSTRUCTIONS ..................................................................... 4

    2. MAJOR COMPONENT LOCATIONS ..................................................... 6

    3. OPERATION .......................................................................................... 10

    4. MAINTENANCE ..................................................................................... 12

    5. TROUBLESHOOTING ........................................................................... 14

    6. SPECIFICATIONS ................................................................................. 15

    7. WIRING DIAGRAMS ............................................................................. 16

    8. TOWING ................................................................................................ 18

    Read and understand this Operator Manual before starting the generator. Failure to do so could

    result in personal injury or equipment damage.

    Refer to the Perkins Engine Operation & Maintenance Manual for important engine-specific

    information.

  • Page | 4

    SAFETY INSTRUCTIONS

    Electric Shock Hazard.

    Contact with electric power lines will cause serious injury or death.

    Contact with AC output terminals or other live electrical circuits on

    this generator during operation will result in severe injury or death.

    Only qualified service personnel should attempt to service the

    generator electrical systems.

    Explosion Hazard.

    Keep Engine, fuel and other combustibles away from sparks, open

    flame and burning objects.

    Do not smoke near the generator.

    Stop the engine before filling or draining the fuel tank.

    Use only diesel fuel do not fuel with gasoline.

    Replace the fuel tank cap after refueling.

    Do not use gasoline or other highly flammable solvents for cleaning.

  • Page | 5

    Electric Shock Hazard

    Disconnect the cranking battery negative terminal and/or disengage

    the battery at the Battery Disconnect Switch before servicing any part

    of the engine, alternator or generator controls.

    Moving Parts Hazard

    Disconnect the cranking battery negative terminal and/or disengage

    the battery at the Battery Disconnect Switch before servicing any part

    of the engine, alternator or generator controls.

    Risk of Sever Burns.

    Do not touch the exhaust system or areas near the exhaust at rear of

    trailer.

    Do not remove radiator cap when engine is hot. Contents are hot and

    under pressure.

  • Page | 6

    MAJOR COMPONENT LOCATIONS

    Generator left-side view (from operators position)

    Generator right-side view (from operators position)

    Lift Hook

    Coolant Drain

    Containment

    Vessel Drain

    Forklift Access (2X)

    Control Panel & Main

    Circuit Breaker

    Voltage Selector Switch

    & Lug Connections

    Emergency Stop

    Switch

    Camlock Connections

    and Convenience

    Receptacles

    Oil Drain

    Containment Vessel Cleanout & Access to Diesel Drain

  • Page | 7

    The Deepsea Genset Controller:

    Located in the Control Panel at the operator end of the generator.

    Refer to the DSE7200/7300 Series Operators Manual for additional information

    Menu Navigation:

    Use the Right-Left (Next-Previous) Navigation Buttons to scroll between menus

    Use the Up-Down (Scroll) Navigation Buttons to scroll within a menu

    Use the center button to select an item

    Menu Navigation Buttons User Configurable LEDs (4)

    Close

    Generator

    (Manual

    Mode only)

    Stop/Reset Mode

    Manual Mode

    Auto Mode

    Mute Alarm & Lamp Test

    Start Engine (Manual

    Mode only)

    Display

    Generator

    Available LED Closed

    Generator

    LED

  • Page | 8

    Lower AC Connection Panel

    Located behind the flip-up panel on the generator right side.

    Emergency Stop Switch

    Located outside, beside the AC electrical connection panel on the generator right side.

    The Emergency Stop Switch shuts down the engine immediately for Emergency

    use only. See the Operating Section for instructions on normal engine shutdown.

    Circuit Breakers for

    convenience receptacles

    120V GFCI Convenience

    Receptacles

    Shore Power Inlet for engine coolant

    heating and battery charging

    Camlock fittings for connecting three-phase loads. Consult a

    qualified electrician before connecting to these terminals

    120/240V CS6369

    Convenience Receptacles

    Remote Start Terminals

  • Page | 9

    Main Circuit Breaker

    Located in the Control Panel at the operator end of the generator

    The Main Circuit Breaker is present to protect the AC alternator windings

    from overload damage. When the circuit breaker is in the ON position,

    current can flow from the alternator to the AC output connections. When in

    the OFF position, no current or voltage will be present at any AC output

    connection.

    This circuit breaker may switch OFF during operation if it detects an overload

    condition.

    Voltage Selector Switch

    Located behind the hinged cover in the Upper AC Connection Panel on the generator right side.

    The Voltage Selector Switch reconfigures the alternator output wiring to allow the

    generator to power a wide variety of loads. See Section 3 - Operating the

    Generator for more information on switching voltages. NEVER change the Voltage

    Selector Switch while the engine is running.

    Battery Disconnect Switch

    Located inside the engine compartment on the generator right side.

    ON Position 12VDC from the cranking battery is available to the engine and

    controller. This switch must be ON for the Controller to operate and for starting

    the engine.

    OFF Position the cranking battery is disconnected, allowing maintenance to be

    conducted safely on the engine and control panels. This position also reduces

    unintended battery drain when not in use.

  • Page | 10

    OPERATING THE GENERATOR Selecting and Adjusting the Output Voltage

    Never turn the Voltage Selector Switch while the engine is running.

    With the engine OFF, use the Voltage Selector Switch to select the desired output voltage depending on the

    loads to be powered:

    480/277V 3PH position provides 480V L-L / 277 L-N three-phase

    208/120V 3PH position provides 208V L-L / 120V L-N three-phase

    240/120V 1PH position provides 240V L-L / 120V L-N single-phase

    Once the engine is running, use the Voltage Adjust Rheostat to fine tune the output voltage. Nominal

    480/277V loads should not be powered if the output voltage is below 460V. Likewise, 208/120V loads should

    not be powered if the output voltage is above 220V.

    The 120V single phase GFCI convenience receptacles may be used in any of the three Voltage Selector

    Switch positions. The 120/240V CS6369 convenience receptacles can only be used when the Voltage

    Selector Switch is in one of the three-phase positions do not use these receptacles when the Voltage

    Selector Switch is in the 240/120V single-phase position.

    Before starting the engine:

    Check engine oil level

    Check engine coolant level

    Confirm that sufficient fuel is in the fuel tank

    Confirm that the Emergency Stop Button is not depressed

    Confirm that the Battery Disconnect is closed

    Confirm that the Main Circuit Breaker is in the OFF position.

    Confirm that the Voltage Selector Switch ) is in the desired position

  • Page | 11

    Starting the engine in Manual Mode: All engine starting controls are located at the operator end of the generator.

    Switch the Controller Power toggle to the ON position.

    Review and resolve any notices or alarms from the Controller.

    Press and release the Manual Mode button on the Controller.

    Press and release the Start Engine button on the Controller. It may take a couple of seconds

    before the starter engages.

    Allow the engine to warm up for a few minutes.

    Stopping the engine in Manual Mode: Emergency shutdown - Press the Emergency Stop Button (located beside the electrical connection

    panel) to immediately stop the engine in the event of an emergency.

    DO NOT use the Emergency Stop Button for normal shutdown.

    Normal shutdown - Press and release the Stop/Reset button on the Controller.

    Connect (Close) the Generator to the Load in Manual Mode: Confirm that the Voltage Selector Switch is in the correct position for the intended load. DO NOT

    turn the Voltage Selector Switch while the engine is running.

    Adjust the output voltage using the Voltage Rheostat if necessary - this may be done while the

    engine is running.

    Confirm that the Generator Available LED is lit on the Controller.

    Close the Main Circuit Breaker.

    Monitor the output voltage and frequency for any abnormalities.

    Disconnect (Open) the Generator from the Load in Manual Mode:

    Turn off loads as appropriate depending on how the generator is being used.

    Switch the Main Circuit Breaker open.

  • Page | 12

    MAINTENANCE

    Engine Service Schedule

    Refer to Perkins SEBU8311 Operation Manual for additional information and for service intervals beyond

    than 1000hrs.

    Frequency Task

    Daily Check coolant

    Inspect air cleaner service indicator

    Inspect air precleaner element

    Check oil level, add as needed

    Drain water from primary fuel/water separator

    Visual inspection for leaks, loose parts, etc.

    50hrs or Weekly Drain water and sediment from the main fuel tank

    250hrs or every 6mo Inspect/adjust engine alternator and fan belts

    500hrs or every 12mo Replace the main fuel system filter

    Check battery electrolyte level

    Test coolant, add Supplemental Coolant Additive (SCA) as needed

    Clean/replace air cleaner primary element

    Inspect/replace air precleaner element

    Replace engine oil and filter

    Inspect/replace fluid hoses and clamps

    Clean dirt and debris from radiator fins

    1000hrs Replace engine alternator and fan belts

    Inspect/adjust valve lash

    Inspect turbocharger (if applicable)

  • Page | 13

    Perkins Engine Fluids and Common Service Parts

    Fuel D1/D2 Diesel, minimum cetane 40, low sulfur (LSD or ULSD)

    Coolant Perkins ELC or ethylene glycol meeting ASTM D4985, mixed 1:1 with water

    Air filter element 135326206

    Fuel pre-filter 130306360

    Fuel filter 26561117

    Oil filter 140517050

    Engine oil API CH-4 or higher, or EMA DHD-1. Mineral or synthetic base:

    SAE 0W20 40 C (40 F) 10 C (50 F)

    SAE 0W30 40 C (40 F) 30 C (86 F)

    SAE 0W40 40 C (40 F) 40 C (104 F)

    SAE 5W30 30 C (22 F) 30 C (86 F)

    SAE 5W40 30 C (22 F) 40 C (104 F)

    SAE 10W30 20 C (4 F) 40 C (104 F)

    SAE 15W40 10 C (14 F) 50 C (122 F)

  • Page | 14

    TROUBLESHOOTING

    Problem Common Solutions

    The Deepsea controller display is blank Confirm the Battery Disconnect Switch is closed

    The engine will not crank Check all battery cables for damage

    Confirm the battery voltage is at least 12.0 volts

    The engine cranks but will not start Confirm sufficient fuel is in the fuel tank

    Confirm battery voltage is at least 12.0 volts

    The engine shut down unexpectedly Review any alarms on the Deepsea controller

    Confirm sufficient fuel is in the fuel tank

    Confirm the engine oil level is Full (do not overfill)

    No voltage at the main power terminals Confirm the Main Circuit Breaker is in the ON position

    Incorrect voltage at the main power terminals Check the Voltage Selector Switch position

    Adjust using the Voltage Adjust Rheostat as needed

    No voltage at the convenience receptacles Confirm the convenience receptacle circuit breakers are ON

    Incorrect voltage at the convenience receptacles Do not use the CS6369 receptacles in 240/120V 1PH mode

    Adjust using the Voltage Adjust Rheostat as needed

  • Page | 15

    Section 6 - SPECIFICATIONS

    Wanco Model WSP25 WSP40

    Standby Rating 27 kVA / 22 kW 38 kVA / 30 kW

    Prime Rating 25 kVA / 20 kW 35 kVA / 28 kW

    Voltage Selections 480/277 V 3-Phase 480/277 V 3-Phase

    208/120 V 3-Phase 208/120 V 3-Phase

    240/120 V 1-Phase 240/120 V 1-Phase

    Fuel Tank Capacity 68 gal (257 L) 68 gal (257 L)

    Fuel Containment Full Full

    Genset Controller Deepsea 7310 Deepsea 7310

    Cranking Battery 12V Maintenance Free, BCI 31 12V Maintenance Free, BCI 31

    Engine Brand/ Model Perkins 404D-22G Perkins 404D-22TAG

    EPA Emission Compliance Tier 4i Flex Tier 4i Flex

    Cylinders/Displacement 4-cylinder / 2.2 L 4-cylinder / 2.2 L

    Coolant Capacity 1.8 gal (7.0 L) 2.4 gal (9.3 L)

    Lube Oil Capacity 2.8 gal (10.6 L) maximum 2.8 gal (10.6 L) maximum

    Fuel Type Diesel Diesel

    Fuel Consumption 1.6 gal (6 L) per hour Full Load 2.3 gal (8.7 L) per hour Full Load

    Alternator Mecc Alte ECP28-2L/4 Mecc Alte ECP28-VL/4

    Frequency 60 Hz 60 Hz

    Voltage Regulator DER1 DER1

    Excitation Boost MAUX PMG MAUX PMG

    Dimensions L x W x H 77 x 39 x 59 inch (196 x 99 x 150 cm) 93 x 39 x 59 inch (236 x 99 x 150 cm)

    Weight dry w/o trailer 2921 lb (1325 kg) 4026 lb (1826 kg)

    * With optional Wanco trailer

  • Page | 16

    Section 7 - WIRING DIAGRAMS

  • Page | 17

    503

    CT3

    CT2

    CT1

    508

    509

    507

    501

    502

    510

    500

    VOLTAGE

    SELECTOR

    SWITCH

    GFCI DUPLEX 1

    20 AMPS

    120 VOLTS

    GFCI DUPLEX 2

    20 AMPS

    120 VOLTS

    TWIST LOCK 1

    50 AMPS

    120/240 VOLTS

    TWIST LOCK 2

    50 AMPS

    120/240 VOLTS

    3PH 480V3PH 208V1PH 240V

    3PH 480V3PH 208V1PH 240V

    3PH 480V3PH 208V

    3PH 480V3PH 208V

    217216

    2SX440

    1R1

    KA3415 416

    T9-1

    F MC C B

    T7-1FU6

    GEN

    CB

    T3

    T6T5

    T2 T4T1T12

    T7T10

    T9T8

    T11

    23 11 20 13 1 2 28 12

    103 19 25

    H

    H N

    N H

    H N

    N Y

    W GRD

    X Y

    W GRD

    X

    CB-1 CB-2 CB-3 CB-4

    3 88 25

    2215

    NA CB GROUND

  • Page | 18

    Section 8 - TOWING

    Check tires, wheels, and axle lock:

    Failure to properly follow these precautions can result in property damage, serious

    injury or death

    Check tires for wear. Replace worn tires.

    Ensure tires are inflated to the proper pressure.

    Verify all wheel lugs are in place and tightened. Do not tow the trailer if a wheel lug is missing.

    Check the drawbar, tow hitch, and safety chains:

    Failure to properly follow these precautions can result in property damage, serious

    injury or death

    Ensure the tow hitch on the tow vehicle is rated for weight equal to or greater than the genset gross

    vehicle weight rating (GVWR). The GVWR is listed on the vehicle identification tag.

    Ensure the tow hitch on the tow vehicle and the drawbar hitch on the trailer are compatible.

    Inspect the tow hitch and drawbar hitch for wear and damage. Replace or repair if necessary.

    If the trailer has a removable drawbar, ensure the drawbar is attached securely to the trailer frame

    with two sets of bolts, washers, and nuts. The bolts should engage the drawbar and the nuts should

    be tight.

    Lower the drawbar jack into the down position by pulling the jack locking pin and rotating the jack

    downward. Release the pin and continue rotating the jack until it is vertical. When the jack is properly

    set, the locking pin snaps into position with an audible click. Use the hand-crank on the jack to

    lower the wheel to the ground.

    Verify the trailers four corner leveling jacks (if equipped) are in the up position and secured with their

    locking pins. To raise the leveling jacks, use the hand-crank on each jack to raise the jack foot off the

    ground, then pull the jack locking pin and rotate the jack upward. Release the pin and continue

    rotating the jack until it is horizontal and the pin reengages with an audible click.

    Use the drawbar jack to raise the front of the trailer and set the drawbar hitch on the tow vehicle

    hitch. Ensure the coupling is properly engaged and locked.

  • Page | 19

    Raise, rotate, and lock the drawbar jack in the up or horizontal position.

    Verify approved safety chains are attached properly to both the trailer and tow vehicle. The chains

    should cross underneath the tow hitch.

    Ensure the trailer brake lights, taillights, and directional (turn) indicators are

    connected and functioning properly.

    Tow-chain hook-up:

    Failure to properly follow these precautions can result in property damage, serious

    injury or death

    During towing

    Failure to properly follow these precautions can result in property damage, serious

    injury or death

    Do not tow the trailer with any people, parts, supplies, or additional equipment attached to the trailer

    or loaded onto it.

    Do not tow additional trailers or other equipment in tandem with the message sign trailer.

    The recommended maximum speed for highway towing is 65 mph (105 km/h). For off-road towing,

    the recommended maximum speed is 15 mph (25 km/h) or less, depending on terrain. Always tow

    at a safe speed.

    Adhere to applicable transportation department regulations when towing the trailer.

  • Page | 20

    After towing

    After towing, unhook the tow chains from the tow vehicle, then use the drawbar-mounted jack to raise the

    drawbar and release the drawbar hitch from the tow vehicle. Pull the vehicle away from the message sign

    trailer when ready.

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