Mastervolt WHISPER 30 ULTRA User manual

USERS 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 V3 December 2008
Art.nr. . 50200444

TABLE OF CONTENTS
2Copyright © 2008 Mastervolt / December 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:
1INTRODUCTION.............................................................................................................................................................. 4
1.1 General .............................................................................................................................................................. 4
1.2 Service and maintenance................................................................................................................................... 4
1.3 Guarantee .......................................................................................................................................................... 4
1.4 Liability ............................................................................................................................................................... 5
1.5 Identification ....................................................................................................................................................... 5
1.5.1 General.............................................................................................................................................. 5
1.5.2 Identification plate ............................................................................................................................. 5
2INFORMATION................................................................................................................................................................ 7
2.1 Safety ................................................................................................................................................................. 7
2.1.1 General.............................................................................................................................................. 7
2.1.2 Electrical safety ................................................................................................................................. 7
2.1.3 Earth insulation failures ..................................................................................................................... 7
2.1.4 Installation ......................................................................................................................................... 7
2.1.5 Operation........................................................................................................................................... 8
2.1.6 Fire and explosion ............................................................................................................................. 8
2.1.7 Chemicals.......................................................................................................................................... 8
2.2 Transport, lifting and storage.............................................................................................................................. 9
2.3 The Whisper 30 ULTRA ..................................................................................................................................... 9
2.3.1 Features ............................................................................................................................................ 9
2.3.2 Remote control .................................................................................................................................. 9
2.3.3 Documentation .................................................................................................................................. 9
2.3.4 Accessories included in the standard delivery...................................................................................9
2.4 Components ..................................................................................................................................................... 10
2.4.1 Main components ............................................................................................................................ 10
2.4.2 Generator control panel................................................................................................................... 12
2.4.3 Remote control panel ...................................................................................................................... 12
2.5 Technical Information ....................................................................................................................................... 12
2.5.1 AC alternator ................................................................................................................................... 12
2.5.2 Engine ............................................................................................................................................. 13
2.5.3 Digital Diesel Control system........................................................................................................... 13
2.5.4 Battery charger................................................................................................................................ 13
2.5.5 Alarms and shut down ..................................................................................................................... 13
2.5.6 Monitoring........................................................................................................................................ 13
2.5.7 Control............................................................................................................................................. 14
2.5.8 Remote control ................................................................................................................................ 14
2.5.9 Hour counter.................................................................................................................................... 14
2.5.10 Load indicator.................................................................................................................................. 14
2.5.11 Fuel specification............................................................................................................................. 14
2.5.12 Oil information ................................................................................................................................. 14
2.5.13 Cooling liquid................................................................................................................................... 14
2.5.14 Technical data ................................................................................................................................. 15
2.5.15 Electrical diagram control wiring Whisper 30 Ultra .......................................................................... 16
2.5.16 Overview of AC terminal modes Whisper 30 Ultra .......................................................................... 17
2.5.17 AC wiring diagram Split-Phase 120 – 240Volt / 60Hz with AVR (DOUBLE DELTA) ....................... 18
2.5.18 AC wiring diagram Three Phase 3 x 120/208 Volt / 60Hz with AVR (Double STAR)....................... 19

TABLE OF CONTENTS
US / WHISPER 30 ULTRA / December 2008 / Copyright © 2008 Mastervolt 3
3OPERATION.................................................................................................................................................................. 20
3.1 General ............................................................................................................................................................ 20
3.2 Operating Instructions ...................................................................................................................................... 20
3.2.1 Summarised operating instructions (daily use)................................................................................ 20
3.2.2 Extended operating instructions ...................................................................................................... 20
4MAINTENANCE............................................................................................................................................................. 23
4.1 Alternator.......................................................................................................................................................... 23
4.2 Engine .............................................................................................................................................................. 23
4.2.1 Preliminary instructions ................................................................................................................... 23
4.2.2 Bleeding fuel lines ........................................................................................................................... 23
4.2.3 Valve clearance............................................................................................................................... 23
4.2.4 Replacing fuel filter .......................................................................................................................... 23
4.2.5 Replacing oil filter ............................................................................................................................ 24
4.2.6 Tensioning V-belt............................................................................................................................. 24
4.3 Regular maintenance ....................................................................................................................................... 25
4.3.1 Maintenance schedule..................................................................................................................... 26
4.3.2 Taking out of service ....................................................................................................................... 26
5TROUBLE SHOOTING.................................................................................................................................................. 27
5.1 Alternator/ electrical faults ................................................................................................................................ 27
5.1.1 General............................................................................................................................................ 27
5.1.2 Trouble shooting table ..................................................................................................................... 27
5.2 Engine faults..................................................................................................................................................... 29
5.2.1 General............................................................................................................................................ 29
5.2.2 Trouble shooting table ..................................................................................................................... 29
5.2.3 Warnings ......................................................................................................................................... 32
5.2.4 Service address............................................................................................................................... 32
5.3 Special procedures alternator........................................................................................................................... 33
5.3.1 Automatic Voltage Regulator (AVR) ................................................................................................ 33
5.3.2 Residual voltage check / excitation procedure (flashing)................................................................. 34
5.3.3 Testing rotary rectifier diodes .......................................................................................................... 34
5.3.4 Winding resistant values.................................................................................................................. 35
5.3.5 Meggering ....................................................................................................................................... 35
5.4 Special procedures engine ............................................................................................................................... 35
5.4.1 Setting the RPM .............................................................................................................................. 35
5.4.2 Adjusting valve clearance and retightening the cylinder head bolts. ............................................... 36
5.4.3 Measuring exhaust backpressure.................................................................................................... 36
5.4.4 Disassembling instructions .............................................................................................................. 37
6SPARE PARTS.............................................................................................................................................................. 39
MAINTENANCE LOG ............................................................................................................................................................... 42

INTRODUCTION
4Copyright © 2008 Mastervolt / December 2008 / WHISPER 30 ULTRA / US
1 INTRODUCTION
1.1 General
This manual applies to the Mastervolt Whisper 30 ULTRA
generating set controlled by Digital Diesel Control first
launched in September 2005 This user’s 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
The Whisper 30 ULTRA Marine Diesel Generating set is
manufactured and marketed by Mastervolt. It is important
to read this manual before installing and operating the
generating set. Both safety and durability rely very much
on the correct identification, installation and a good
understanding of ratings, features, design, maintenance
and operation procedures.
The information, specifications, illustrations and
statements contained within this publication are given with
our best intentions and are believed to be correct at the
time of going to press.
Our policy is one of continued development and we re-
serve the right to amend any technical information without
prior notice. Whilst every effort is made to ensure the
accuracy of the particulars contained within this publication
neither the manufacturer, distributor, or dealer in any
circumstances shall be held liable for any inaccuracy or
the consequences thereof.
WARNING
A warning symbol draws attention to special
warnings, instructions or procedures which, if
not strictly observed, may result in damage or
destruction of equipment, severe personal
injury or loss of life.
DANGER
This danger 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 Service and maintenance
Regular service and maintenance should be carried out
according to the directions in this manual. For service and
maintenance one can appeal to the manufacturer or the
dealers.
1.3 Guarantee
Mastervolt guarantees that this generating set has been
built according to good workmanship, according to the
specifications in this manual and according to European
Community safety regulations.
During production and prior to delivery, all of our
generating sets are tested and inspected.
The well functioning of this generating set is subject to
guarantee. The period and conditions of this guarantee are
laid down in the general conditions of delivery as
registered with the Chamber of Commerce and Industries
in Amsterdam number 33279951 and are available on
request. The guarantee period is two years, limited to
1000 running hours. For USA deliveries there are
additional conditions. These are available at Mastervolt
USA. Some aspects of our guarantee scheme are given
here in more detail:
Guarantee does not cover failures that are caused by
misuse, neglect or a faulty installation.
Example 1. Faulty installation:
Seawater entering the engine is the most common cause
of damage to combustion engines in boats. (Both to
propulsion and generator engines.) The entry of water
must be avoided under all conditions. Be aware that the
conditions in blue water sailing can be extreme. See the
installation manual for instructions but remember these are
for guidance only as many factors influence the installation
of a generator. The ultimate responsibility will always be
with the owner to ensure a safe and compliant installation.
WARNING
Damage caused by the ingress of water is
never covered by guarantee
Example 2: Misuse:
Long term running with no load or too little load can cause
the exhaust to get choked with soot or carbon. Cleaning
the exhaust is not covered by guarantee.
Example 3: Neglect
Sometimes the seal of the raw water pump starts leaking.
Mostly this begins with a little drip and slowly gets worse.

INTRODUCTION
US / WHISPER 30 ULTRA / December 2008 / Copyright © 2008 Mastervolt 5
Regular visual inspection of the generator is necessary to
prevent damage to occur from a leaking water pump.
When one find serious damage after weeks of neglect
guarantee claims will not be honoured.
Example 4: Neglect
Whisper generators have an option for an auto start/stop
mode or interval mode.
Mastervolt cannot be held responsible for damage caused
by the unattended running generator.
Guarantee means that faulty parts are repaired or
replaced free of charge. If necessary the whole generator
unit will be exchanged. Labour necessary to complete
repairs on board a vessel executed by an authorized
service engineer is covered, but is limited to a reasonable
number of hours and reasonable rates in relation to the
actual repair work that has to be done.
Travel expenses and travel hours are not covered. Also
not covered is the labour required to take a generator out
of a boat or for reinstallation. There is no cover for labour
needed to get access to the generator, for example to
remove equipment or bulkheads etc.
Goods to be delivered under guarantee will be invoiced.
Only after the faulty goods are returned will the invoice be
credited. Payment in advance may be required or
guaranteed by credit card. If after the faulty goods are
returned, it is indicated that the failure was not covered by
guarantee a credit will not be issued. For example if a
Printed Circuit Board is returned with clear damage
caused by seawater, guarantee will be refused.
Freight costs to deliver spares by normal mail or carriers is
covered under guarantee. Special services like express
mail, overnight delivery etc. are not covered. Taxes and
duties are not covered. For shipments to remote off shore
areas any additional costs incurred over normal carriage
will be invoiced to the customer.
The cost for returning faulty goods is not covered under
guarantee.
Additional agreements could be part of the contract of
delivery.
If any problem arises which could be subject of guarantee,
procedures should be followed as described in the
guarantee conditions, unauthorised repairs could lead to
further damage and violate the guarantee conditions.
Should work take place, which is not in
accordance with the guidelines, instructions
and specifications contained in this user’s
manual and the supplementary installation
manual, then damage may occur and the
generating set may not fulfil its specifications.
In all these cases the guarantee may become
invalid. Use original spareparts only!
1.4 Liability
Mastervolt does not accept responsibility for damage,
injuries or casualties which are the result of operation of
the generating set in specific conditions which brings
dangers which could not be foreseen, or could be avoided
by additional measures. Mastervolt does not accept
liability for damage due to use of the generator, possible
errors in the manuals and the results thereof.
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.
1.5 Identification
1.5.1 General
Before using this generating set it is very important to
identify the set correctly. To communicate for service or
ordering parts it is also essential to correctly identify the
generating set. Also for the daily operation of the genera-
ting set it is necessary that the operator knows the correct
specifications.
1.5.2 Identification plate
All required identification data are on the identification
plate.
Fig. 1: Location identification plate.

INTRODUCTION
6Copyright © 2008 Mastervolt / December 2008 / WHISPER 30 ULTRA / US
Fig. 2: Identification plate.
1 The identity of the generating set is given by the
SERIAL NUMBER.
Example:
When this number is available the manufacturer can
trace the specifications of the generating set. On the
nameplate are also some basic features of the set:
2 POWER
The nameplate gives the nominal maximum continues
load in kVA = kW calculated with power factor one.
When calculating a load one should always take into
account the power factor or cos phi of this load. The
power should never exceed the nominal power as
shown on the nameplate. Power is rated at an
ambient temperature of 104°F (40°C) and a seawater
temperature of 77°F (25ºC) For higher temperatures
the generating set has to be de-rated.
3 VOLTAGE. This shows the nominal voltage.
This voltage should be within the specified tolerance
at the nominal frequency. The Whisper 30 ULTRA
can be connected for different voltages in split phase
(120-240V) or three phase (120-208V). The
nameplate indicates the connection as made in the
factory; BE AWARE THAT THE CONNECTIONS
COULD BE RECONNECTED BY FORMER USERS
4 FREQUENCY. This is shown in Hz and is determined
by the speed of the engine (RPM). 60 Hz correlates
with 1800 rpm.
5 CURRENT. This shows the maximum current that is
acceptable at the specified frequency, voltage and
power factor. When connected in tri phase the
indicated current is the current between two phases
that can be taken off three times.
6 WEIGHT shows the net dry weight (approximately) in
kg. This is without fuel, oil, packing and external
installation equipment
7 CE MARKING.. The CE symbol shows that the
generating set is build according to European
Community safety regulations. This includes the
regulations regarding the safety of pleasure craft,
safety of machinery, regarding electric safety and
electric magnetic compatibility (EMC).
8 Exhaust emission of the engine used in this
generating set is according EPA regulations and the
engine is certified and labelled as such by the
manufacturer
Safety also relies on the installation, application and
circumstances. See also the remarks in this manual under
SAFETY
Before changing a factory setting you are advised to
consult the manufacturer. When the generating set you
have to identify is not new you have to take into account
the possibility that former users did change the settings.
Check the settings (voltage, frequency, rpm) when there is
any doubt.
SERIAL NO: : W822B001
version “B”
EPA
Manufacturer :
Mastervolt b.v.
Snijdersbergweg 93
1105 AN Amsterdam
The Netherlands
Tel. [phone]
: 2005YEAR OF MANUFACTURING
WEIGHT : 480 kg - 1280 lbs
: 49.6 x 26.8 x 31.5 inchDIMENSIONS
PHASE : Split phase
: 2 x 125ACURRENT
FREQUENCY : 60Hz
: 120 - 240VVOLTAGE
MAX.POWER : 30kW (kVA) cos = 1
:SERIAL NO
A
RTICLE NO : 51101055
: Whisper 30 ULTRAMODEL

INFORMATION
US / WHISPER 30 ULTRA / December 2008 / Copyright © 2008 Mastervolt 7
2 INFORMATION
2.1 Safety
2.1.1 General
When correctly installed and used in normal
circumstances this generating set fulfils EC safety
regulations. This generating set could be part of an
installation or could be used in a way that additional
regulations of the EC or other authorities have to be taken
into account.
DANGER
Warning signs draw 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.
Circumstances could make it also necessary
to take additional measures. Be aware of wet
conditions and hazardous environments
caused by explosive gases etc
2.1.2 Electrical safety
This warning sign indicates parts which could
be live. The voltage of 120V-240V or 120V-
208V generated by this generating set is
dangerous and if instructions and procedures
are not strictly observed may result in
electrical shock which will result in severe
personal injury or loss of life.
•Check all wiring at least once a year. Defects, such as
loose connections, burned cables etc. must be
repaired immediately.
•Do not work on the electrical system if it is still
connected to a current source. Only allow changes in
your electrical system to be carried out by qualified
electricians.
•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.
•Connection and protection must be done in
accordance with local standards.
2.1.3 Earth insulation failures
According to local regulations and depending on the
application it could be necessary to take measures for
protection against earth insulation failures.
With the USA versions “neutral” and “ground” are
connected with each other on the alternator. This requires
an insulation protection device as commonly used in the
U.S.A. This installation is beyond the influence of
Mastervolt and Mastervolt cannot be held responsible for
any consequence as a result of the installation
In all situations the transfer switches between
shore, inverter and generator should switch
both neutral and line(s).
2.1.4 Installation
Whisper generating sets are not self contained and have
to be properly installed in enclosed areas such as a
machine room.
Installation includes measures to be taken to
outlet exhaust fumes which contain carbon
monoxide and are extremely dangerous.
Carbon monoxide (CO) is an invisible odourless gas.
Inhalation produces headache, nausea or death.
Installation includes measures for proper ventilation, safe
electric connections, safe installation of the starting
battery, proper fitting of the cooling system and fuel pipes
etc. See the installation manual.

INFORMATION
8Copyright © 2008 Mastervolt / December 2008 / WHISPER 30 ULTRA / US
2.1.5 Operation
External moving parts like fans and V-belts are covered by
the canopy and therefore the Whisper 30 ULTRA is very
safe when the canopy is closed.
Nevertheless take note of the signs on the
generating set which show symbols in a
triangle indicating danger.
When service has to be carried out while the
engine is running, be aware of moving parts
like V-belts.
•The generating set should be operated by authorised
personnel only.
•Be aware of hot parts and especially parts of the
exhaust system and cooling system.
•If the generating set is unsafe, fit danger notices and
disconnect the battery positive (+) lead so that it
cannot be started until the condition is corrected.
•Do not attempt to operate the generating set with a
known unsafe condition. Disconnect the battery
positive (+) lead prior to attempting any repairs or
cleaning inside the enclosure.
•Always consult the manual before carrying out
maintenance.
•Do not change the settings without consulting the
manufacturer. Keep a record of setting changes in this
manual.
2.1.6 Fire and explosion
Fuels can be flammable. Proper handling
limits the risk of fire and explosion.
•Avoid refilling the fuel tank while the engine is running.
When oil or fuel is leaking do not use the generating
set.
•Do not run the engine close to explosives or gasses.
•Hydrogen gas generated by charging batteries is
explosive. Take measures for proper ventilation. Do
not smoke or allow sparks, flames, or other sources of
ignition around batteries.
•Keep a fire extinguisher on hand.
INCASEOFFIRE, DONOTOPENSOUNDSHIELD.
TOAVOID SERIOUS INJURY OR DEATH FROM FIRE
IMMEDIATELY DISCHARGE ENTIRE CONTENTS OF GASEOUS
SHUT DOWN ENGINES, GENERATOR SETS AND BLOWERS.
PORTABLE FIRE EXTINGUISHER THROUGH THIS PORT.
THROUGH
HERE
FIRE EXTINGUISHER PORT :
BREAK
Fig. 3 Fire extinguisher port.
•In case of fire do not open the soundshield. To avoid
serious injury or death from fire, shut down engines,
generator sets and blowers. Break through the label
which is indicated by BREAK THROUGH HERE and
then immediately discharge entire contents of gaseous
portable fire extinguisher through the fire extinguisher
port. On the generating set this fire extinguisher port is
indicated by the label as shown in figure 3.
•Poor electrical connections or using wiring which is not
suited for the rated currents can cause overheating
and possibly fire.
2.1.7 Chemicals
•Fuels, oils, coolants, and battery electrolyte can be
hazardous to personnel if not treated properly. Do not
swallow or have skin contact with these liquids. Do not
wear clothing that has been contaminated by fuel or
lubricating oil.
•Gaskets may be manufactured from asbestos.
Particles of this material should not be inhaled as this
may result in fatal diseases.
•On no account allow any unprotected skin to come into
contact with the injector spray as the fuel may enter
the blood stream with fatal results.
•Engines may be fitted with seals or O-rings
manufactured from "viton" or similar material. When
exposed to abnormal high temperatures in excess of
750°F (400°C) an extremely corrosive acid is produced
which cannot be removed from the skin. If signs of

INFORMATION
US / WHISPER 30 ULTRA / December 2008 / Copyright © 2008 Mastervolt 9
decomposition are evident, or if in doubt, always wear
disposable heavy duty gloves.
2.2 Transport, lifting and storage
When lifting the generating set avoid any risk
of personal injuries, do not stand under the
generating set.
•Use soft slings to avoid damage
•On the engine are lifting eyes, which can be used to
take the generator out of the capsule. The lifting eyes
can also be used to lift the entire generator set,
including the capsule
•After transporting the generating set check for damage
before installation.
•Long term storage can have detrimental effects on
engine and alternator. The engine should be put
through an engine preservation procedure. (See the
maintenance chapter)
•The alternator windings tend to condense. To minimise
condensation, store the generating set in a dry and
warm storage area.
•After removing the generating set from long term
storage perform an insulation check. (See the
alternator maintenance paragraph for procedures)
•While the battery is stored it should be recharged
every 12 weeks.
2.3 The Whisper 30 ULTRA
2.3.1 Features
This generating set includes a 4 cylinder diesel engine
which is connected by close coupling to a tri phase
synchronous alternator in a sound attenuated capsule.
The set is mounted on a steel base frame and mounted
securely on anti vibration mounting pads to the capsule
base. The complete set is again on rubber mountings. All
cables and hoses are guided through the capsule’s sides.
The set is not self contained and is only operable after
proper installation using additional accessories and
installation materials.
Installation accessories are listed in the installation manual
and are available through the supplier of the generating
set. The full automatic Digital Control is based on
microprocessor technology. Several automatic start/stop
functions can be programmed and monitored (see Digital
Diesel Control users manual).
2.3.2 Remote control
The full automatic remote control panel including 49ft (15
mtr) cable comes as standard with the Whisper 30
ULTRA.
2.3.3 Documentation
Included in the delivery is:
•This users manual (number: 50200444)
•An installation manual (number: 50200454)
•An users manual for DCC (number: 50200261).
•A quick reference guide for DDC (number 50200275)
Not included in the standard delivery but available as
options are:
•Parts manual; number: 50200187
•Workshop manual; number: 50200174
However in this manual there is a list of important parts for
maintenance and spare parts as well as a chapter on
maintenance and problem solving.
All manuals are available on our web site
www.mastervolt.com.
2.3.4 Accessories included in the standard
delivery
•Expansion tank, hose and fittings
•Template to mount the generator

INFORMATION
10 Copyright © 2008 Mastervolt / December 2008 / WHISPER 30 ULTRA / US
2.4 Components
2.4.1 Main components
Fig. 4: Left View main components Whisper 30 Ultra
Fig. 5 Top View main components Whisper 30 Ultra
01 Thermostat housing
02 Boiler connection
03 Engine coolant pump
04 V-belt
05 Exhaust connection
06 Bypass cooling water out
07 Bypass cooling water in
08 Battery +
09 Battery -
10 Fuel out
11 Fuel in
12 Raw water inlet
13 Raw water pump
14 Rubber engine mounting
15 Filler cap engine oil
16 Filler cap engine coolant
17 Rubber engine mounting
18 Rocker cover

INFORMATION
US / WHISPER 30 ULTRA / December 2008 / Copyright © 2008 Mastervolt 11
Fig. 6 Front View main components Whisper 30 Ultra.
Fig. 7: Rear View main components Whisper 30 Ultra.
19 Hoist eye rear
20 Engine speed adjusting
screw
21 Fuel injector
22 Glowplug (4x)
23 Fuel filter
24 Fuses
25 Control panel
26 Air cleaner element
27 Indentification plate
28 Oil swump handpump
29 Coolant drain plug
30 Engine oil dipstick
31 Fuel solenoid
32 Oil filter
33 Injection pump air bleeding
screw
34 Fuel lift pump for manual
primimg
35 Fuel injection pump
36 Heat exchanger
37 Temperature switch
38 Hoist eye front
39 Alternator
40 Exhaust manifold
(watercooled)
41 Hoist eye alternator
42 Digital Diesel Control (DDC)
43 Expansion tank
44 Power take off hydro pump
45 Remote control
46 AC power output
47 Temperature switch exhaust
48 Cooling water injection bend
49 Engine oil pressure switch
50 Starter motor solenoid
51 Starter motor
52 Engine serial number (above
starter motor solenoid)
53 Automatic voltage regulator
(AVR)

INFORMATION
12 Copyright © 2008 Mastervolt / December 2008 / WHISPER 30 ULTRA / US
2.4.2 Generator control panel
Start / Stop
Remove fuse
Internal fuel pump
Fuse 3A
before maintenance
Digital Diesel Control
Fuse 3A
Auxiliary
Fuse 10A External Fuel Pump Fuse 3A
Observe instructions in the manual
Replace fuseswith same type and rating
Whisper Digital Diesel OperationUnit
Fig. 8 Control panel.
Fig. 9 Digital Diesel Control unit
2.4.3 Remote control panel
04
03
02
01
05 07 06
01 Generator load indicator
02 Failure LED
03 Start button
04 Stop button
05 Display
06 Select button
07 Set button
Fig. 10 Digital Diesel remote control panel.
2.5 Technical Information
2.5.1 AC alternator
The tri phase synchronous alternator is directly coupled,
one bearing, brushless, rotating field design, 12 wire, four
pole (1800 RPM) and regulated by an Automatic Voltage
Regulator (AVR).
The exciter stator has a residual magnetism, which
guarantees self-exciting of the generator on start-up (that
thereby generates a residual voltage of about 10%
nominal voltage).
Fig. 11 Automatic Voltage Regulator (AVR)
The AVR, powered by an auxiliary circuit on the main
stator, acts on the exciter stator indirectly controlling the
field generated by the main rotor by means of the
sequence exciter rotor - diode bridge - main rotor.
The voltage regulator controls and keeps constant the
average voltage of one phase. The voltage setting on the
AVR can be adjusted with the help of a trimmer “V”
between 100 and 140 Volts (or 200 and 280V @ nominal
voltage 230V). (See par. 5.3.1)
A frequency control progressively deactivates the machine
when the drive motor speed drops below a pre-set,
adjustable threshold preventing over-excitement at low
operating speeds and abating the load engage effects on
the engine.
The AVR works only within limits of the set frequency 60
Hz. When operating below the lower limit of 56 Hz ± 1 Hz
the AVR will stop regulating to avoid overloading the
exciter coil (This setting can be changed with trimmer
“UF”). (See par. 5.3.1)
When applying the generator set at 50 Hz the AVR is re-
adjustable as well. To operate at 50 Hz the engine RPM
and Digital Diesel Control settings must also be changed.
For the European market a dedicated manual (Art. No
50200441) is available for 50 Hz applications. Please refer
to the Mastervolt service centre for specific instructions to
convert the generating set to 50 Hz.
A further option is to readjust the stability of the regulator.
In the event of very irregular (alternating) loads it could be
necessary to change this setting with the help of trimmer

INFORMATION
US / WHISPER 30 ULTRA / December 2008 / Copyright © 2008 Mastervolt 13
“S” to avoid interference of the regulator and the
alternating load. In conclusion the regulator reaction time
can be modulated to eliminate any voltage instability that
may arise. (See par. 5.3.1)
Fig. 12 AVR Trimmers (potentiometers).
The power comes from 12 wires that can be connected in
star, delta or combined double / star and double / delta
arrangements to take off different voltages. For 60Hz
applications The Whisper 30 ULTRA should be connected
in one of 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.
Further technical data on the connections of the alternator
can be found in drawings and diagrams in this manual.
The three phase synchronous alternator is directly
coupled, one bearing, brushless, rotating field design, 12
wire, four pole (1800 RPM) and regulated by an Automatic
Voltage Regulator (AVR).
Residual magnetism causes a small voltage over the
stator windings and allows a current to flow in the
windings, which is magnified because of the feed back
effect between rotor and stator. The field windings in the
rotor are short-circuited over a diode to rectify the current.
A capacitor over an additional winding in the stator which
is at an angle with the power-winding keeps the voltage
stable within 5 % at the specified rpm and provides voltage
fall off with speed, preventing over-excitation at low engine
speeds and softening the effect of load switching to relieve
the burden on the engine.
Further technical data on the design of the alternator can
be found in drawings and diagrams in this manual.
2.5.2 Engine
The Whisper 30 generating set is based on the Mitsubishi
S4S 4 cylinder 4 stroke diesel engine. The engine is
indirectly injected. The engine is water cooled and the
cooling liquid is cooled by a heat exchanger and raw (sea)
water. The heat exchanger and all other parts which are in
direct contact with the raw (sea) water are made of
seawater resistant material like naval brass and copper
nickel.
The engine has been specially adapted for the Mastervolt
application and is very different from the standard engine
supplied for industrial applications!
2.5.3 Digital Diesel Control system
The standard electrical engine control system is 12 Volt
negative earth, non earth return (ungrounded) is available
as optional. Check your identification data to determine
which system is applied. The system is designed
according to the "energise to run" system. The Digital
Diesel Control is a very advanced microprocessor based
full automatic system. Besides automatic start the system
offers many monitoring options. See the separate Digital
Diesel Control users manual (number 50200261).
The microprocessor unit of the Digital Diesel Control is
located in the black box on top of the AC alternator (see
figures 7 and 9).
2.5.4 Battery charger
On the engine is an alternator generating 50 Amp 12V.
This current is rectified to charge the battery. The voltage
is regulated at approx. 14.4V.
2.5.5 Alarms and shut down
In case of malfunctioning this will be indicated by the
failure light, details will be shown on the display and the
engine will be shut down. There are three functions
guarded: oil pressure, oil temperature and exhaust
temperature.
Exhaust temperature too high indicates the cooling water
to be blocked.
All alarm switches are closed when no malfunction occurs.
A contact is cut in the event of an alarm. This means that
the generating set will not work when the alarm switches
are broken or there is a loose wire. The system therefore
is intrinsically safe. The panel will display details about the
alarm.
2.5.6 Monitoring
Refer to the operating of the Digital Diesel Control
Trimmer V
Trimmer UF
Trimmer ST
Trimmer ST
Trimmer V
Trimmer UF
Jumper J

INFORMATION
14 Copyright © 2008 Mastervolt / December 2008 / WHISPER 30 ULTRA / US
2.5.7 Control
The generating set can be operated by push buttons on
the panel on the alternator or by the remote control. By
pushing the START button the control system is activated
and will start the engine automatically. Pushing the STOP
button will stop the engine and the electrical system will be
deactivated. Stopping the engine is executed by the
solenoid that will shut off.
2.5.8 Remote control
All wiring connections from the remote control to the board
are made by plug in connectors.
An intermediate communication cable is in the standard
supply. If necessary an optional longer 8 wire
communication cable can be connected if the standard
length does not suit the required distance. Numerous
remote control units can be put in parallel by using the
connectors on the back of the units. (See installation
instructions)
2.5.9 Hour counter
The remote control offers several timer functions that help
to schedule maintenance.
2.5.10 Load indicator
On the remote control the load will be indicated on the
display and by the LED-bar. The load is measured by
current transformers on the alternator. All phases are
monitored and overload of all phases or just one or two
phases will provoke an alarm or even shut down when the
alarm is ignored.
2.5.11 Fuel specification
The engine must only be used with diesel fuel oil which
conforms to the standards for use in modern diesel
engines. Fuel free from water and contaminants is of the
utmost importance.
2.5.12 Oil information
1 Specification:
The oil must be suitable for oil changes as specified in
the maintenance chapter. The Mitsubishi engine must
be run on heavy duty lubricating oil meeting the
requirements of API class CC, CD, CF or CF_4.
It is very important to use the correct oil
specification. Very often local oil suppliers
recommend a higher class, because they
assume that a higher class is allowed. This is
not the case. One should not follow these
recommendations.
Using the wrong specification will cause high
oil consumption.
2 Oil viscosity:
We recommend a multigrade oil 15W40.
3 Oil capacity:
Excluding the oil filter the content of the crankcase is
9.5 US qts (9 litres). Including the oil filter it is 9.8 US
qts (9.3 litres). Note that the engine may contain
some residual oil due to testing at the factory.
While filling, check the lubricating oil level by means
of the engine oil dipstick. Do not overfill with
lubricating oil as this may have a detrimental effect on
engine performance
4 Oil pressure
•Minimum at idle 98 kPa (1 kgf/cm²/14psi) (1 bar).
•At 2230 rpm ±300 kPa (3 kgf/cm²/45 psi) (3 bar).
2.5.13 Cooling liquid
The engine is cooled by cooling liquid. The capacity of this
system of the Whisper 30 ULTRA is 10 US qts (9.5 litres).
Always use coolant which is compatible with
aluminum components of the cooling system.
Do not mix coolants with different kinds of
chemical compound, as this may cause
congelation of the coolant. In case of doubt
refresh the content of the entire cooling
system.
We recommend not using water but cooling liquid that is
marketed for the use in combustion engines. Cooling liquid
protects the engine against frost to minus 13 °F (minus
25°C). Also it protects the engine block against corrosion.
One can fill the engine via the filling cap on the exhaust
manifold. Fill up till the level is just below the filling cap.
When the engine is on temperature the liquid will expand
and the redundant liquid will be pressed into the expansion
tank. This tank has to be filled up till the mark. When
cooling liquid is not available clean fresh water could be
used with an additive of anti freeze. When using water with
anti freeze the right mixture has to be calculated according
to the information of the supplier of the anti freeze. When
the cooling is based on keel cooling or radiator cooling the
capacity of these coolers and piping has to be taken into
account calculating the right mixture.
The cooling liquid in the engine is pressurised and has a
boiling point above 212°F (100°C). The temperature
switch in the thermostat housing switches at 230°F
(110°C).. When keel cooling or radiator cooling is applied
the cooling system is not pressurised. There should be a
special cap on the manifold without valves leaving the
connection to the expansion tank open. Refer to the
manual on keel cooling and radiator cooling.

INFORMATION
US / WHISPER 30 ULTRA / December 2008 / Copyright © 2008 Mastervolt 15
2.5.14 Technical data
GENERAL
Model WHISPER 30 ULTRA
RPM 1800 rpm
Alternator 3 phase synchronous (air cooled)
Engine Mitsubishi diesel, model S4S (Japan)
Number of cylinders 4
Displacement 203 cubic inches (3331 cm³)
Bore X stroke 3.70 x 4.72 inches (94 x 120 mm)
Combustion air consumption 350 cf/m (10 m³/min.)
Continuous power 60Hz 30 kW electric power
Cooling system indirect cooling by raw water, 5.3 – 6.6 US gpmin (20-25 l/min.).
Cooling water pump PTO driven Mastervolt self priming impeller pump, type M16
Fuel lift pump engine Mechanical pump, additional electrical pump available upon request
Battery capacity min. 120 Ah
Fuel consumption 0.53 – 2 US gph (2-7 litre/hour), load dependent
Control Digital Diesel Control including automatic start/stop
ELECTRICAL SPECIFICATIONS
Output voltage 120-240V, 3x 120V or 3x 120 / 208V 60Hz alternating current (AC)
Output rating 60Hz 30kVA at powerfactor cos phi = 1
Voltage tolerance ± 2% (balanced load)
Frequency tolerance ± 3%
Alternator Air cooled, brushless, four pole, twelve wire, synchronous
Voltage regulation: AVR
MECHANICAL SPECIFICATIONS
Supply includes Sound shield with steel base, mounted on rubber anti vibration mounts. (Genset
without sound shield is optional)
Dimensions in sound shield hxwxd 49.6 x 26.8 x 31.5 inch – 126 x 68 x 80 cm (L x W x H)
Dimensions without sound shield 45.3 x 23.6 x 29.5 inch – 115 x 60 x 75 cm (L x W x H)
Color: metallic silver / grey
Weight with sound shield 1280 Lbs – 580 kg
Weight without sound shield 1060 Lbs –480 kg
Max. operation angle 25 degrees
Standard supplies Remote panel (+49ft / 15 m cable), fuel filter, fuel lift pump, user and installation
manuals
Optional Installation kits, mobile (vehicle) version, non earth return, spare part kits, PTO to
drive hydraulic pump

INFORMATION
16 Copyright © 2008 Mastervolt / December 2008 / WHISPER 30 ULTRA / US
2.5.15 Electrical diagram control wiring Whisper 30 Ultra
Fig. 13 Electrical Diagram control wiring Whisper 30 Ultra

INFORMATION
US / WHISPER 30 ULTRA / December 2008 / Copyright © 2008 Mastervolt 17
2.5.16 Overview of AC terminal modes Whisper 30 Ultra
Fig. 14 Terminal modes Whisper 30U

INFORMATION
18 Copyright © 2008 Mastervolt / December 2008 / WHISPER 30 ULTRA / US
2.5.17 AC wiring diagram Split-Phase 120 – 240Volt / 60Hz with AVR (DOUBLE DELTA)
Fig 15. AC wiring diagram Split-Phase with AVR 120 - 240V / 60Hz (Double Delta)

INFORMATION
US / WHISPER 30 ULTRA / December 2008 / Copyright © 2008 Mastervolt 19
2.5.18 AC wiring diagram Three Phase 3 x 120/208 Volt / 60Hz with AVR (Double STAR)
Fig 16. AC wiring diagram three phase 3 x 120/208 Volt with AVR (Double Star)

OPERATION
20 Copyright © 2008 Mastervolt / December 2008 / WHISPER 30 ULTRA / US
3 OPERATION
3.1 General
The generating set is operational after full installation and
filling up with: fuel, engine lubricating oil and cooling liquid,
connecting the battery to earth and connecting the digital
remote control panel.
Fig. 17 Engine Oil Dipstick markings.
3.2 Operating Instructions
3.2.1 Summarised operating instructions (daily
use)
Routine "pre-start" checks:
1 Check oil level (see fig 17).
2 Water inlet (all valves open).
3 Power source selector switch (off/shore
power/generator power). Switch to power source
switch "OFF", or switch off all consumers in the usual
way.
4 Switch on battery switch (when installed).
5 Fuel valve: open.
Starting:
Push the start button to initiate the full automatic
starting procedure. You can monitor the procedure on
the display.
In operation checks:
1 Check for abnormal noise or vibration
2 Check the voltage
3 Check sea water flow at exhaust outlet
4 Power source selector switch (off/shore
power/generator power). Switch to power source
generator.
5 Before loading the generating set up to maximum,
have it run warm. Continuous load should be
restricted to 70 % of maximum load.
Stopping generator:
1 Switch off all electrical devices (consumers). If the
generating set has been running under full load for a
longer period, do not shut it down abruptly. Reduce
the electrical load to about 30% of the rated load and
let it run for approx. 5 minutes.
2 Press the STOP button.
3 Close the inlet sea water cock.
4 Switch to another AC power source, if available.
3.2.2 Extended operating instructions
Check when starting the first time or after a longer
period of rest:
1 If there is any damage caused by transport or
installation.
2 Check if installation conforms to the installation
instructions.
3 Ensure the generating set is free to turn without
obstruction.
4 Check all hoses and hose connections for leaks.
5 Check all cables and cable end terminal connections.
6 Check the engine and generator mounting bolts.
1
2
1 Maximum oil level
2 Minimum oil level