Mastervolt WHISPER 30 ULTRA User manual

INSTALLATION MANUAL U.S.A EDITION
WHISPER 30 ULTRA
- 1800 RPM -
Marine diesel generating set - Digital Diesel Control
120/240V / 60Hz split phase
120/208V / 60Hz three phase
MASTERVOLT
Snijdersbergweg 93,
1105 AN Amsterdam
The Netherlands
Tel.: [phone]
Fax.: [phone]
www.mastervolt.com V2 November 2008
Art.nr. 50200454

TABLE OF CONTENTS
2Copyright © 2008 Mastervolt / November 2008 / WHISPER 30 ULTRA / 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
1.3.1 Further recommendations .................................................................................................................3
1.4 Ventilation...........................................................................................................................................................4
1.5 Connections .......................................................................................................................................................4
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 ............................................................................................................................ 16
2INSTALLATION SPECIFICATIONS.............................................................................................................................. 18
2.1 General ............................................................................................................................................................ 18
2.2 Commission table............................................................................................................................................. 18
2.3 Installation specifications Whisper 30 ULTRA.................................................................................................. 19
2.4 Specifications of the accessories ..................................................................................................................... 19
2.5 Installation materials Whisper 30 ULTRA......................................................................................................... 20
3DIAGRAMS & DRAWINGS ........................................................................................................................................... 25
3.1 DC wiring diagram............................................................................................................................................ 25
3.2 overview of AC terminal modes Whisper 30 Ultra............................................................................................ 26
3.3 AC wiring diagram Split-Phase 120 - 240Volt / 60Hz with AVR (Double Delta)................................................ 27
3.4 AC wiring diagram Three Phase 3 x 120/208 Volt / 60Hz with AVR (Double Star)........................................... 28
3.5 Whisper remote panel ...................................................................................................................................... 29
3.6 Whisper 30 ULTRA dimensions and footprint................................................................................................... 30

INSTALLATION
US / WHISPER 30 ULTRA / November 2008 / Copyright © 2008 Mastervolt 3
1 INSTALLATION
1.1 General
This manual applies to the Mastervolt Whisper 30 ULTRA
Marine Diesel Generating set controlled by Digital Diesel
Control first launched in September 2005. This installation
manual is valid for the following models:
Part number Description
51101055 Whisper 30 Ultra 120V-240V/60Hz
Split phase (1800rpm)
51101056 Whisper 30 Ultra120V-240V/60Hz
Split phase (1800rpm) ungrounded
51101355 Whisper 30 Ultra 120V-208V/60Hz
Three Phase (1800rpm)
51101356 Whisper 30 Ultra 120V-208V/60Hz
Three Phase (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. The generating set is already secured to the base
frame by means of flexible engine mountings. The base
frame can be mounted to the vessel’s main structure on a
second set of rubber mountings that is included in the
delivery. Use the included mounting template to determine
the mounting spots.
1.3.1 Further recommendations
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. See figure 1. 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 / November 2008 / WHISPER 30 ULTRA / 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 16 sq inch (100 cm2)
is required 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 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
01 Remote control 05 Bypass cooling water out Ø1”(25.4mm) 09 Fuel out Ø5/16” (8 mm)
02 AC power output 06 Bypass cooling water in Ø1”(25.4mm) 10 Fuel in Ø5/16” (8 mm)
03 Exhaust connection Ø2½”(63mm) 07 Battery positive + AWG 2 (35mm2) 11 Raw water inlet
04 Expansion tank 08 Battery negative – AWG 2 (35mm2) 12 Rubber engine mounting
Figure 2 Connections

INSTALLATION
US / WHISPER 30 ULTRA / November 2008 / Copyright © 2008 Mastervolt 5
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 3 ft (1 m).
If the pump has to lift the fuel higher than one meter an
external electrical fuel lift pump must be installed. The
control board is already prepared to connect an extra fuel
pump.
3 FUEL PIPES
When the fuel 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 (see figure 3).
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 (see figure 4)
1 Fuel return
2 Fuel supply
3 Prefilter / Water separator (optional)
5 Fuel Tank
Figure 3 Fuel supply

INSTALLATION
6Copyright © 2008 Mastervolt / November 2008 / WHISPER 30 ULTRA / US
A
1
3
2
5
4
1 Fuel return
2 Fuel supply
3 Prefilter / Water separator (optional)
4 Extra fuel lift pump (optional)
5 Fuel tank
Figure 4: Fuel supply
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
or to other consumers of diesel fuel, such as the
propulsion engine and heaters 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
US / WHISPER 30 ULTRA / November 2008 / Copyright © 2008 Mastervolt 7
1.5.2 Cooling
Intercooling is based on a raw water pump, heat
exchanger and water-injected exhaust. Cooling liquid in
the internal cooling system is cooled in a heat exchanger
by outboard water (raw water or seawater). After the raw
water is warmed up in the heat exchanger 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 with 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 in the canopy
MAX.
Figure 5: Expansion tank placement
The tank has to be placed close to the generator. When it
is mounted above the top of the manifold the liquid in the
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.
Figure 6. Internal cooling system
1 Water level;
2 Water/exhaust separator;
3 Seacock;
4 Waterlock;
5 Air vent;
6 Water strainer;
7 Seacock.
MIN. 60CM (24")
MAX. 150CM (60")
5 CM (2”)
1
3
5
6
7
4
2
MIN. 60CM (24")

INSTALLATION
8Copyright © 2008 Mastervolt / November 2008 / WHISPER 30 ULTRA / US
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, trough-hull fitting, inlet filter, etc.) must have an
inner diameter of at least 1” (25.4 mm) diameter. 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! (see figure
7).
Figure 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.
SAILING DIRECTION
SAILING DIRECTION
FLOW DIRECTION
FLOW DIRECTION

INSTALLATION
US / WHISPER 30 ULTRA / November 2008 / Copyright © 2008 Mastervolt 9
4 WATER STRAINER
Use an appropriate water strainer with connections of 1”
(25.4 mm). Install the water strainer in a well accessible
position, 2” (5 cm) above the waterline (see fig. 6, ref. 6).
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). See
figure 2. In the standard delivery the connections are
bypassed. Hose of 1" (25.4 mm) inner diameter should be
used.
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).
See figure 6, ref. 5.
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
OPEN
Figure 8: Wrong siphon breaker hose routing
On the valve is a little hose to drain a little water that could
be spilled from the valve. See figure 8. This hose should
go down and may not end under water, because it should
ventilate air into the valve to break the siphoning.
Check the air vent at regular intervals. Open, clean and
lubricate the valve as required.
OPEN
Figure 9 Mastervolt siphon breaker

INSTALLATION
10 Copyright © 2008 Mastervolt / November 2008 / WHISPER 30 ULTRA / US
1.5.3 Exhaust system
Water is injected in the exhaust system of the generating
set. In this way the cooling water that has passed the heat
exchanger is mixed with the exhaust gases. Temperature
and volume of the gases are thereby reduced
considerably, so that a rubber exhaust hose can be used
and the level of noise is reduced as well.
1 STANDARD EXHAUST SYSTEM INSTALLATION
The generating set exhaust system must remain
completely independent and separate from the exhaust
system of any other engine on board. A water lock
prevents the generating set from being flooded by cooling
water and should be installed as close to the generating
set as possible. The lock must be large enough to hold the
entire water volume held in the hose from the top of the
goose neck to the water lock. The water lock must be
installed at the lowest point of the exhaust system (ref. to
fig. 10, ref. 1). The exhaust hose must have an inner
diameter of 2½” (63 mm). The exhaust system must be
installed so that the back pressure inside the exhaust does
not exceed 0.07 bar (1psi – 70 cm watercolumn) and total
length from the genearot to the top of the goose neck or or
water/separator does not exceed 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 inch (50
mm) above the water line (see fig. 10, 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.
Figure 10: 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.
33
4
2
5
6
A
Minimum 60cm (24")
Maximum 150cm (60")
5 cm (2")
B
1
Maximum length A-B =
3 meter (10 feet)
1

INSTALLATION
US / WHISPER 30 ULTRA / November 2008 / Copyright © 2008 Mastervolt 11
1 Water level 3 Seacock
2 Water/exhaust separator 4 Waterlock
Figure 11: Super silent exhaust system
Figure 12: Only after the exhaust / water separator the exhaust hose may have a length of over 25 ft (7.5 m)
MAX. 10CM (4")
MIN. 60CM (24")
MAX. 150CM (60")
MIN. 3CM (1,2") 1
2
34
Ø 51 mm (2”)
Ø 63 mm (2½”)
B
A
Ø 63 mm (2½”)
Ø 63 mm (2½”)
A
B
WRONG!
OK!
Max. length A - B = 3 m (10 ft.)
Maximum length: 10 m (30ft)
Ø 2½” (63 mm)
Ø 2” (51 mm) Ø 2½” (63 mm) Ø 2½” (63 mm)

INSTALLATION
12 Copyright © 2008 Mastervolt / November 2008 / WHISPER 30 ULTRA / US
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 (figure 11, ref. A) 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 24” (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 an exhaust/water separator must
definitely be installed (Total length of the exhaust piping
from generator to top of goose neck (water separator) is
more than 10ft / 3 m.) (ref. to fig. 12).
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 25 ft (7.5 m) (ref. to fig. 12)
However watertraps should be avoided as the fumes still
contains water and this should not accumulate in bents
(see figures 13a and 13b). An additional outlet exhaust
muffler close to the hull outlet will help further to reduce
noise emission
Figure 13a: Water trap in exhaust system
Figure 13b: Water will collect in the hanging bend of the exhaust gas hose and will cause back pressure
OK! WRONG!
OK!
WRONG

INSTALLATION
US / WHISPER 30 ULTRA / November 2008 / Copyright © 2008 Mastervolt 13
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 (centre 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. 14).
Do not direct the outlet directly toward the
water surface.
Figure 14: 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 49ft (15 m) intermediate 8-pole
communication cable is in the standard supply too (refer to
fig. 15). 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.
Figure 15 Remote control cable
OK!
WRONG!

INSTALLATION
14 Copyright © 2008 Mastervolt / November 2008 / WHISPER 30 ULTRA / US
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. 16
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. 16.
WIRINGCOLOURS
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
Figure 16 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. 16.
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. 17. 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
Figure 17
Connection for emergency stop / fire alarm switch
Remove bypass
between J7 - J18
Normal operation
Alarm / emergency
local control panel
(rear view)

INSTALLATION
US / WHISPER 30 ULTRA / November 2008 / Copyright © 2008 Mastervolt 15
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. 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 requires a battery with a capacity
of at least 120 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.
230VAC
IVO12/10
AB
12V
+-
Figure 18 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 kit, art. no.
50230220 (160Ah)

INSTALLATION
16 Copyright © 2008 Mastervolt / November 2008 / WHISPER 30 ULTRA / US
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 5
ft. (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 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
The electric power supplied by the generator
is of a high voltage and dangerous to people.
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 30 ULTRA 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.

INSTALLATION
US / WHISPER 30 ULTRA / November 2008 / Copyright © 2008 Mastervolt 17
1 FUSE
An input fuse (from the generating set to the electrical
system) should be installed to protect the installed
electrical system.
Depending on the configuration of the AC wiring, the
following maximum single phase currents apply:
AC configuration Maximum rating AC-fuse
120 / 240 Volt split phase 125 Amps
3 x 208 Volt three phase 48 Amps
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 4 wire (split
phase) or 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 (L) as wel as
neutral (N).

INSTALLATION SPECIFICATIONS
18 Copyright © 2008 Mastervolt / November 2008 / WHISPER 30 ULTRA / US
2 INSTALLATION SPECIFICATIONS
2.1 General
1 Install the generating set on the 4 anti vibration
mounts. Use the template included in the shipment to
drill the 8 mounting holes.
MOUNTS
ANTIVIBRATION
Figure 19 Anti-vibration mounts
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 inch
(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 To bleed the fuel system use the manual pump by
turning the cap loose and pumping as long as
necessary to bleed the system
10 Check if the air intake in the canopy is not blocked.
11 Check the oil level and colour of the oil. Check the
coolant level
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
US / WHISPER 30 ULTRA / November 2008 / Copyright © 2008 Mastervolt 19
2.3 Installation specifications Whisper 30 ULTRA
TECHNICAL DATA
Dimensions incl. sound shield. 49.6 x 26.8 x 31.5 inch – 126 x 68 x 80 cm (L x W x H)
Dimensions w/o. sound shield. 45.3 x 23.6 x 29.5 inch – 115 x 60 x 75 cm (L x W x H)
Weight incl. sound shield 1280 Lbs – 580 kg
Weight w/o. sound shield 1060 Lbs –480 kg
Max. operation angle 25°
Remote panel 49 ft (15 m) cable Digital Diesel Control System
Battery capacity min. 120 Ah
Fuel consumption 0.3 – 1.6 US gph (1-6 l/hr), load dependent
Lift fuel pump Mechanical driven; manually priming; lift 1m
Cooling Indirect cooling
Cooling pump Mastervolt self priming impeller pump, PTO driven, type M16
Minimum water supply 5.3 – 6.6 US gpmin (20-25 l/min.)
Alternator synchronous brushless, maintenance free water cooled
Voltage regulation AVR
Output power at power factor cos phi = 1 30kW, 120-240V or 3x 120 / 208V 60Hz
Battery charger alternator including regulator (50 Amps)
2.4 Specifications of the accessories
Water scoop 1” = 25,4 mm
Inlet valve 1” in / 25,4 mm out
Water strainer 1” (25,4 mm) in, 1” (25,4 mm) out
Air vent 1” (25,4 mm)
Inlet suction hose 1” (25,4 mm)
Fuel filter/water separator 30 micron
Fuel inlet and return Ø5/16” (8 mm)
Exhaust hose Ø 2½” (63 mm) inner
Water lock Ø 2½” (63 mm)
Water/gas separator Ø 2½” (63 mm) - 2” (51 mm) - 2½” (63 mm)
External anti vibration mounts Included, art. nr. 50230588

INSTALLATION SPECIFICATIONS
20 Copyright © 2008 Mastervolt / November 2008 / WHISPER 30 ULTRA / US
2.5 Installation materials Whisper 30 ULTRA
Figure 20: Installation materials Water inlet kit and Syphon breaker kit
WATER INLET KIT 1” (25 mm)
pos qty article no description
1 1 50230053 Intake strainer 1"
2 1 50230043 Lever operated ball valve FF 1"
3 2 50221008 Male hose connection 3/4x25
4 4 50221503 Hose clamp stainless 25-35 mm
5 3m 50220050 Cooling water hose transp.spiral 25x33mm
6 1 50230061 Nickel plated brass intake strainer 3/4"
7 1 50221010 Male hose connection 1"x25
TOTAL 50230221 WATER INLET KIT 1" (25 MM )
SYPHON BREAKER KIT 1” (25 mm)
pos qty article no description
1 1 50230001 Syphon breaker valve
2 1 50221043 TEE fittings 3/4"
3 2 50221083 Elbow 90 degr male/female 3/4"
4 4 50221503 Hose clamp stainless 25-45 mm
5 1 50221522 Hose clamp stainless 10-16
6 50221008 Male hose connection 3/4x25
7 1 50230002 TEE fitting syphon breaker valve
8 1 50221102 Straight reducer male/female 3/4-1/2
9 3m 50220050 Cooling water hose transp.spiral 25x33mm
10 1.5m 50220054 Cooling water hose transparant spiral 20x28 mm
TOTAL 50230222 SYPHON BREAKER KIT 1" (25 MM )
Generator
cooling water inlet
WATER INLET KIT 1” (25 mm)
Generator
Bypass
cooling water out
Generator
Bypass
cooling water in
SYPHON BREAKER KIT 1” (25 mm)