Mastervolt WHISPER 3 User manual

INSTALLATION MANUAL FOR MOBILE APPLICATIONS
WHISPER 3,5
- 3000 RPM -
Mobile diesel generating set 230V / 50Hz
Digital Diesel Control
MASTERVOLT
Snijdersbergweg 93,
1105 AN Amsterdam
The Netherlands
Tel.: [phone]
Fax.: [phone]
www.mastervolt.com V4. November 2006
Art.nr. 50200319

CONTENTS
2November 2006 / WHISPER 3,5 for mobile applications / EN
This manual applies to the Mastervolt Whisper 3,5 Mobile Diesel Generating
set controlled by Digital Diesel Control first launched in April 2004. For earlier
models refer to other manuals available on our website: www. mastervolt.com
CONTENTS:
1INTRODUCTION.............................................................................................................................................................. 3
1.1 General ..............................................................................................................................................................3
1.2 Generating sets for vehicles...............................................................................................................................3
1.2.1 Marine and mobile generators...........................................................................................................3
1.2.2 Why two radiators:.............................................................................................................................3
2INSTALLATION............................................................................................................................................................... 4
2.1 Location..............................................................................................................................................................4
2.2 Instructions for optimal sound and vibration insulation.......................................................................................4
2.2.1 Steel base plate.................................................................................................................................4
2.2.2 Further recommendations .................................................................................................................5
2.3 Ventilation...........................................................................................................................................................5
2.4 Connections ....................................................................................................................................................... 5
2.4.1 Fuel supply........................................................................................................................................6
2.4.2 Radiator cooling ................................................................................................................................8
2.4.3 Dry exhaust system......................................................................................................................... 10
2.4.4 Electric installation (12 Volt)............................................................................................................ 12
2.4.5 AC power system (230 Volt)............................................................................................................ 14
3INSTALLATION SPECIFICATIONS.............................................................................................................................. 15
3.1 TECHNICAL DATA .......................................................................................................................................... 15
3.2 Installation materials......................................................................................................................................... 16
4DIAGRAMS & DRAWINGS ........................................................................................................................................... 20
4.1.1 Lay out control DC control system 230V radiator fan Whisper 3,5 .................................................. 20
4.1.2 Lay out control DC control system 12V radiator fan Whisper 3,5.................................................... 21
4.1.3 Lay out control DC control system 24V radiator fan Whisper 3,5.................................................... 22
4.2 Connection diagram radiator fan 230VAC........................................................................................................ 23
4.3 Wiring codes and colours................................................................................................................................. 24
4.4 AC wiring diagram 230V / 50Hz ....................................................................................................................... 25
4.5 Remote control panel drawings........................................................................................................................ 26
4.6 Whisper 3,5 dimensions................................................................................................................................... 27

INTRODUCTION
EN / WHISPER 3,5 for mobile applications / November 2006 3
1 INTRODUCTION
1.1 GENERAL
This manual applies to the installation of Mastervolt
Whisper 3,5 generating set in vehicles.
Special attention has to be given to the
chapter on safety that is in the users manual.
A warning symbol draws attention to warnings
and instructions or procedures which, if not
strictly observed, may result in damage or
destruction of equipment, severe personal
injury or loss of life.
This warning symbol refers to electric danger
and draws attention to special warnings,
instructions or procedures which, if not strictly
observed, may result in electrical shock which
will result in severe personal injury or loss of
life.
1.2 GENERATING SETS FOR VEHICLES
1.2.1 Marine and mobile generators
Whisper Generators originate from the marine sector. But
there are also specially designed Whispers available for
mobile applications, suitable for supplying power on board
of vehicles to use professional apparatus and equipment,
strong lightning and air conditioning etc. The cooling
system and exhaust system on vehicles is completely
different from standard marine systems. Standard marine
generators are cooled by seawater that nowhere exceeds
30° Celsius and is seldom warmer than 20° Celsius in the
northern territories. Cold seawater is pumped through the
alternator, through the heat exchanger and is injected in
the exhaust. The exhaust gasses are therefore cooled and
rubber exhaust hose can be used.
On vehicles the engine and alternator are individually
cooled by radiator with an electric (12V/24V or 230V)
driven fan. The radiators can be fitted below, on top or in
the side of the vehicle.
The exhaust is of the dry type and includes a stainless
flexible bellow and high quality mufflers.
Never use rubber exhaust hose, neither
fibreglass nor plastic exhaust parts in a dry
exhaust system as applied on vehicles.
Figure1: Typical vehicle application radiator side mounted.
Figure 2: Typical vehicle application radiator top mounted.
Fig. 3: Typical vehicle application radiator bottom mounted
1.2.2 Why two radiators:
The Whisper 3,5 engine is cooled by oil. The optimal
engine operating temperature is 87° up to 92° Celsius.
The radiator cools the temperature of the oil in the engine
only 5° to 12° down. The returning “cold” oil therefore has
a minimum temperature of 75° Celsius.

INTRODUCTION
4November 2006 / WHISPER 3,5 for mobile applications / EN
The alternator should be kept as cool as possible. In
practice an alternator starts getting less efficient above 40°
Celsius. It is hardly possible to cool down the coolant of
the alternator below 40° using a radiator. When a vehicle
is in the sun on a parking place the ambient temperature
itself could be 40° Celsius.
Because of the divergence in the working temperature of
engine and alternator it will be clear that it is not possible
to combine the cooling of the engine and alternator in one
radiator system.
Furthermore it will be clear that it is very difficult to cool an
alternator optimally with the aid of a radiator in conditions
with high ambient temperatures.
The two radiators used to cool the engine and alternator of
the Whisper 3,5 are integrated in one housing and one
electric driven fan blows the air through both radiators.
Why the alternator should be cooled by water:
The Whisper 3,5 has an unique engine being cooled by oil
instead of water. The oil is used for both cooling and
lubrication and has to be refreshed regularly. As the
separate cooling system for the alternator is only for
cooling it is better to use “water” or in fact special cooling
liquid. For normal industrial use alternators are cooled by
air. This requires a flow of air through the alternator of
many m3 per minute. With the air, the noise comes out
into the open. Generators on vehicles can only made silent
by full enclosure in a sound shield canopy. The only
opening in the Whisper canopy is the inlet for combustion
air. For that reason the alternator is cooled by water.
Although cooling the alternator by circulating water
through a radiator is not ideal; it is much better than by air.
Therefore aircooled alternators are rarely used in vehicles.
2 INSTALLATION
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.
2.1 LOCATION
When looking for a proper place for a generator in a
vehicle all relevant aspects have to be taken into account
•Accessibility
•Solid foundation
•Space to mount the radiator (Refer to par. 2.4.3)
•Space to mount the exhaust (Refer to par. 2.4.2)
•A way to fit the fuel lines
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 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. Full access is possible from the front and
from above.
Oil filling can be done on the service side and on the top.
Cooling liquid can be filled via the expansion tank. The top
of the engine (rocker cover) has to be accessible for
adjustment of the valve clearance.
Please also note that in spite of the automatic oil pressure
sensor it is still essential that the oil level is checked
regularly.
2.2 INSTRUCTIONS FOR OPTIMAL SOUND
AND VIBRATION INSULATION
When it is possible to mount the unit directly on the
chassis of the vehicle this has advantages in preventing
vibrations by resonance.
2.2.1 Steel base plate
When it is not possible to fit the generator directly on the
chassis and the unit is on a light floor or other light
construction, Mastervolt recommends the use of an extra
set of rubber mountings and a heavy steel base plate if the
additional weight is no objection. To keep resonant
vibrations at a minimum, it is possible to mount the
generating set on a solid steel base plate, approx. 40 mm
weighing approx. 50% of the weight of the generating set.
A heavy base plate is available as an optional installation
kit. (Ref. to fig. 24, item 62).
~
3,5
Whisper
MASTERVOLT
Figure 4. Schematic installation diagram. Two radiators are
integrated in one housing with one fan.

INSTALLATION
EN / WHISPER 3,5 for mobile applications / November 2006 5
2.2.2 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 In larger vehicles a separate and insulated space for
the generator will help to damp the noise even further.
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 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.
4 Never connect the base of the generating set directly
to bulkheads or tanks.
2.3 VENTILATION
The generating set normally draws combustion air from
the engine room. A full enclosure with natural ventilation
must have ventilation 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 100 cm2 is required. The radiator need its own
airflow. (Refer to par. 2.4.2 - 4).
Air inlets should be louvered, where appropriate, to protect
the generating set from water spray.
2.4 CONNECTIONS
The generating set comes with all supply lines and output
cables (i.e. electric cables, cooling water and oil
connections, exhaust, fuel lines etc.) already connected to
the engine and alternator. The supply lines are led through
the capsule’s base. The connections are marked as shown
in fig. 5.
ATTENTION!
Before working (installation) on the system
read the section safety instructions
WHISPER 3,5 / 3000RPM
1 Fuel lift pump cable
2 Battery connection (positive)
3 Connectors radiator temperature switch; wire no. 7
4 Oil pipe out
5 Cooling water out
6 Battery connection (negative)
7 Exhaust connection
8 Oil pipe in
9 Cooling water in
10 Fuel pipe return
11 AC 230V wiring
12 Remote control cable
13 Fuel pipe inlet
1
2
3
4
5
6
7
8
9
10
11
12
13
figure 5.
1
2
3
4
5
6
7
8
9
10
11
12
13 Figure 5

INSTALLATION
6November 2006 / WHISPER 3,5 for mobile applications / EN
All electrical connections, cable types and sizes must
comply with the appropriate national regulations. Supplied
electric cables are rated for ambient temperatures up to
70°C. If the cables are required to meet higher
temperature, they must be run through conduits.
2.4.1 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; 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. Using
the existing fuel tank of the car-engine the fitting
should be executed with extra care. Both a supply line
and a return line should be installed and go into the
tank from the top. Interference of the two systems (car
engine and generator engine) should be avoided.
Do NOT connect the fuel lines to the lines of
the vehicles engine fuel supply. Driving the
tank empty below the level of the suction pipe
of the generator could make it necessary to
bleed the fuel system.
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 1 m. 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. It is recommended to
mount the loose supplied pump close to the tank and
mount it in an angle or vertical to prevent air bubbles
to block the system. The pump will become quite hot
and should be mounted out of touch. (Refer to fig. 6)
The pump makes clicking noises and therefore could
be mounted on rubber mountings. When the clicking
noises of the pump are not acceptable another
noiseless pump is available as an option.
3 FUEL PIPES
When the tank is above the generating set we
recommend to end the return line on the top of the
tank (A).
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.
Both supply and return fuel pipe lines should be
appropriate material and 8 mm outer diameter tubing.
The quality of the tubing of fuel pipes could be
submitted to local regulations depending on the
application of the vehicle.
The fuel pipes can be plumbed to the flexible hoses
which are on the generating set and have a connec-
tion to fit to 8 mm pipe. The fuel lines Mastervolt
supplies 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. The return line
should be of 8 mm diameter and go straight back via
the top to the bottom of the tank. When the return is
too narrow, has too many bents and goes back to the
bottom of the fuel tank, the back-pressure could be to
high. This results in irregular running of the engine.
When the engine runs irregular, one can check if
back-pressure is the problem by disconnecting the
return line just outside the canopy and draining it in a
canister. When the engine runs smooth now, the
return piping has to be changed. It could also help to
install a second (electrical 12V) fuel lift pump
Fig. 6. Fuel line assembly with vertical mounted pump
and fuel lift pump mounted vertical or in an
angle.

INSTALLATION
EN / WHISPER 3,5 for mobile applications / November 2006 7
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
2
3
5
67
Fig. 2.
1 Fuel return;
2 Fuel supply;
3 Prefilter / water separator (optional);
5 Fuel tank;
6 Standard fuel lift pump;
7 Standard fuel filter.
Figure 7: The fuel tank above the generator
> 1m
1
2
3
4
5
67
g. 3.
1 Fuel return;
2 Fuel supply;
3 Prefilter / water separator (optional);
4 Extra fuel lift pump (optional);
5 Fuel tank;
6 Standard fuel lift pump;
7 Standard fuel filter.
Fig. 8: The fuel tank below the generator

INSTALLATION
8November 2006 / WHISPER 3,5 for mobile applications / EN
2.4.2 Radiator cooling
1 GENERAL INSTRUCTIONS
The radiator unit can be mounted below the floor, in the
side or on the roof of the vehicle.
Wherever the radiator is mounted the well functioning of
the system depends on the well circulation of the coolant.
Roof mounted radiators bring the most risk for circulation
problems because air trapped in the radiators or a low
level of the coolant, will immediately affect the cooling
capacity of the radiators.
It is recommended to keep the radiators as close as
possible to the unit. The piping should be fitted as direct as
possible.
When the radiators are above the engine, the piping
should be fitted below the top of the radiators! (refer to
figure 9). Bents in the piping, that can trap air bubbles,
should be avoided.
2 ALTERNATOR COOLING SYSTEM
Special attention should be paid to the ventilation of the
alternator cooling system. The installation kit is standard
supplied with an expansion tank for the coolant, which is
also used to release air bubbles and makes it possible to
add coolant into the system in an easy way. This
expansion tank should be at the highest point of the
system and mounted as high as possible.
Different from marine seawater-cooling installations,
radiator systems use an open -non pressurised- system.
Therefore the 12 mm overflow pillar on the expansion tank
should stay open. A piece of hose can be used to drain
redundant liquid that is thrown out because of the
expansion of the liquid in the system. When open the
expansion tanks can easily release air that is ventilated by
the different connections.
As the capacity of the alternator cooling system is very
small, the filling can be done via the expansion tank. It
could be necessary to refill the tank a few times. The
pump of the alternator cooling system is self-priming and
this makes the system less sensitive for air traps.
When mounting the radiator unit it is important to take care
that the outgoing connection, which is the connection to
the alternator inlet, is on the top position (refer to figure 10
detail A) and is connected to the expansion tank. Also
when the radiator is mounted flat at the bottom of the
vehicle the outgoing connection is connected to the
expansion tank This is the best way to have the system
release air and to add liquid when necessary.
ATTENTION!
The expansion tank must be fitted in the outlet
of the radiator = the inlet pipe of the engine
Figure 9. Remove the air trap
No bent of piping above the radiator
Figure 10. Outgoing connection connected to the
expansion tank
bottom mount
Bottom mount
Side mount

INSTALLATION
EN / WHISPER 3,5 for mobile applications / November 2006 9
When the radiator is flat mounted on the roof, the
expansion tanks should be mounted a little higher. (refer to
figure 11 detail B).
3 ENGINE RADIATOR SYSTEM
The oil cooling system of the Whisper 3,5 is ventilated in
the engine itself and no expansion tank is applied. To
prevent the oil in the radiator - when mounted higher than
the engine - to flow to the engine after stopping the engine
(overflow the engine), a pressure valve has to be fitted
(refer to figure 8).
When it is not possible to drain the oil from the radiator
every time the oil is changed, one should pump out the
engine oil as good as possible from the engine sump and
increase the oil change intervals to every 50 running
hours.
It is very important to use good quality heat
resistant hose and fittings. Therefore it is
strongly advised to use Mastervolt installation
kits.
4 HOW AND WHERE TO MOUNT THE RADIATORS
The radiator kit includes rubber mountings to prevent
vibrations to be transferred to the body of the vehicle (fig.
13). Due to the difference between vehicles general
instructions are not available. One has to find out where
the best place for mounting is. For OEM customers
Mastervolt can supply a special customised installation kit.
When bottom mounted the radiator should not be the
lowest point of the vehicle to avoid damage. A free flow of
air should be guaranteed. When horizontal mounted the
fan should be on top, so that it causes a flow of air
downwards. Often it is possible to find a place where extra
space above the fan helps to create a free flow of air. It is
recommended to make a shield below the radiator to catch
stones and dirt and operates as a spoiler. The distance
between the radiator and the shield should be at least 50
mm. Sometimes it is possible to build the radiators and
shield on a sub frame that is mounted below the vehicle as
a module.
Measures have to be taken to prevent the hot
air circulating and reducing the capacity of the
radiators. Refer to figure 14.
Top mount
Figure 11. Low profile radiator assembly on the roof
Figure 12. Pressure valve in the return line to prevent
the engine to overflow as a result of siphoning. Only
when radiator higher than engine.
Figure 13.Radiator on rubber mountings
Figure 14. Bottom mounted with shield

INSTALLATION
10 November 2006 / WHISPER 3,5 for mobile applications / EN
Most effective and easy is to mount the radiator in the side
of the vehicle. (If possible below the level of the top of the
engine.) A louvered grid should protect the radiator from
rain and objects, but must not block the airflow. The fan
should be inwards which causes the air to blow outwards.
A free flow of air should be guaranteed. The ventilation
(connection to the expansion tank) should be in the
outgoing flow on top of the radiator.
A disadvantage of having the radiator in the side is
possibly more noise of the electric fan and a flow of air that
could be felt by people passing by.
The radiator on the roof is often the best option from the
point of view of keeping the noise of the fan away from
people and it give the best result in dissipating the heat.
However often this option conflicts with the possible need
to keep the vehicle as low as possible. Another
disadvantage is that the piping has to go through the roof
that requires provisions to be waterproof.
Also negative is that roof mounted radiators are more
sensitive for air traps.
When having enough space it would be ideal to have the
radiators vertically mounted on the roof. The expansion
tank should be above the radiator.
When having the radiator horizontally mounted on the roof
(refer to figure 17) enough space (50 mm) should be
between the roof and the fan to have a fre flow of air.
When the radiator is roof mounted there should be
protection against the weather. To avoid damage while the
vehicle is driving at high speed a spoiler could be needed.
2.4.3 Dry exhaust system
1 GENERAL REMARKS
A dry exhaust muffler system should be as effective in
silencing the exhaust as a wet marine exhaust system
when applying the right mufflers. However noise could be
generated by vibrations in the mufflers and be transferred
to the chassis. Tacit factors like the length of specific pipe
sections could be important. It is very difficult to take these
factors into account.
The standard Mastervolt exhaust kit contains the materials
to perform a professional installation. In the kit is a
stainless steel flexible bellow (hose) to allow for expansion
and to prevent vibrations to be transferred. Rubbers are
supplied to mount the mufflers flexible. The insulation
blanket for the flexible bellow and the resonance muffler
are also very effective in damping vibrations. Still it could
be that additional measures has to be taken like an extra
clamp in a vibrating section of pipe, insulation blankets on
other parts of the system and possibly even additional
mufflers.
When the exhaust is led to the roof of a
vehicle, measures has to betaken to prevent
rainwater to enter the system. Special rain
caps are available as an option.
Figure 15. Making use of the space below the floor to get
an optimal flow of air through the radiators.
Side mounted
Airflow
Figure 16
Figure 18: Dry exhaust systems on vehicles
vertical
horizontal
Figure 17. Two examples of top mount radiators

INSTALLATION
EN / WHISPER 3,5 for mobile applications / November 2006 11
A negative feature of a dry exhaust system is the heat
radiated by its components.
Measures are taken to overcome the heat problem: The
exhaust bent to bring the exhaust out of the canopy is
cooled by water. Insulation blankets are included in the
exhaust kit to insulate the flexible bellow and the first
muffler.
When a dry exhaust has its outlet on the roof, all the pipes
inside the vehicle has to be insulated.
The exhaust pipes will be very hot and all
accessible pipes and mufflers are dangerous
to people when not insulated.
There are companies that are specialised in insulating hot
pipes and fancy systems are available to make it good
looking.
However it is also possible to do it yourself by winding
fibreglass or rockwool around the pipes and seal it with
aluminium tape.
2 THE STANDARD DRY EXHAUST SYSTEM
The standard exhaust system contains:
•On the generator set:
A water-cooled exhaust bent
•In the exhaust installation kit:
•A stainless steel shielded flexible bellow.
•One resonance muffler
•One absorption muffler
•Clamps and rubbers to mount the system flexible
•Fittings, bents and pipes to make the different
connections
•Blankets for thermal and sound insulation.
The mufflers are high quality industrial mufflers that are
much more effective, robust and durable than mufflers
made for automotive use.
3 INSTALLATION OF THE EXHAUST
Before determining the location of the generator set one
has to consider how to get away with the exhaust. Often
one can find space below the vehicle between the chassis
to mount the mufflers. The outlet should blow the fumes
away from the doors to avoid a nasty smell. When the
gasses are in the flow of air blowing from the radiators this
will help to avoid the fumes to be noticed. Under no
condition the fumes should be sucked into the flow of air
into the radiators. In wind still conditions a light smell of
exhaust fumes around the vehicle will not be avoidable.
To bring the exhaust to the top of the vehicle gives the
best results on noise and smell. However, when the pipes
go through the vehicle they should be insulated and
around the hole in the roof should be a collar to prevent
rainwater to leak in. Both mufflers could be on the roof or
one of them or both could be below the vehicle.
In general it is better to have the mufflers wide apart: the
resonance muffler close to the generator and the
absorption muffler on the end of the line. A short pipe
(30cm) should be on the far end after the absorption
muffler. The absorption muffler has no flow direction and
could be mounted both ways. The resonance muffler
should be mounted according to the indication on the
muffler itself.
The resonance muffler should be fitted
according to direction of the gas flow
indicated.
In the kit are clamps to mount the exhaust pipes to
stainless steel bars. These bars should be mounted to the
chassis of the vehicle. It is recommend to use rubber
mountings whenever possible. However take care that the
heat conducted through the brackets will not affect the
rubber. Refer to figure 20 how to mount the rubber in a
safe way. When any doubt an extra safe guard could be
constructed from steel wire or chain.
Figure 20. Mounting bracket in rubber with safe guard
Figure 19. Ways to prevent water to get in.

INSTALLATION
12 November 2006 / WHISPER 3,5 for mobile applications / EN
2.4.4 Electric installation (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. All electrical wiring has been prepared on
the generating set and to the control panel prior to
despatch from the factory.
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
too. If necessary an optional longer (max 30 m)
intermediate cable can be connected if the standard
length does not suit the required distance. When a
longer distance than 30 m is required, consult the
Mastervolt service department for advice. Refer to fig.
21.
One can mount the control panel after drilling a hole
in the dashboard using the plastic cover. Refer to the
dimensional drawing in paragraph 4.5. 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.
22 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 up-date 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. 22.
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. 22.
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.
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
Fig. 21
WIRING COLOURS
1 RED
2 GREEN
3 BROWN
4 YELLOW
5 PINK
6 PURPLE
7 BLUE
8 WHITE
9 RED/BLUE
10 GREY/PINK
11 GREY
12 BLACK
Fig. 22

INSTALLATION
EN / WHISPER 3,5 for mobile applications / November 2006 13
“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. 22. 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 3,5 requires a battery with a
capacity of at least 55 Ah. 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.
A battery switch is recommended to be used to
interrupt the positive connection.
The starter battery is charged by the alternator of the
generator. An additional battery charger will help to
keep the battery in good condition when the
generating set is not used.
3 12V OR 24V DC TO DRIVE THE FAN
When applying 12V or 24 V DC to drive the fan of the
radiators the fan should be wired with minimum 4
mm2 cable according to the wiring diagram. The
negative return wire should be of the same diameter.
The return current should never be lead over the
chassis.
The consumption of power by the 12V DC powered
fan makes it necessary to install an additional 30
Amps battery charger to prevent the starter battery to
be drained. A much larger battery (120 Ah) is
required. The battery charging winding in the
generating set is not capable of powering the fan.
Neither is the small charger that is included in the
battery kit. Mastervolt supplies high quality battery
chargers that continuously supply the rated power.
Chargers of other suppliers are often rated to other
standards and give the rated current (Amps) only for a
short period if at all. Using 24V separate batteries to
power the fan also require a large battery capacity
and 24V/ 25 Amp charger.
To avoid the need of an extra heavy battery charger a
230 Volt fan on the radiator is recommended. One
should realize that the power for the fan is to the cost
of the output power. (Refer to paragraph 4.2)
4 OTHER RECOMMENDATIONS AND WARNINGS
The battery should be secured for poor road
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 vehicle 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.
IVO 12/10
A
12V
B
230V AC
Figure 23

INSTALLATION
14 November 2006 / WHISPER 3,5 for mobile applications / EN
Never take off 12 Volt from one battery off a
24-Volt battery bank (12-Volt batteries that are
in series). This will cause serious damage to
the batteries in 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.
2.4.5 AC power system (230 Volt)
The electric power supplied by the generator
is of a high voltage and dangerous to people.
Realise hat people are not used to have 230V
available on a vehicle. Put warning signs on
wall sockets and on junction boxes. Instruct
non-regular users of the vehicle. Warn
maintenance personal of garages that do
service on the vehicle.
Generators used on vehicles that are
operated in a hazardous environment have
often to fulfil special regulations and additional
measures have to be taken accordingly.
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 vehicle’s power supply system (grid) 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. Wire colours should comply with AC
standards. 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 input fuse (from the generating set to the system)
should be installed to protect the installed electrical
system.
For the Whisper 3,5 the maximum single phase
current at 230V is 13A.
The fuses must be of the slow reacting type. For
electrical motors connected to the system, a motor
protection switch must be installed.
2 INSULATION FAILURES
The AC alternator windings are not grounded.
The housing of the alternator and all other metal parts
are grounded.
To make a connection between “neutral” and “ground”
could be necessary as part of a specific insulation
failure protection system.
It is possible that the electric installation in the vehicle
must be protected against insulation failures. Methods
of protection are subjected to rules that can be
different depending on the use of the vehicle and local
standards.
In the standard marine manual is more information,
but this is according CE regulations for boats.
Vehicles are subject to different regulations
depending on the application of the vehicle. Experts in
this field should be consulted
3 CABLE
For the power cable in single phase installations we
recommend the use of flexible 3 wire oil resistant
cable with a sufficient cross sectional area 3 x 2,5
mm2. One wire for earth is included. For very long
cables it is recommended to apply cables with a
larger cross section.
4 TRANSFER SWITCH
A power source selector switch must be installed
between the generating set and the car’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
chattering.
Mastervolt advises the installation of a
MASTERSWITCH 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
MASTERSWITCH switches automatically after 10
seconds delay time over to the generating set
position.

INSTALLATION
EN / WHISPER 3,5 for mobile applications / November 2006 15
Warnings: In all situations the transfer switches between
shore, inverter and generator should switch
both neutral and L1. Of course this is the case
when using a Mastervolt Masterswitch.
3 INSTALLATION SPECIFICATIONS
3.1 TECHNICAL DATA
Article no 50900520
Dimensions wxdxh. 505x400x500 mm
Weight 97 kg including sound shield
Max. operation angle 25°
Remote panel 15 m cable Digital Diesel Control System
Battery capacity min. 12V, 55 Ah
Fuel consumption 0,7-1,5 l/hr, load dependent
Lift fuel pump electric driven 12 V DC, max. lift 1 m
Cooling radiator cooling
Cooling pump Mastervolt self priming impeller pump, PTO driven, type K
Crank case lube oil capacity 1.3 litre + 0.7 oil cooler, total 2 litre
Alternator synchronous brushless, maintenance free water cooled
Voltage regulation capacitor
Output power 3 kW, 230V/50 Hz at power factor cos phi =1 including the power to drive the
electric radiator cooling fan
Battery charger additional 12V winding including regulator (6 Amps)

INSTALLATION SPECIFICATIONS
16 November 2006 / WHISPER 3,5 for mobile applications / EN
3.2 INSTALLATION MATERIALS
Fuel kit
Battery installation kit
Base plate kit
Fig. 24

INSTALLATION SPECIFICATIONS
EN / WHISPER 3,5 for mobile applications / November 2006 17
FUEL KIT
no qty article no description dimensions
41 2 50221203 straight coupling 8 mm
42 1 50230090 fuel strainer/water separator M14x1,5 mm
43 2 50221618 parallel male stud coupling M14 - 8 mm
44 2 50221644 reducing male nipple M14-M16 60 gr.
45 2 50221615 hose connection 8 mm
46 2 50221616 nut coupling M16x1,5 mm
47 1 50221352 nipple hose pipe 8 mm
TOTAL 50230205 FUEL KIT
OPTIONAL INSTALLATION MATERIALS
no qty article no description dimensions
48 1 50222020 copper fuel pipe 6x8 mm
49 1 50220063 fuel hose 8x16 mm
BATTERY INSTALLATION KIT 55 Ah
no qty article no description dimensions
51 1 64000550 battery 55Ah
52 1 43011030 battery charger IVO SMART 12/10
53 1 68060100 battery terminal + M8
54 1 68060200 battery terminal – M8
55 1 68456902 isolation cap
56 1 68456914 isolation cap
57 1 79009005 battery switch 250 Amp
58 4 6503001608 cable connectors M8x16
TOTAL 50230206 BATTERY INSTALLATION KIT 55 Ah
BASE PLATE KIT
no qty article no description dimensions
61 4 50230052 rubber mountings M12
62 1 50230012 base plate Whisper 3,5
63 1 50230011 fastener kit base plate
TOTAL 50230207 BASE PLATE KIT

INSTALLATION SPECIFICATIONS
18 November 2006 / WHISPER 3,5 for mobile applications / EN
Fig. 25
Only when radiator is
placed above the engine
It is one combined radiator that is showed twice
Whisper 3,5
EXHAUST KIT
RED
BLACK
OIL OUT
WATER OUT
OIL IN
WATER OUT
RADIATOR OIL COOLER KIT ENGINE
RADIATOR COOLER KIT ALTERNATOR

INSTALLATION SPECIFICATIONS
EN / WHISPER 3,5 for mobile applications / November 2006 19
COMBINED RADIATOR COOLER KIT WHISPER 3,5 230VAC
no qty article no description
2 2 ST 50221106 Straight reducer m/f1-1/2
3 1 ST 50221062 Mal nipple 1/2”
5 2 ST 50221003 Male hose connection 1/2x13
6 1 ST 50221007 Male hose connection 1/2x20
14 6 M 50220057 Cooling water hose warm water 13x21 mm
15 12 ST 50221521 Hose clamp stainless 12-20
16 16 ST 50221595 Hose support stainless 22x20 mm
17 1 ST 50230529 Bracket expansion tank for 50230531
17 1 ST 50230531 Expansion tank 20 mm
17 1 ST 50230532 Cap tank 050230531
20 2 M 50220011 Hose vacum SAE100R4 (3/4)” 19x31,5 mm
21 2 ST 50221502 Hose clamp stainless 19-29
31 1 ST 50201319 Combined radiator cooler W3,5 230V
32 2 ST 50221648 Adapter BSP 3/8
33 2 ST 50221107 Straight reducer m/f1-3/8
36 4 ST 50201121 Vibration mounting 30x25
37 4 ST 50211152 Bolt hexagonal ZP M8x16
38 4 ST 50211465 Nut hexagonal SP M8
39 8 ST 50211405 Washer SPM8
40 8 ST 50211445 Washer spring SP M8
41 6 M 50220001 Hose hydraulic 9,5x17,4 mm
42 1 ST 50221042 TEE fitting 1/2”
42 4 ST 50221655 BSP female swivel 3/8”-10
43 1 ST 50209203 Temperature failure switch
1 ST 50201300 Combined radiator cooler W3,5 12VDC
1 ST 50201305 Combined radiator cooler kit W3,5 12VDC
1 ST 50201310 Combined radiator cooler W3,5 24VDC
1 ST 50201312 Combined radiator cooler kit W3,5 24VDC
DRY EXHAUST KIT 1”
no qty article no description
61 1 ST 50220041 Exhaust hose 500mm SS male/female 1”
62 1 ST 50220042 Insul. blanket 35x60 exhaust hose 1 1/2
63 1 ST 50230520 Absorption muffler steel 1”
64 1 ST 50230521 Resonance muffler steel 1”
65 1 ST 50230522 Insulation blanket R-muffler 1”
66 2 ST 50221401 Pipe nipple 1”x300mm galvanised
67 2 ST 50221421 Parallel male coupling 1” galvanised
68 2 ST 50221411 Straight coupling f/f 1”galvanised
69 3 ST 50221661 U-clamp 42mm M10
70 3 ST 50221664 Bracket U-clamp 25cm M10/48mm passivated
71 6 ST 50211406 Washer SP M10
72 6 ST 50211447 Washer spring SP M10
73 6 ST 50211466 Nut hexagonal SP M10
75 1 ST 50221471 Elbow 90 degr m/f galvanised 1”

DIAGRAMS & DRAWINGS
20 November 2006 / WHISPER 3,5 for mobile applications / EN
4 DIAGRAMS & DRAWINGS
4.1.1 Lay out control DC control system 230V radiator fan Whisper 3,5
Fig.26