Mastervolt WHISPER 15 ULTRA User manual

INSTALLATION MANUAL U.S.A EDITION
WHISPER 15 / 20 ULTRA
- Three phase - 1800 RPM -
Marine diesel generating set 120/208V-60 Hz
Digital Diesel Control
MASTERVOLT
Snijdersbergweg 93,
1105 AN Amsterdam
The Netherlands
Tel.: [phone]
Fax.: [phone]
www.mastervolt.com V4. October 2008
Art.nr. 50200384

TABLE OF CONTENTS
2Copyright © 2008 Mastervolt / October 2008 / WHISPER 15/20 ULTRA - Three Phase / US
Copyright © 2008 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.
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 (120/208 Volt)..................................................................................................... 18
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 15 Ultra Three Phase......................................................................................................... 26
3.2 DC wiring Whisper 20 Ultra Three Phase......................................................................................................... 28
3.3 Overview of AC terminal modes Whisper 15/20 Ultra Three phase ................................................................. 30
3.4 AC wiring diagram 120 / 208 V AC / 60 Hz three phase (star configuration) .................................................... 31
3.5 AC wiring diagram Split-Phase 120 – 240Volt / 60Hz with AVR (DOUBLE DELTA) ........................................ 32
3.6 Diagram electronic governor (Whisper 15 Ultra Three Phase only) .................................................................33
3.7 Remote control panel drawings ........................................................................................................................ 34
3.8 Dimensions Whisper 15 Ultra Three Phase...................................................................................................... 35
3.9 Dimensions Whisper 20 Ultra Three Phase...................................................................................................... 36

INSTALLATION
US / WHISPER 15/20 ULTRA - Three Phase / October 2008 / Copyright © 2008 Mastervolt 3
1 INSTALLATION
1.1 GENERAL
This installation manual is valid for the following models:
Part number Description
51107355 Whisper 15 Ultra Three Phase
120V-208V 1800rpm
51107356 Whisper 15 Ultra Three Phase
120V-208V 1800rpm -ungrounded
51108355 Whisper 20 Ultra Three Phase
120V-208V 1800rpm
51108356 Whisper 20 Ultra Three Phase
120V-208V 1800rpm -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
4Copyright © 2008 Mastervolt / October 2008 / WHISPER 15/20 ULTRA - Three Phase / US
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 80 sq inch (500 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.
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 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

INSTALLATION
US / WHISPER 15/20 ULTRA - Three Phase / October 2008 / Copyright © 2008 Mastervolt 5
Fig. 3a Connections Whisper 15 Ultra Three Phase
Fig. 3b Connections Whisper 15 Ultra Three Phase
01
04
03
02
05
06
07 Battery – AWG 3
(25mm2)
08 Battery + AWG 3
(25mm2)
09 Raw water inlet Ø 3/4"
(Ø19mm)
10 Fuel in Ø5/16” (8 mm)
11 Fuel out Ø5/16” (8 mm)
01 Expansion tank Ø5/16” (8
mm)
02 Bypass cooling water out
Ø3/4" (Ø19mm)
03 Bypass cooling water in
Ø3/4" (Ø19mm)
04 Exhaust hose Ø 2” (51
mm)
05 Remote control
06 AC power output

INSTALLATION
6Copyright © 2008 Mastervolt / October 2008 / WHISPER 15/20 ULTRA - Three Phase / US
Fig. 4a Connections Whisper 20 Ultra Three Phase
Fig. 4b Connections Whisper 20 Ultra Three Phase
06
11
10
09
07
08
01 Fuel in Ø5/16” (8 mm)
02 Battery – AWG 2
(35mm2)
03 Battery + AWG 2
(35mm2)
04 Fuel out Ø5/16” (8 mm)
05 Raw water inlet 1" (25.4
mm)
06 Expansion tank Ø5/16” (8
mm)
07 Bypass cooling water out
Ø 1" (25.4 mm)
08 Bypass cooling water in
Ø1" (25.4 mm)
09 Exhaust hose Ø2” (51
mm)
10 Remote control
11 AC power output

INSTALLATION
US / WHISPER 15/20 ULTRA - Three Phase / October 2008 / Copyright © 2008 Mastervolt 7
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
A
1
3
2
5
4
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
8Copyright © 2008 Mastervolt / October 2008 / WHISPER 15/20 ULTRA - Three Phase / US
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 3 ft (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 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.
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.
MAX.
Fig.7: Expansion tank placement

INSTALLATION
US / WHISPER 15/20 ULTRA - Three Phase / October 2008 / Copyright © 2008 Mastervolt 9
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 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 15 Ultra Three Phase 3/4" (19 mm)
Whisper 20 Ultra Three Phase 1" (25.4 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
1
2
34
5
6
7
24"
60cm
60cm
24"
60"
150cm
Max. Min.
Min.
5cm
2"
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
10 Copyright © 2008 Mastervolt / October 2008 / WHISPER 15/20 ULTRA - Three Phase / US
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 15 Ultra Three Phase 3/4" (19 mm)
Whisper 20 Ultra Three Phase 1" (25.4 mm)
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 15 Ultra Three Phase 3/4" (19 mm)
Whisper 20 Ultra Three Phase 1" (25.4 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. 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
SAILING DIRECTION
FLOW DIRECTION
FLOW DIRECTION

INSTALLATION
US / WHISPER 15/20 ULTRA - Three Phase / October 2008 / Copyright © 2008 Mastervolt 11
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
12 Copyright © 2008 Mastervolt / October 2008 / WHISPER 15/20 ULTRA - Three Phase / 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. 14, ref. 1). The exhaust hose must have an inner
diameter of 2” (51 mm) no less, no more-. The exhaust
system must be installed so that the back pressure inside
the exhaust does not exceed 1psi (0.07 bar – 27 inches
(70 cm) watercolumn, 2 inches mercury) and total length
from the genearot to the top of the goose neck or or
water/separator does not exceed 10 ft (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. 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 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. .
3
3
4
2
5
6
A
Minimal 24"60cm
Maximal 60"150cm
2" 5cm
B
HOSEROUTEA- BMAX. 10ft (3m)
Fig. 14: Standard exhaust system
1 Exhaust water lock;
2 Exhaust outlet muffler;
3 Exhaust line 2½” (Ø 63 mm);
4 Goose neck
5 Through-hull exhaust outlet 2½” (Ø 63 mm);
6 Water level.
1

INSTALLATION
US / WHISPER 15/20 ULTRA - Three Phase / October 2008 / Copyright © 2008 Mastervolt 13
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")
1
2
34
Ø 2”
51 mm
Ø 1
5
/
8
”
40 mm
Ø 2”
51 mm B
A
AB
WRONG!
OK!
Max. length A - B = 3 m (10 ft.)
Maximum length: 10 m (30ft)
Ø 2” (51 mm)
Ø 2” (51 mm)
Ø 2” (51 mm)
Ø 1
5
/8” (40 mm)

INSTALLATION
14 Copyright © 2008 Mastervolt / October 2008 / WHISPER 15/20 ULTRA - Three Phase / US
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
US / WHISPER 15/20 ULTRA - Three Phase / October 2008 / Copyright © 2008 Mastervolt 15
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
16 Copyright © 2008 Mastervolt / October 2008 / WHISPER 15/20 ULTRA - Three Phase / US
WIRING COLOURS
RED
GREEN
BROWN
YELLOW
PINK
PURPLE
BLUE
WHITE
GREY/ PI NK
GREY
RED/BLUE
BLACK
MAX. 150 mA
WARNING RELAY
REMOTE CABLE
REMOTE CABLE
2
1
5
4
3
8
7
6
11
10
9
12
SENSE BAT. 2
121110987654321
Whisper Remote Panel
WRP/2
J3
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
US / WHISPER 15/20 ULTRA - Three Phase / October 2008 / Copyright © 2008 Mastervolt 17
2 STARTER BATTERY
For starting, the Whisper requires a 12V starter battery
with the following capacity:
Model Minimum capacity
Whisper 15 Ultra Three Phase 70Ah
Whisper 20 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
AB
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.

INSTALLATION
18 Copyright © 2008 Mastervolt / October 2008 / WHISPER 15/20 ULTRA - Three Phase / US
1.5.5 AC power system (120/208 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 Whisper 15 / 20 ULTRA Three Phase can be
connected in the following ways:
- As a 120/240Volt split phase generator by an
arrangement of the wiring in double DELTA.
- As a 3 x 120V/208 Volt three phase generator when
the wires are arranged in double STAR. Here, 3x 208
Volt is available between the phases while 120 Volt is
available between every phase and neutral.
See chapter 3 for connection of the AC-terminals. With all
applications the installation should be laid out in such a
way that there is a reasonable balance of load between
the different phases.
1 FUSE
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 15 Ultra Three Phase 3 x 28 Amp
Whisper 20 Ultra Three Phase 3 x 34 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
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.
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
US / WHISPER 15/20 ULTRA - Three Phase / October 2008 / Copyright © 2008 Mastervolt 19
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 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. 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 colour of the oil. Check the
coolant level
11 To bleed the fuel system:
•Whisper 15 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 20 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
20 Copyright © 2008 Mastervolt / October 2008 / WHISPER 15/20 ULTRA - Three Phase / US
2.3 INSTALLATION SPECIFICATIONS
TECHNICAL DATA
Model Whisper 15 Ultra Three Phase Whisper 20 Ultra Three Phase
Dimensions lxwxh. 41.7 x 22.6 x 25.2” (106 x 58 x 63 cm) 45.7 x 26.8 x 27.6” (116 x 58 x 70 cm)
Weight including sound shield 838 lbs (380 kg) 1000lbs (454kg)
Max. operation angle 25° 25°
Remote panel 15 m cable Digital Diesel Control System
Battery capacity min. 12V / 70Ah 12V / 120Ah
Fuel consumption 0.53 – 1.4 US gph (2-5.5 litre/hour) 0.53 – 2 US gph (2-7 litre/hour)
Model fuel pump Electrical driven 12V Mechanical driven, manual priming
Max lift fuel pump 3 ft (1m) 3 ft (1m)
Cooling Indirect Indirect
Cooling pump Mastervolt self priming raw water impeller pump, PTO driven
Model cooling pump M12 M16
Minimum water supply 4.8 – 6 US gpmin (18-22 l/min.) 5.3 – 6.6 US gpmin (20-25 l/min.)
Alternator synchronous brushless, maintenance free air cooled
Voltage regulation Automatic Voltage Regulator (AVR) Automatic Voltage Regulator (AVR)
Output power at 60Hz
power factor cos phi = 1
15 kW 20 kW
Battery charger alternator including regulator (50 Amps)
2.4 SPECIFICATION OF THE ACCESSORIES
Model: Whisper 15 Ultra Three Phase Whisper 20 Ultra Three Phase
Water scoop 3/4” = 19 mm 1” = 25.4 mm
Inlet valve 3/4” in / 3/4” out (19 mm in / 19 mm out) 1” in / 1” out (25.4 mm in / 25.4 mm out)
Water strainer 3/4” in / 3/4” out (19 mm in / 19 mm out) 1” in / 1” out (25.4 mm in / 25.4 mm out)
Air vent 3/4” = 19 mm 1” = 25.4 mm
Inlet suction hose 3/4” = 19 mm 1” = 25.4 mm
Fuel filter/water separator 30 micron 30 micron
Fuel inlet and return 5/16” = 8 mm 5/16” = 8 mm
Exhaust hose Ø 2” = 51 mm inner Ø 2” = 51 mm inner
Water lock Ø 2” = 51 mm Ø 2” = 51 mm
Water/gas separator Ø 2” (51mm) – 1 5/8’ (40mm) – 2” (51mm) Ø 2” (51mm) – 1 5/8’ (40mm) – 2” (51mm)
Anti shock mounts Included Included
Battery charger (optional) IVO SMART 12/10; 12V / 10 Amps, 230V/50-60Hz