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.: +31-20-3422100

Fax.: +31-20-6971006

www.mastervolt.com

V7. July 2009

Art.nr. 50200364

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.

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

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

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

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

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

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

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")

5CM (2")

INSTALLATION

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

FLOW DIRECTION

INSTALLATION

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

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)

Minimum 60cm (24")

Maximum 150cm (60")

5 cm (2")

INSTALLATION

1 Water level 3 Seacock

Figure 11 2 Water/exhaust separator 4 Waterlock

MAX. 4" (10CM)

MIN. 24" (60CM)

MAX. 60" (150CM)

MIN. 1,2" (3CM)

Ø 1

”

Ø 1

”

Ø 1

”

Figure 12: Only after the exhaust / water separator the exhaust hose may have a length of over 24 feet (7.5 meter)

OK!

WRONG!

Ø 1

/8 “

(40 mm)

Ø 1

/8 “

(40 mm)

Ø 1

/8 “

(40 mm)

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

Up to 10ft (3m): Ø 1 5/8 “ (40 mm)

10-30 ft (3-10 m): Ø 2” (51 mm)

INSTALLATION

2 "SUPER SILENT" EXHAUST SYSTEM

See figure 11. 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 10ft / 3m.), an exhaust/water separator must

definitely be installed. The sea water from the separator

must then run down along the shortest possible path to the

through-hull outlet.

Only after the exhaust/water separator the exhaust hose

may have a length of over 7,5 m if the exhaust hose

diameter is also increased from Ø 40 mm (1 5/8”) to 51 mm

(2”) in order to reduce the back pressure (ref. to figure 12)

However watertraps should be avoided as the fumes still

contains water and this should not accumulate in bents

(refer to figures 13 and 14). An additional outlet exhaust

muffler close to the hull outlet will help further to reduce

noise emission

Fig.13: Water trap in exhaust system

Figure 14: 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 fig. 15).

Do not direct the outlet directly toward the

water surface.

Figure 15

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 50ft (15m) intermediate 8-pole

communication cable is in the standard supply as well

(refer to fig. 16). If necessary an optional longer (up to

100ft / 30m) intermediate cable can be connected if the

standard length does not suit the required distance. When

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

Mastervolt service department for advice.

Fig. 16 Remote control cable

Figure 10

OK!

WRONG!

INSTALLATION

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 can be

connected by means of the green connector.

Pay attention to the colour codes as indicated in fig. 17

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. 17.

WIRINGCOLOURS

RED

GREEN

BROWN

YELLOW

PINK

PURPLE

BLUE

WHITE

GREY/ PI NK

GREY

RED/BLUE

BLACK

MAX. 150 mA

WARNING RELAY

REMOTE CABLE

SENSE BAT. 2

121110987654321

Whisper Remote Panel

WRP/2

Fig. 17 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. 17.

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. 18. 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

Fig. 18: Connection for emergency stop / fire alarm switch

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.

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.

Remove bypass

between J7 - J18

Normal operation

Alarm / emergency

local control panel

(rear view)

INSTALLATION

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. 17. 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.

2 STARTER BATTERY

For starting, the Whisper generator requires a battery with

a capacity of at least 70Ah. 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.

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.

The starter battery is charged by the standard internal

charger in the alternator. 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 kit, art. no. 50230210 (70Ah)

IVO 12/10

12V

230V AC

Figure 19

INSTALLATION

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.

In the negative battery cable a 250 Amp starter battery

switch could be applied to switch off the battery. 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

the 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 are 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 (120 - 240 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.

1 FUSE

An output fuse (from the generating set to the system)

should be installed to protect the installed electrical

system. The following maximum output current applies for

each separate phase:

Maximum single phase

output current

Model

120V 240V

Whisper 6 – 3600 rpm 48 Amps 24 Amps

Whisper 8 – 3600 rpm 61 Amps 30 Amps

Whisper 11 – 3600 rpm 90 Amps 45 Amps

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

motors connected to the system, a motor protection switch

must be installed

INSTALLATION

2 GROUNDING

With the U.S.A. models neutral of the AC

alternator is grounded. The housing of the

alternator and all other metal parts are

grounded as well.

The connection between “neutral” and “ground” is

necessary as part of a insulation failure protection system

as commonly used in the U.S.A.

WARNING

In all situations the transfer switches between

shore, inverter and generator should switch all

connections, the phase line(s) (L) as wel as

neutral (N). Off course this is the case when

using a Mastervolt Masterswitch

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 oil resistant cable

with the following cross sectional area:

Model cross sectional area

Whisper 6 – 120-240V

3600 rpm

4xAWG12 / 4 mm²

(15ft / 5m. included)

Whisper 6 – 120V

3600 rpm

3xAWG6 / 10 mm²

(not included)

Whisper 8 – 120-240V

3600 rpm

4xAWG12 / 4 mm²

(15ft / 5m. included)

Whisper 8 – 120V

3600 rpm

3xAWG6 / 10 mm²

(not included)

Whisper 11 – 120-240V

3600 rpm

4xAWG6 / 10 mm2

(not included)

Whisper 11 – 120V

3600 rpm

3xAWG4 / 16 mm2

(not included)

One wire for earth is included. For longer 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.

Mastervolt recommends the installation of a Mass

Systemswitch as the power source selector. This works

automatically when the generating set is not running the

input remains in the shore position and as soon as the

generating set is running the Mass Systemswitch switches

automatically after 10 seconds delay time over to the

generating set position.

INSTALLATION

2 INSTALLATION SPECIFICATIONS

2.1 INSTALLATION TABLE

1 Install a steel foundation plate between ship’s hull and

generating set, with 4 shock mounts (ref. to fig. 20)

‘foundation plate’ (optional for Whisper 6 and 8).

2 Mount the generating set directly to the foundation

plate.

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

4 Connect exhaust system.

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

circuit, if necessary.

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

filter.

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

8 Connect remote panel (just plug in).

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

source selector or Mass Systemswitch.

10 Connect plus and minus from the 12V starter battery

to the battery cables.

11 Install a Mastervolt battery charger. (optional)

Fig. 12.

Fig. 20

INSTALLATION

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 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 waterlock, maximum lift.

Also check the minimum required height of 24” (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 and bleed the fuel system. Check

if there are no air leaks in the fuel supply line, and

check if the lift of the fuel is less than 3 ft (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 color of the oil. Check the

coolant level

11 To bleed the fuel system push the startbutton on the

local control (not on the remote panel) and hold at

least 5 seconds and as long as necessary to bleed

the system.

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 WHISPER 6, 8 AND 11 – 3600RPM

TECHNICAL DATA

Whisper 6 Whisper 8 Whisper 11

Dimensions wxdxh. 26” x 19.5” x 21.7”

660 x 495 x 550 mm

26” x 19.5” x 21.7”

660 x 495 x 550 mm

31.9” x 20.7” x 24.2”

810 x 525 x 615 mm

Weight including sound shield 392 Lbs / 178 kg 392 Lbs / 178 kg 463 Lbs / 210 kg

Max. operation angle 25° 25° 25°

Remote panel 15 m cable Digital Diesel Control System

Battery capacity min. 12V, 60 Ah 12V, 60 Ah 12V, 60 Ah

Fuel consumption 0.5 – 1 gl/h (1,5 – 4 l/hr), load dependent

Lift fuel pump electric driven 12 V DC, max. lift 3ft (1 m)

Cooling indirect cooling

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

Minimum water supply 3-4 gl/min (9-15 l/min) 3-4 gl/min (9-15 l/min) 3-4 gl/min (9-15 l/min)

Crank case lube oil capacity 2.5 US qts + 0.5 US qts oil

filter; total: 3 US qts

(2.4l.+ 0.5l oil filter, total

2.9l.)

2.5 US qts + 0.5 US qts oil

filter; total: 3 US qts

(2.4l.+ 0.5l oil filter, total

2.9l.)

3.7 US qts + 0.5 US qts oil

filter; total: 4.2 US qts

(3.6l. + 0.5l oil filter, total

4.1l)

Alternator synchronous brushless, maintenance free water cooled

Voltage regulation Capacitor Capacitor capacitor + AVR

Output power at

power factor cos phi = 1

6 kW, 120-240V 60 Hz 8 kW, 120-240V 60 Hz 11 kW, 120-240V 60 Hz

Battery charger alternator including regulator (40 Amps)

2.4 SPECIFICATION OF THE ACCESSORIES

Water scoop 3/4” = 19 mm

Inlet valve 3/4” = 19 mm

Water strainer 3/4” (19 mm) in, 3/4” (19 mm) out

Air vent 3/4” (19 mm)

Inlet suction hose 3/4” (19 mm)

Fuel filter/water separator 30 micron

Fuel inlet and return 5/16” (8 mm)

Exhaust hose in/out Ø 1 5/8” (40 mm)

Water lock Ø 1 5/8” (40 mm)

Water/gas separator Ø 1 5/8” (40 mm)

Anti shock mounts art. nr. 50230552

Foundation plate min. 60 kg (only for the Whisper 6 and 8)

Battery charger (optional) IVO SMART 12/10; 12V / 10 Amps, 230V/50-60Hz

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