Mastervolt Whisper 6 User manual

INSTALLATION MANUAL U.S.A EDITION
WHISPER 6 / 8 / 11
- 3600 RPM -
Marine diesel generating set 120/240V / 60Hz
Digital Diesel Control
MASTERVOLT
Snijdersbergweg 93,
1105 AN Amsterdam
The Netherlands
Tel.: [phone]
Fax.: [phone]
www.mastervolt.com
V7. July 2009
Art.nr. 50200364

CONTENTS
2Copyright © 2009 Mastervolt / July 2009 / WHISPER 6/8/11 / US
Copyright © 2009 Mastervolt. All rights reserved.
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.
CONTENTS:
1INSTALLATION............................................................................................................................................................... 3
1.1 General .............................................................................................................................................................. 3
1.2 Location.............................................................................................................................................................. 3
1.3 Instructions for optimal sound and vibration insulation ....................................................................................... 3
1.3.1 Steel base plate................................................................................................................................. 3
1.3.2 Further recommendations ................................................................................................................. 3
1.4 Ventilation........................................................................................................................................................... 4
1.5 Connections ....................................................................................................................................................... 5
1.5.1 Fuel supply ........................................................................................................................................ 5
1.5.2 Cooling .............................................................................................................................................. 7
1.5.3 Exhaust system ............................................................................................................................... 10
1.5.4 Digital Diesel Control system (12 Volt) ............................................................................................ 13
1.5.5 AC power system (120 - 240 Volt)................................................................................................... 16
2INSTALLATION SPECIFICATIONS.............................................................................................................................. 18
2.1 Installation table ............................................................................................................................................... 18
2.2 Commission table............................................................................................................................................. 19
2.3 Installation specifications Whisper 6, 8 and 11 – 3600RPM............................................................................. 20
2.4 Specification of the accessories ....................................................................................................................... 20
2.5 Installation materials Whisper 6/8/11................................................................................................................ 21
3DIAGRAMS & DRAWINGS ........................................................................................................................................... 25
3.1 DC wiring diagram............................................................................................................................................ 25
3.2 Wiring codes and colours ................................................................................................................................. 26
3.3 Diagram electronic governor Whisper 8 and 11 3600 rpm ............................................................................... 27
3.4 AC wiring diagram 120 - 240V / 60Hz .............................................................................................................. 28
3.5 Remote control panel drawings ........................................................................................................................ 29
3.6 Dimensions Whisper 6, 8 and 11...................................................................................................................... 30

INSTALLATION
US / WHISPER 6/8/11 / July 2009 / Copyright © 2009 Mastervolt 3
1 INSTALLATION
1.1 GENERAL
This installation manual is valid for the following models:
Part number Description
50902055 Whisper 6 / 120/240V 3600rpm
50902056 Whisper 6 / 120/240V 3600rpm –
ungrounded
50903055 Whisper 8 / 120/240V 3600rpm
50903056 Whisper 8 / 120/240V 3600rpm –
ungrounded
50604055 Whisper 11 / 120/240V 3600rpm
50604056 Whisper 11 / 120/240V 3600rpm –
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 can be mounted directly to the vessel’s main
structure.
1.3.1 Steel base plate
However to keep resonant vibrations at a minimum, it is
recommended to mount the generating set on a solid steel
base plate, approx. 3/4” (20 mm) weighing approx. 130Lbs
(60 kg) or 50% of the weight of the generating set. The
engine draws its inlet combustion air through several holes
in the capsule base. Therefore the capsule must be fitted
with sufficient clearance between the capsule underside
and the base plate. For the Whisper 6/8-3600rpm a steel
base plate is available from Mastervolt as an optional
accessory (ref. fig. 20, page 18)
1.3.2 Further recommendations
Whisper generating sets are standard equipped with a
"GRP" (Glass Reinforced Plastic) 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 Avoid mounting the generating set in close proximity
to thin walls or floors that may cause resonance.
2 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 at least be reinforced with stiffening struts or
ribbing. If possible, holes should be bored 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.
Figure 1: Mounting of the Whisper generating set. X = wrong, V = OK

INSTALLATION
4Copyright © 2009 Mastervolt / July 2009 / WHISPER 6/8/11 / US
3 Never connect the base of the generating set directly
to bulkheads or tanks.
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 16 sq inch (100 cm2)
is 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 104°F (40°C)
reduce the engine power by 1% for each 5°F of rise. To
minimise these effects the engine room temperature must
not be more than 27ºF (15 ºC) 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.
EXHAUST (1)
40 mm REMOTE CABLE (2)
12x0,3 mm2
AC CABLE (3)
FUEL RETURN (6)
16 mm2
BATTERY - (7)
8 mm
FUEL IN (4)
8 mm
16 mm2
BATTERY + (5)
AIRVENT IN (10)
19 mm
AIRVENT OUT (9)
WATER IN (8)
19 mm
19 mm
WHISPER 6/8
EXHAUST (1)
1 5/5” (40 mm)
AC CABLE (3)
REMOTE CABLE (2)
12xAWG22 (0.25mm2)
FUEL IN (4)
5/16” 8mm)
BATTERY + (5)
AWG2 (25mm²)
FUEL RETURN (6)
5/16” 8mm)
BATTERY – (7)
AWG2 (25mm²)
WATER IN (8)
3/4” (19mm)
AIRVENT OUT (9)
3/4” (19mm)
AIRVENT IN (10)
3/4” (19mm)
EXHAUST (1)
1 5/5” (40 mm)
REMOTE CABLE (2)
12xAWG22 (0.25mm2)
AC CABLE (3)
FUEL IN (4)
5/16” 8mm)
BATTERY + (5)
AWG2 (25mm²)
FUEL RETURN (6)
5/16” 8mm)
BATTERY – (7)
AWG2
(
25mm²
)
AIRVENT IN (8)
3/4” (19mm)
AIRVENT OUT (9)
3/4” (19mm)
WATER IN (10)
3/4” (19mm)
Figure 2
Whisper 6 and 8
Whisper 11

INSTALLATION
US / WHISPER 6/8/11 / July 2009 / Copyright © 2009 Mastervolt 5
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 fig. 2.
All electrical connections, cable types and sizes must
comply with the appropriate national regulations. Supplied
cables are rated for ambient temperatures up to 158ºF
(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
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.
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. The maximum suction height is 3ft (1m).
If the pump has to lift the fuel higher than 3ft (1m) 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 (figure 3)`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 (figure 4) we
recommend ending the return line on the bottom of the
tank (A) below the inlet of the supply line to discharge
under the lowest fuel level. This prevents air getting into
the fuel line. Here also one needs a fuel cock only in the
supply line
Both supply and return fuel pipe lines should be
appropriate material and 5/16” (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
5/16” (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.

INSTALLATION
6Copyright © 2009 Mastervolt / July 2009 / WHISPER 6/8/11 / US
Fig. 3: Fuel supply (fuel tank is above the generating set)
Fig. 4: Fuel supply (fuel tank is above the generating set)
1 Fuel return;
2 Fuel supply;
3 Prefilter / water separator (optional);
5 Fuel tank;
pp y
1 Fuel return;
2 Fuel supply;
3 Prefilter / water separator (optional);
4 Extra fuel lift pump (optional);
5 Fuel tank;

INSTALLATION
US / WHISPER 6/8/11 / July 2009 / Copyright © 2009 Mastervolt 7
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.
See figure 5. The tank has to be placed close to the
generator. When it is mounted above the top of the
manifold the liquid in the 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
Afb. 4a.
Fig 5.
1 Water level 5 Air vent;
2 Water/exhaust separator 6 Water strainer;
3 Seacock 7 Seacock.
4 Waterlock
Fig. 6.
MAX. 10CM (4")
MIN. 60CM (24")
MAX. 150CM (60")
MIN. 3CM (1,2")
1
5
6
7
2
3
4
5CM (2")

INSTALLATION
8Copyright © 2009 Mastervolt / July 2009 / WHISPER 6/8/11 / US
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 6 – 3600 rpm 3/4" (19 mm)
Whisper 8 – 3600 rpm 3/4" (19 mm)
Whisper 11 – 3600 rpm 3/4" (19 mm)
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
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. 7 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.
Use a sealant when mounting the skin fitting.
4 WATER STRAINER
Use an appropriate water strainer with connections of the
following dimensions:
Model Inner dimensions
Whisper 6 – 3600 rpm 3/4" (19 mm)
Whisper 8 – 3600 rpm 3/4" (19 mm)
Whisper 11 – 3600 rpm 3/4" (19 mm)
Install the water strainer in a well accessible position,
(refer to fig. 6-6) 5 cm above the waterline.
SAILING DIRECTION
SAILING DIRECTION
FLOW DIRECTION
FLOW DIRECTION

INSTALLATION
US / WHISPER 6/8/11 / July 2009 / Copyright © 2009 Mastervolt 9
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.
Hoses with the following inner diameter should be used:
Model Inner dimensions
Whisper 6 – 3600 rpm 3/4" (19 mm)
Whisper 8 – 3600 rpm 3/4" (19 mm)
Whisper 11 – 3600 rpm 3/4" (19 mm)
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.
Extend the water hose of the by-pass 24” (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).
The hose of the drain should go downwards. Water must
flow out freely and air has to flow in freely as well.
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 WARRANTEE
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 (figure 8).
OPEN
Fig 8: Wrong siphon breaker hose routing
Check the air vent at regular intervals. Open, clean and
lubricate the valve as required.
OPEN
Fig. 9 Mastervolt siphon breaker

INSTALLATION
10 Copyright © 2009 Mastervolt / July 2009 / WHISPER 6/8/11 / US
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. 10-1). The exhaust hose must have an inner diameter
of 1 5/8” (40mm), no less, no more. The exhaust system
must be installed so that the back pressure inside the
exhaust does not exceed 1psi (2 inches mercury, 27
inches – 70 cm watercolumn) and total length from the
genearot to the top of the goose neck or or
water/separator does not exceed 10ft (3m). (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 2" (5 cm)
above the water line (ref. to fig. 10-5.) The "goose neck"
must be vertical and situated preferable along the ship’s
keel center line. If the generating set is mounted less than
24" (60 cm) 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.
1 Exhaust water lock; 4 Goose neck;
2 Exhaust outlet muffler; 5 Through-hull exhaust outlet Ø 1 5/8” (40mm);
Fig 10 3 Exhaust line Ø 1 5/8” (40mm) 6 Water level.
Max. length A - B = 10 ft. (3 m)
3
3
4
2
5
6
A
Minimum 60cm (24")
Maximum 150cm (60")
5 cm (2")
B
1