Mastervolt Whisper 12 ultra User manual

INSTALLATION MANUAL

WHISPER 12 / 16 ULTRA

- Three phase - 1500 RPM -

Marine diesel generating set 230/400V-50 Hz

Digital Diesel Control

MASTERVOLT

Snijdersbergweg 93,

1105 AN Amsterdam

The Netherlands

Tel.: +31-20-3422100

Fax.: +31-20-6971006

www.mastervolt.com V4. October 2008

Art.nr. 50200381

TABLE OF CONTENTS

Reproduction, transfer, distribution or storage of part or all of the contents in this document in any form without the prior written

permission of Mastervolt is prohibited.

TABLE OF CONTENTS:

1INSTALLATION............................................................................................................................................................... 3

1.1 General .............................................................................................................................................................. 3

1.2 Location.............................................................................................................................................................. 3

1.3 Instructions for optimal sound and vibration insulation ....................................................................................... 3

1.4 Ventilation........................................................................................................................................................... 4

1.5 Connections ....................................................................................................................................................... 4

1.5.1 Fuel supply ........................................................................................................................................ 7

1.5.2 Cooling .............................................................................................................................................. 8

1.5.3 Exhaust system ............................................................................................................................... 12

1.5.4 Digital Diesel Control system (12 Volt) ............................................................................................ 15

1.5.5 AC power system (230 Volt)............................................................................................................ 17

2INSTALLATION SPECIFICATIONS.............................................................................................................................. 19

2.1 General ............................................................................................................................................................ 19

2.2 Commission table............................................................................................................................................. 19

2.3 Installation specifications.................................................................................................................................. 20

2.4 Specification of the accessories ....................................................................................................................... 20

2.5 Installation materials......................................................................................................................................... 21

3DIAGRAMS & DRAWINGS ........................................................................................................................................... 26

3.1 DC wiring Whisper 12 Ultra Three Phase......................................................................................................... 26

3.2 DC wiring Whisper 16 Ultra Three Phase......................................................................................................... 28

3.3 Electrical diagrams AC connections (alternator models with 6 wires) .............................................................. 30

3.4 Electrical diagrams AC connections (alternator models with 12 wires) ............................................................32

3.5 Diagram electronic governor (Whisper 12 Ultra Three Phase only) .................................................................34

3.6 Remote control panel drawings ........................................................................................................................ 35

3.7 Dimensions Whisper 12 Ultra Three Phase...................................................................................................... 36

3.8 Dimensions Whisper 16 Ultra Three Phase...................................................................................................... 37

INSTALLATION

1 INSTALLATION

1.1 GENERAL

This installation manual is valid for the following models:

Part number Description

51107305 Whisper 12 Ultra Three Phase

230V-400V 1500rpm

51107306 Whisper 12 Ultra Three Phase

230V-400V 1500rpm -ungrounded

51108305 Whisper 16 Ultra Three Phase

230V-400V 1500rpm

51108306 Whisper 16 Ultra Three Phase

230V-400V 1500rpm -ungrounded

For other models see our website: www.mastervolt.com

To ensure reliability and durability of the equipment, it is

very important that the installation is carried out with the

utmost care and attention. To avoid problems, such as

temperature problems, noise levels, vibration, etc. the

instructions set out in this manual must be followed and all

installation work must be carried out professionally.

1.2 LOCATION

Since Whisper generating sets have extremely compact

dimensions, they can be installed in tight locations. Please

consider that even almost maintenance-free machinery

must still remain accessible.

When selecting the location area in which to mount the

generating set, make sure there is sufficient room to carry

out any maintenance work. The unit must be easily

accessible on the service side and on the distribution side

to have access to the V-belt

Please also note that in spite of the automatic oil pressure

sensor it is still essential that the oil level is checked

regularly.

1.3 INSTRUCTIONS FOR OPTIMAL SOUND

AND VIBRATION INSULATION

Position the generating set as low as possible in the

vessel. As the generating set is already secured to the

base frame by means of flexible engine mountings, the

frame must be mounted directly, without additional

vibration dampers, to the vessel’s main structure. Use the

included mounting template to determine the mounting

spots.

Whisper generating sets are standard equipped with a

sound cover. The canopy has been designed to give

effective sound insulation. For optimum sound and

vibration dampening, the following factors should be

considered.

1 Most important is the structure on which the generator

is places to be stiff. Directly below the rubber

mountings the structure should be supported vertically

to the superstructure of the ship.

2 Avoid mounting the generating set in close proximity

to thin walls or floors that may cause resonance.

3 Sound dampening is extremely poor if the generating

set is mounted on a light weight flimsy surface such

as plywood which will only amplify vibrations. If

mounting on a thinner surface cannot be avoided, this

should be at least be reinforced with stiffening struts

or ribbing. If possible, holes should be drilled or cut

through the surface to help reduce the resonance.

Covering the surrounding walls and floors with a

heavy coating plus foam will certainly improve the

situation.

4 Never connect the base of the generating set directly

to bulkheads or tanks.

Figure 1: Mounting of the Whisper generating set. X = wrong, V = OK

INSTALLATION

1.4 VENTILATION

The generating set normally draws air from the engine

room. Engine rooms with natural ventilation must have

vent openings of adequate size and location to enable the

generating set to operate without overheating. To allow an

ample supply of air within the temperature limits of the

generating set an opening of at least 500 c m2is required.

A "sealed" engine compartment must have a good

extraction ventilator to maintain reasonable engine room

temperatures. High temperature of intake air reduces

engine performance and increases engine coolant

temperatures. Air temperatures above 40°C reduce the

engine power by 2% for each 5°C of rise. To minimise

these effects the engine room temperature must not be

more than 15ºC above the outside ambient air

temperature.

Apply a combination of ventilators, blowers and air intake

ducting to meet the temperature limit. The air inlet ducts

should run to the bottom of the engine room to clear fumes

from the bilge and to circulate fresh air. Air outlets should

be at the top of the engine room to remove the hottest air.

An engine room blower should be used as an extraction

ventilator to remove air from the engine room.

In cases where it is impossible to meet the above

mentioned temperature limit by using machine room

ventilation, connections are to be made for an air inlet

directly to the enclosure. With these connections the

generating set can be directly connected to an air duct.

Air inlets should be louvered, where appropriate, to protect

the engine room and to protect the generating set from

water spray. As an extra precaution, the fitting of a cowl

ventilator with a cover box located as high as possible, is

recommended.

1.5 CONNECTIONS

The generating set comes supplied with all supply lines

and output cable (i.e. electric cables, cooling water

connections, exhaust, fuel lines etc.) already connected to

the engine and generator. The supply lines are fed through

the capsule’s front base. The connections are marked as

shown in figures 3 to 4.

All electrical connections, cable types and sizes must

comply with the appropriate national regulations. Supplied

cables are rated for ambient temperatures up to 70°C. If

the cables are required to meet higher temperature

requirements, they must be run through conduits.

ATTENTION!

Before working (installation) on the system

read the section safety instructions

INSTALLATION

Fig. 3a Connections Whisper 12 Ultra Three Phase

Fig. 3b Connections Whisper 12 Ultra Three Phase

07 Battery NEG (–) 25mm2

08 Battery POS (+) 25mm2

09 Raw water inlet Ø19mm

10 Fuel in Ø8mm

11 Fuel out Ø8mm

01 Expansion tank Ø8mm

02 Bypass cooling water out

Ø19mm (3/4")

03 Bypass cooling water in

Ø19mm (3/4")

04 Exhaust hose Ø51mm

05 Remote control

06 AC power output

INSTALLATION

Fig. 4a Connections Whisper 16 Ultra Three Phase

Fig. 4b Connections Whisper 16 Ultra Three Phase

01 Fuel in Ø8mm

02 Battery - 35mm2

03 Battery + 35mm2

04 Fuel out Ø8mm

05 Raw water inlet Ø25.4mm

06 Expansion tank Ø8mm

07 Bypass cooling water out

Ø25.4mm

08 Bypass cooling water in

Ø25.4mm

09 Exhaust hose Ø51mm

10 Remote control

11 AC power output

INSTALLATION

1.5.1 Fuel supply

1 FUEL TANK

Fuel tanks should be made of appropriate material such as

(stainless) steel or plastic. Steel tanks should not be

galvanised or painted inside. Condensation can occur in

metal tanks when temperature changes. Therefore, water

accumulates at the bottom of the tank and provisions

should be made for the drainage of this water.

The tank will need a filling connection, a return connection

and an air ventilation connection which will require

protection against water entry.

Some official regulations do not allow connection points at

the base of the fuel tank; in this instance connections are

to be made at the top of the tank with internal tubing down

to a few cm above the bottom of the tank.

Fig. 5 Fuel supply (fuel tank is above the generating set)

1 Fuel return

2 Fuel supply

3 Prefilter / Water separator (optional)

5 Fuel Tank

Fig. 6 Fuel supply (fuel tank is below the generating set)

1 Fuel return

2 Fuel supply

3 Prefilter / Water separator (optional)

4 Extra fuel lift pump (optional)

5 Fuel tank

INSTALLATION

2 FUEL LIFT PUMP

The generating set itself is equipped with a fuel lift pump;

therefore the tank can be installed at a lower level than the

generating set. See figure 6. The maximum suction height

is 1 m. The Whisper 16 ULTRA has a mechanical fuel lift

pump that should be primed manually when the first time

used.

If the pump has to lift the fuel higher than one meter an

external fuel lift pump must be installed. The control board

is already prepared to connect an extra fuel pump.

3 FUEL PIPES

When the tank is above the generating set we recommend

ending the return line on the top of the tank.

When the return is on the top - in case of a leakage the

return line cannot overflow because of siphoning. One will

only need a fuel cock in the fuel supply line. When the tank

is below the generating set we recommend ending the

return line on the bottom of the tank (A) below the inlet of

the supply line.

Both supply and return fuel pipe lines should be

appropriate material and 8 mm outer diameter tubing. The

quality of the tubing of fuel pipes could be submitted to

local regulations depending on the application of the

vessel.

The fuel pipes can be plumbed to the flexible hoses which

are on the generating set and have a connection to fit to 8

mm pipe. This fuel lines fulfils CE standards and are

according to ISO 7840 A2.

It is important to avoid bends in the pipes, as they could

trap air bubbles. The return pipe should never be

connected to the suction pipe. Other consumers of diesel

fuel, such as the propulsion engine and heaters, have to

be connected to separate suction and return pipes

4 FUEL FILTERS

A fine fuel filter is installed which requires maintenance.

Mastervolt advises to install an extra fuel filter/ water fuel

separator near the fuel tank.

Before starting your generating set for the first time follow

the fuel system bleeding procedure in the users manual.

1.5.2 Cooling

Intercooling is based on a raw water pump, heat

exchanger and water-injected exhaust. Cooling liquid in

the internal cooling system is cooled in a heatexchanger

by outboard water (raw water or seawater). After the raw

water is warmed up in the heatexchanger it is dumped

overboard by injecting it in the exhaust.

The generating set should have its own sea water (coolant

water) inlet and should not be connected to any other

engine systems. A properly installed cooling system is

critical to keep engine temperatures within an acceptable

range. Ensure that the installation complies to the

following installation instructions.

1 THE INTERNAL COOLING SYSTEM

The internal cooling system should be filled with cooling

liquid. (Refer to the users manual 2.5.12) When the engine

becomes hot the liquid expands and the system is

pressurised. After the pressure becomes too high the

release valve in the filling cap on the manifold opens and

the expanding liquid is pressed into the expansion tank

that is in the delivery. Also the air in the system that is

collected at the top of the manifold is released in this way.

When the liquid cools down there will be under-pressure.

Another valve opens and the liquid is sucked into the

manifold again. This system works only when there is

enough liquid initially. This has to be checked when

commissioning the generator set. By filling up the

expansion tank when necessary there will always be

enough liquid in the system. The hose that is in the

delivery has to be connected to the connection on the side

of the filling cap. This hose is made of heat resistant

plastic and is not sensitive for kinks.

The hose goes through a hole that has to be drilled in the

lower part of the canopy close to the place where the tank

is mounted.

MAX.

Fig.7: Expansion tank placement

The tank has to be placed close to the generator. When it

is mounted above the top of the manifold the liquid in the

INSTALLATION

tank will be drained when the cap on the manifold is taken

off. When keel cooling or radiator cooling is applied the

system will not be pressurised. A cap without release

valve should be applied. Refer to the special manual for

these applications.

2 RAW WATER SUPPLY

For raw water supply the following installation materials

are required: -a skin fitting - a sea cock - a water strainer -

hoses and clamps. In order to keep the suction resistance

in the line at a minimum, the sea water intake system (i.e.

sea cock, tru-hull fitting, inlet filter, etc.) must have the

following inner diameter at least:

Model Minimum inner

diameter

Whisper 12 Ultra Three Phase 19 mm (3/4")

Whisper 16 Ultra Three Phase 25.4 mm (1")

The suction hose should be kept as short as possible.

Raw water plumbing should avoid bends as much as

possible.

Restriction of raw water flow, caused by kinked hoses,

undersized pipes or connections, will reduce the engine

cooling capability. This is the main cause for overheating

of an engine.

After running the generating set for the first time, check the

coolant flow rate using a stopwatch and by holding a pail

of a known volume under the wet-exhaust outlet. The flow

rate should be according to the data in the users manual

24"

60cm

24"

60"

150cm

Max. Min.

Min.

5cm

Fig. 8. Internal cooling system

1 Water level;

2 Water/exhaust separator;

3 Seacock;

4 Waterlock;

5 Air vent;

6 Water strainer;

7 Seacock.

INSTALLATION

3 INSTALLATION OF THROUGH HULL FITTING

It is good practice for yachts to use a hull inlet fitting with

an integrated strainer (water scoop). For propulsion

engines in motorboats the water scoop is often mounted

against the sailing direction to induce more water intake

for cooling.

This should not be done in the case of a

generating set! When sailing at higher

speeds, water will be forced into the inlet and

your generating set will overflow!

Fig. 9 Installing water intake

On motorboats and on sailing boats the water scoop for a

generating set should be fitted with the opening faced

backwards to prevent water being forced in during sailing.

4 WATER STRAINER

Use an appropriate water strainer with connections of the

following dimensions:

Model Inner dimensions

Whisper 12 Ultra Three Phase 19 mm (3/4")

Whisper 16 Ultra Three Phase 25.4 mm (1")

Install the water strainer in a well accessible position,

(refer to fig. 8, ref. 6) 5 cm above the waterline.

5 SIPHON BREAKER (AIR VENT)

When the point of water injection is below the waterline,

then -when the engine is stopped -there is a risk that the

cooling water may enter the engine as a result of

siphoning. To avoid this happening, the generating set is

designed to accommodate a siphon breaker (air vent). In

the standard delivery the connections are bypassed. See

figure 10

Fig. 10: Bypassed siphon breaker connections

Hoses with the following inner diameter should be used:

Model Inner dimensions

Whisper 12 Ultra Three Phase 19 mm (3/4")

Whisper 16 Ultra Three Phase 25.4 mm (1")

If the generating set cannot be mounted such that the

bottom of the generating set is placed above the waterline,

an air vent must be installed. See figure 11

Extend the water hose of the by-pass 60 cm above

waterline and install an air vent. Ideally, the air vent should

be mounted above the yacht keel center line (i.e. to

minimize the influence of swaying on the water intake).

Fast motorboats will lay deeper when sailing at large

speed and can cause pressure on the waterinlet. This

should be avoided to prevent fleeding the engine.

If the air vent is clogged the water hoses will

not be vented when the generating set has

stopped and water can be forced into the

engine. This leads to immediate engine

problems and eventually severe damage!

DAMAGE CAUSED BY THE INGRESS OF WATER IN

THE ENGINE IS NOT COVERED BY GUARANTEE

SAILING DIRECTION

FLOW DIRECTION

INSTALLATION

Fig.11 siphon breaker connected

On the valve is a little hose to drain a little water that could

be spilled from the valve. This hose should go down and

may not end under water, because it should ventilate air

into the valve to break the siphoning.

OPEN

Fig 12: Wrong siphon breaker hose routing

Check the air vent at regular intervals. Open, clean and

lubricate the valve as required.

OPEN

Fig. 13 Mastervolt siphon breaker

Siphon breaker

INSTALLATION

1.5.3 Exhaust system

Water is injected in the exhaust system of the generating

set. In this way the cooling water that has passed the heat

exchanger is mixed with the exhaust gases. Temperature

and volume of the gases are thereby reduced

considerably, so that a rubber exhaust hose can be used

and the level of noise is reduced as well.

1 STANDARD EXHAUST SYSTEM INSTALLATION

The generating set exhaust system must remain

completely independent and separate from the exhaust

system of any other engine on board. A water lock

prevents the generating set from being flooded by cooling

water and should be installed as close to the generating

set as possible. The lock must be large enough to hold the

entire water volume held in the hose from the top of the

goose neck to the water lock. The water lock must be

installed at the lowest point of the exhaust system (ref. to

fig. 14, ref. 1). The exhaust hose must have an inner

diameter of 51 mm no less, no more-. The exhaust system

must be installed so that the back pressure inside the

exhaust does not exceed 0.07 bar (1psi – 70 cm

watercolumn) and total length from the genearot to the top

of the goose neck or or water/separator does not exceed

3m (10 ft.). (Refer to paragraph 5.4.3 of the users manual).

The exhaust hose descends from the capsule to the water

lock. Then the hose rises via the "goose neck" to the

through-hull exhaust outlet, situated minimum 50 mm

above the water line (ref. to fig. 14, ref. 5.) The "goose

neck" must be vertical and situated preferable along the

ship’s keel center line. If the generating set is mounted

less than 60 cm (24") above the waterline, a "goose neck"

must be installed to prevent the engine from overflowing. It

is recommended to install an extra muffler close to the

through-hull fitting. .

Minimal 24"60cm

Maximal 60"150cm

2" 5cm

HOSEROUTEA- BMAX. 10ft (3m)

Fig. 14: Standard exhaust system

1 Exhaust water lock;

2 Exhaust outlet muffler;

3 Exhaust line Ø 51 mm (2”);

4 Goose neck

5 Through-hull exhaust outlet Ø 51 mm (2”);

6 Water level.

INSTALLATION

1 Water level 3 Seacock

2 Water/exhaust separator 4 Waterlock

Figure 15: Super silent exhaust system

Figure 16: Only after the exhaust / water separator the exhaust hose may have a length of over 7.5 meter

MAX. 10CM (4")

MIN. 60CM (24")

MAX. 150CM (60")

MIN. 3CM (1,2")

Ø 2”

51 mm

Ø 1

”

40 mm

Ø 2”

51 mm B

WRONG!

OK!

Max. length A - B = 3 m (10 ft.)

Maximum length: 10 m (30ft)

Ø 2” (51 mm)

Ø 1

/8” (40 mm)

INSTALLATION

2 "SUPER SILENT" EXHAUST SYSTEM

See figure 15. In order to reduce the noise level of the

generating set to a minimum, an option to reduce the

exhaust noise further (especially exhaust water splashing)

is an exhaust/water separator. The exhaust/water

separator allows the cooling water to be ejected through a

line separate from the exhaust fumes and also functions

as a goose neck to prevent water from flooding the engine.

If the exhaust/water separator is mounted more than 60

cm above the water level an additional goose neck is not

required.

If the through-hull exhaust outlet has to be mounted far

from the generating set (total length of the exhaust piping

from generator to top of goose neck (water separator) is

more than 3 m.), an exhaust/water separator must

definitely be installed (see figure 16). The sea water from

the separator must then run down along the shortest

possible path to the through-hull outlet.

However watertraps should be avoided as the fumes still

contains water and this should not accumulate in bents

(refer to fig 17 and 18). An additional outlet exhaust

muffler close to the hull outlet (fig. 14, ref 2) will help

further to reduce noise emission

Figure 17: Water trap in exhaust system

Figure 18: Water will collect in the hanging bend of the exhaust gas hose and will cause back pressure

OK!

WRONG

OK! WRONG!

INSTALLATION

If the generating set and the exhaust system have been

installed correctly, neighbouring boats will not be disturbed

by generating set noise, With the "super silent" exhaust

system, generating set noises are almost inaudible. For

optimal noise reduction, the sea water outlet from the

exhaust/water separator (center outlet on the unit) should

be installed below the water level to eliminate noisy

splashing of the effluent sea water.

The through-hull outlet for the exhaust fumes should not

direct the fumes directly toward the water surface as this

will cause excessive noise (ref. to figure 19).

Do not direct the outlet directly toward the

water surface.

Figure 19: Outlet direction

1.5.4 Digital Diesel Control system (12 Volt)

1 DIGITAL DIESEL CONTROL SYSTEM

The electrical control system is standard in 12 Volt with

negative earth. Non- earth return is available as an option

for aluminium vessels to prevent corrosion.

All electrical wiring has been prepared on the generating

set to the control panel prior to despatch from the factory.

The engine is controlled by a very advanced

microprocessor based system: Digital Diesel Control.

The “black box” containing the microprocessor is located

on top of the alternator.

A local control panel is on the generating set.

Remote control

A remote control panel also containing a microprocessor is

in the delivery. A 15 m intermediate 8-pole communication

cable is in the standard supply as well (refer to fig. 20). If

necessary an optional longer (up to 30m / 100ft)

intermediate cable can be connected if the standard length

does not suit the required distance. When a longer

distance than 30m / 100ft is required, consult the

Mastervolt service department for advice.

Fig. 20 Remote control cable

One can mount the control panel after drilling a hole in the

dashboard using the plastic cover. Refer to the

dimensional drawing in paragraph 3.5. The panel without

the plastic cover fits the Mastervision modular panel

system.

More remote control panels (slave panels) can be put in

parallel by using the modular connectors on the back of

the units. As a slave one can use the same panel offering

all functions again. It is also possible to use an old or new

type slave panel only to start and stop the generator.

Old type remote panels and system panels (like the

System Manager AC + Whisper or the CSCP4) can be

connected by means of the green connector.

Pay attention to the colour codes as indicated in fig. 21

when fitting cable to the green connector. Some software

versions in old system panels (supplied before May 2004)

could conflict with the software in the DDC and an update

of the software of the system panel could be necessary.

When this is the case consult to the Mastervolt service

department for advice.

When using the factory settings, installation is very simple:

just plug the remote cable into the remote and the

generator is ready to use. Refer to fig. 21.

OK!

WRONG!

INSTALLATION

WIRINGCOLOURS

RED

GREEN

BROWN

YELLOW

PINK

PURPLE

BLUE

WHITE

GREY/ PINK

GREY

RED/BLUE

BLACK

MAX. 150 mA

WARNING RELAY

REMOTE CABLE

SENSE BAT. 2

121110987654321

Whisper Remote Panel

WRP/2

Fig. 21 Remote box terminals

Acoustic alarm or warning lamp

One can connect an external max.150 mA relay to

generate an acoustic warning or applying a warning lamp

etc. Be aware of polarity as some relays has a diode

inside and should be connected plus to plus en minus to

minus as indicated. Refer to fig. 21.

Connection for emergency stop / fire alarm switch

Fig. 22: Connection for emergency stop / fire alarm switch

To connect an emergency stop button or to stop the

generator automatically in case of a fire alarm, you can

use the bypass connection between fastons J7 and J18 on

the backside of the local control panel. See fig. 22. To do

so, remove this bypass connection and then replace it by

an emergency switch or a potential free fire alarm switch

with normally closed contacts

Automatic start/stop

Mastervolt cannot be held responsible for

damage caused by the unattended running

generator using the auto-start/stop mode or

interval mode

Using the auto-start/stop (interval) mode the

generator can start unexpectedly. When

working on the electrical system, the 3 Amp

fuse must be removed from the control panel

and the battery plus cable must be removed

from the battery.

In the delivery are warning stickers to stick on

several parts of the electric installation

(transfer switch, distribution box, etc.) to warn

for automatic start)

The Mastervolt Digital Diesel Control system offers several

options for automatic starting and stopping.

Access to this menu and other menus could be blocked.

For blocking and setting up this options refer to the

APPENDIX of the DDC users manual.

One of these options is to monitor a second battery (not

being the starter battery) to start the generator

automatically when the voltage of this battery drops below

a certain setting.

Other names for this second battery are “auxiliary battery”,

“service battery”, ”users battery” or “consumers battery”.

We will refer to this battery as “the second battery”(BAT2).

In some menus the starter battery could be indicated as

“the first battery” (BAT1).

A sense wire to monitor the second battery should be

connected (attention polarity!) to the connector on the

back of the remote panel. Refer to fig. 21. The sense wires

must be connected directly on the second battery before a

main switch and be protected by a 3 Amps fuse.

(Monitoring the generator starter battery does not require

an extra sense connection)

Settings

When one want to apply other settings than the factory

settings refer to the DDC users manual, especially to the

APPENDIX.

Remove bypass

between J7 - J18

Normal operation

Alarm / emergency

local control panel

(rear view)

INSTALLATION

2 STARTER BATTERY

For starting, the Whisper requires a 12V starter battery

with the following capacity:

Model Minimum capacity

Whisper 12 Ultra Three Phase 70Ah

Whisper 16 Ultra Three Phase 120Ah

The generating set can be connected with the main engine

battery or have its own battery.

We strongly recommend the use of a separate battery for

the generating set and to keep the wiring system for the

propulsion engine and the domestic DC supply system

completely separate and individually connected to

separate batteries.

230VAC

IVO12/10

12V

Fig. 23 Starter battery

However, the negative of all the batteries on the vessel

should be interconnected (when on earth) to avoid

difference in the voltage level of the earth on different

places causing trouble to electronic devices which might

be in the system.

The above recommendation is not valid for ships having

the starter battery of the propulsion engine or other

auxiliary equipment positive grounded. When this is the

case an expert should be consulted.

A battery switch may be used to interrupt the positive

connection.

The starter battery is charged by the alternator on the

engine. An additional battery charger will help to keep the

battery in good condition when the generating set is not

used. A battery charger is not included in the standard

supply. A high efficiency battery charging unit can be

ordered from Mastervolt which is able to charge both the

ship’s main battery and the starter battery. Also a small

charger can be used to charge the starter battery only,

such as the IVO SMART 12/10. A battery switch and a

charger are included in the battery installation kits, art. no.

50230210 (70Ah) or 50230220 (160Ah)

3 OTHER RECOMMENDATIONS AND WARNINGS

The battery should be secured for seagoing conditions and

the terminals should be insulated. For extra safety the

battery can be enclosed in a wooden, plastic, fiberglas etc.

(non metal) box. Even when the earth return system is

applied a negative battery cable should be used and the

vessel should not to be used as a conductor.

The battery cables are supplied in a standard length of 1.5

m, if longer cables are required a larger cross sectional

area should be considered to compensate for voltage

reduction.

When two batteries are used in series to provide a 24 Volt

supply system, never take off 12 Volt (starting) power from

one of these batteries. This will result in severe damage to

both batteries within a short time.

Disconnect the battery leads if electrical welding is to be

carried out, otherwise damage will be caused to the diodes

of the alternator.

As explosive hydrogen gases may be

discharged during charging, the battery

should be located in a well ventilated room.

Ensure that the supplied battery cable

connectors are properly fitted and never

remove during or shortly after charging as

sparking can occur, which may ignite the

hydrogen gasses.

1.5.5 AC power system (230 Volt)

Before working (installation) on the system

read the sections on safety in the users

manual.

Be sure that all electrical installations (including all safety

systems) comply with all required regulations of the local

authorities. All electrical safety/shutdown and circuit

breaking systems have to be installed onboard as the

generating set itself cannot be equipped with such

equipment for every possible variation.

The vessel’s power supply system should be suitable and

safe for the AC voltage which is applied and the power

that will be generated. Special attention has to be paid on

dividing the system in branches which are fused

individually.

It is absolutely essential that each and every circuit in the

on-board electrical system is properly installed by a

qualified electrician.

The AC wiring of the Whisper 12 Ultra – three phase and

the Whisper 16 Ultra – three phase can be arranged as

STAR configuration (230 / 400 V AC / 50 Hz) or a DELTA

configuration (230 V AC / 50 Hz)

When connected as a STAR configuration, 3x 400 Volt is

available between the phases. At the same time 230 Volt

INSTALLATION

is available between every phase and neutral. When

connected as a DELTA configuration 3x 230 Volt is

available between the phases. See chapter 3 for electrical

wiring diagrams.

When applying 3 phases the installation should be laid out

in such a way that there is a reasonable balance of load

between the three phases.

1 FUSES

Output fuses (between the generating set and the

electrical installation) should be installed to protect the

installed electrical system. The following maximum output

current applies for each separate phase:

Model Maximum output

current

Whisper 12 Ultra Three Phase 3 x 14 Amp

Whisper 16 Ultra Three Phase 3 x 17 Amp

The fuses must be of the slow reacting type. For electrical

motors connected to the system, a motor protection switch

must be installed

2 GROUNDING

The AC alternator windings are not grounded.

The housing of the alternator and all other metal parts are

grounded

To make a connection between “neutral” and “ground” is

necessary as part of a specific insulation failure protection

system.

Small pleasure craft in Europe (length up to 24 meter) is

submitted to The Recreational Craft Directive 94/25/EC.

The guidelines of this directive refer to (ISO 13297).

When the installation comply to this standard the “neutral”

and “ground” should be connected on the generating set

by connecting the blue (neutral) wire with the terminal on

which the yellow/green wire is connected.

A Ground Fault Circuit Interrupter (GFCI) or similar device

must be applied

Be aware that insulation protection systems can be

different for different applications and even within the ship

there could be different standards for different spaces. We

did refer to the Recreational Craft Directive that applies to

pleasure craft up to 24 m of length. Sometimes one has to

comply with other standards such as the rules of

certification societies like Lloyds Register of Shipping or

Veritas, regulations for the protection of personal, building

legislation, etc. It is of the greatest importance to have

expert advice on this issue.

For safety reasons connect the main ships ground to

negative point of the generating set start battery. When a

ungrounded DC system or positive grounded DC system is

applied the battery negative should not be connected to

the main ships ground.

3 CABLE

For the power cable we recommend the use of 5 wire tri-

phase oil resistant cable with a sufficient cross sectional

area. One wire for earth is included. For long cables it is

recommended to apply cables with a larger cross section

(refer to ISO 13297 annex A)

4 TRANSFER SWITCH

A power source selector switch much be installed between

the generating set and the ship’s electrical supply system.

This switch must ensure that all AC consumers can be

switched off at once. This switch should also be installed

to keep the generating set and shore (grid) power systems

separate.

Transfer switches - to switch over from shore to ship or

from generating set to inverter - should be well designed to

switch over all wires including neutral (and not only phases

or line) and there should be provisions with the aid of

timers to prevent relays from clattering.

WARNING

In all situations the transfer switches between

shore, inverter and generator should switch all

connections, the phase lines (L1, L2, L3) as

wel as neutral (N).

INSTALLATION SPECIFICATIONS

2 INSTALLATION SPECIFICATIONS

2.1 GENERAL

1 Mount the generating set directly, without additional

vibration dampers, on a solid surface.

2 Connect the (sea) water inlet to the strainer.

3 Connect exhaust system.

4 Connect a siphon breaker or ‘air vent’ into the cooling

circuit, if necessary.

5 Connect ‘fuel supply line’ to the water separator/ fuel

filter.

6 Connect ‘fuel return line’ to the fuel tank.

7 Connect remote panel (just plug in).

8 Connect the AC cable from the AC box to the power

source selector.

9 Connect plus and minus from the 12V starter battery

to the battery cables.

10 Install a Mastervolt battery charger. (optional)

2.2 COMMISSION TABLE

1 Check if a siphon breaker (air vent) is necessary and

has been installed

2 Open the seawater inlet valve and check all water

connections. Check if the strainer is installed on or

just above the seawater level.

3 Check if the exhaust system is properly installed.

Check maximum length of exhaust hose, diameter of

exhaust hose, position of the water lock, maximum lift.

Also check the minimum required height of 60 cm

above sea level of the exhaust loop (goose neck).

4 Open the seawater outlet valve and check all water

connections.

5 Check the AC cables and the grounding.

6 Check if an AC breaker is installed before or after the

power source selector. When there is only a circuit

breaker, use it to disconnect the generating set from

the grid.

7 Check all DC connections, check if the battery switch/

circuit breaker is closed.

8 Open the fuel valve. Check if there are no air leaks in

the fuel supply line, and check if the lift of the fuel is

less than 1 meter. Check if there is no air in the water

fuel separator.

9 Check if the air intake in the canopy is not blocked.

10 Check the oil level and colour of the oil. Check the

coolant level

11 To bleed the fuel system:

•Whisper 12 Ultra Three Phase: push the “Start”

button on the local control (not on the remote

panel) and hold at least 5 seconds and as long as

necessary to bleed the system.

•Whisper 16 Ultra Three Phase: use the manual

pump by turning the cap loose and pumping as

long as necessary to bleed the system. See

chapter 4.2.2. of the user’s manual.

12 Start the engine by pushing the start button

13 Check when the generating set is running, the delay

of 5 to 10 seconds in the power source selector

transfer.

14 Check voltage and frequency under ‘no load’

conditions.

15 Check voltage and frequency under ‘full load’

conditions.

16 Check if the battery charger of the generating set is

working (max. 14.5 Volt).

17 Close the sound shield and check the noise level.

18 Stop the generating set and check the engine again

for leakages of oil, fuel or water.

Installation checklist available on our website:

www.mastervolt.com.

Commissioning form available on our website:

www.mastervolt.com..

INSTALLATION SPECIFICATIONS

2.3 INSTALLATION SPECIFICATIONS

TECHNICAL DATA

Model Whisper 12 Ultra Three Phase Whisper 16 Ultra Three Phase

Dimensions lxwxh. 106 x 58 x 63 cm 116 x 58 x 70 cm

Weight including sound shield 380 kg 440kg

Max. operation angle 25° 25°

Remote panel 15 m cable Digital Diesel Control System

Battery capacity min. 12V / 70Ah 12V / 120Ah

Fuel consumption 1,5 – 4 l/hr, load dependent

Model fuel pump Electrical driven 12V Mechanical driven, manual priming

Max lift fuel pump 1m 1m

Cooling Indirect Indirect

Cooling pump Mastervolt self priming raw water impeller pump, PTO driven

Model cooling pump M12 M16

Minimum water supply 18-22 l/min 20-25 l/min

Alternator Air cooled, brushless, four pole, 6 or 12 wire, synchronous

Voltage regulation Automatic Voltage Regulator (AVR) Automatic Voltage Regulator (AVR)

Output power at 50Hz

power factor cos phi = 1

12 kW 16 kW

Battery charger alternator including regulator (50 Amps)

2.4 SPECIFICATION OF THE ACCESSORIES

Model: Whisper 12 Ultra Three Phase Whisper 16 Ultra Three Phase

Water scoop 3/4” = 19 mm 1” = 25.4 mm

Inlet valve 3/4” in / 19 mm out 1” in / 25.4 mm out

Water strainer 19 mm in / 19 mm out 25.4 mm in / 25.4 mm out

Air vent 19 mm 25.4 mm

Inlet suction hose 19 mm 25.4 mm

Fuel filter/water separator 30 micron 30 micron

Fuel inlet and return 8 mm 8 mm

Exhaust hose Ø 51 mm inner Ø 51 mm inner

Water lock Ø 51 mm Ø 51 mm

Water/gas separator Ø 51 – 40 – 51 mm Ø 51 – 40 – 51 mm

Anti shock mounts Included Included

Battery charger (optional) IVO SMART 12/10; 12V / 10 Amps, 230V/50Hz

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