Mastervolt whisper 3.5m User manual

INSTALLATION MANUAL
WHISPER 3.5M
- 3000 RPM -
Marine diesel generating set 230V / 50Hz
MasterBus controlled
MASTERVOLT
Snijdersbergweg 93,
1105 AN Amsterdam
The Netherlands
Tel.: [phone]
Fax.: [phone]
www.mastervolt.com V5 October 2009
Art.nr. 50261141

CONTENTS
2Copyright © 2009 Mastervolt / October 2009 / WHISPER 3.5 / EN
This manual applies to the Mastervolt Whisper 3.5 Marine Diesel Generating
set controlled by MasterBus first launched in April 2008. For earlier models
refer to other manuals available on our website: www. mastervolt.com
Copyright © 2009 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.
CONTENTS:
1INSTALLATION............................................................................................................................................................... 3
1.1 Location.............................................................................................................................................................. 3
1.2 Instructions for optimal sound and vibration insulation ....................................................................................... 3
1.2.1 Steel base plate................................................................................................................................. 3
1.2.2 Further recommendations ................................................................................................................. 3
1.3 Ventilation........................................................................................................................................................... 4
1.4 Connections ....................................................................................................................................................... 5
1.4.1 Fuel supply ........................................................................................................................................ 5
1.4.2 Cooling .............................................................................................................................................. 7
1.4.3 Exhaust system ................................................................................................................................. 9
1.4.4 Control system ................................................................................................................................ 12
1.4.5 AC power system (230 Volt)............................................................................................................ 15
2INSTALLATION SPECIFICATIONS.............................................................................................................................. 17
2.1 Whisper 3.5 installation table............................................................................................................................ 17
2.2 Commissioning table ........................................................................................................................................ 17
2.3 Installation specifications Whisper 3.5.............................................................................................................. 18
2.4 Specification of the accessories ....................................................................................................................... 18
2.5 Installation materials Whisper 3.5..................................................................................................................... 19
3DIAGRAMS & DRAWINGS ........................................................................................................................................... 24
3.1 DC wiring diagram............................................................................................................................................ 24
3.2 Wiring names and colours ................................................................................................................................ 26
3.3 AC wiring diagram 230V / 50Hz ....................................................................................................................... 27
3.4 Dimensions MasterView Easy Panel................................................................................................................ 28
3.5 Dimensions Whisper 3.5 .................................................................................................................................. 28
4MASTERBUS................................................................................................................................................................. 29
4.1 What is MasterBus? ......................................................................................................................................... 29
4.2 Event-based commands................................................................................................................................... 29
4.3 How to set up a MasterBus network................................................................................................................. 30

INSTALLATION
EN / WHISPER 3.5 / October 2009 / Copyright © 2009 Mastervolt 3
1 INSTALLATION
This installation manual is valid for the following models:
Part
number Description
51200500 Whisper 3.5 / 230V 3000rpm wet exhaust
MasterBus controlled
51200506 Whisper 3.5 / 230V 3000rpm wet exhaust
MasterBus controlled - 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.
1.1 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 raw water pump and oil strainer.
Please also note that in spite of the automatic oil pressure
sensor it is still essential that the oil level is checked
regularly.
1.2 INSTRUCTIONS FOR OPTIMAL SOUND
AND VIBRATION INSULATION
Position the generating set as low as possible in the
vessel. As the generating set is already secured to the
base frame by means of flexible engine mountings, the
frame can be mounted directly to the vessel’s main
structure.
1.2.1 Steel base plate
However to keep resonant vibrations at a minimum, it is
recommended to mount the generating set on a solid steel
base plate, approx. 30 mm weighing approx. 44 kg or 50%
of the weight of the generating set. The engine draws its
inlet combustion air through several holes in the capsule
base. Therefore the capsule must be fitted with sufficient
clearance between the capsule underside and the base
plate. A steel base plate is available from Mastervolt as an
optional accessory (ref. fig. 23, page 21).
1.2.2 Further recommendations
Whisper generating sets are standard equipped with a
"GRP" (Glass Reinforced Plastic) sound cover. The
canopy has been designed to give effective sound
insulation. For optimum sound and vibration dampening,
the following factors should be considered.
1 Avoid mounting the generating set in close proximity
to thin walls or floors that may cause resonance.
2 Sound dampening is extremely poor if the generating
set is mounted on a light weight flimsy surface such
as plywood which will only amplify vibrations. If
mounting on a thinner surface cannot be avoided, this
should at least be reinforced with stiffening struts or
ribbing. If possible, holes should be bored or cut
through the surface to help reduce the resonance.
Covering the surrounding walls and floors with a
heavy coating plus foam will certainly improve the
situation.
Figure 1: Mounting of the Whisper generating set. X = wrong, V = OK

INSTALLATION
4Copyright © 2009 Mastervolt / October 2009 / WHISPER 3.5 / EN
3 Never connect the base of the generating set directly
to bulkheads or tanks.
1.3 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 100 cm2 is required.
A "sealed" engine compartment must have a good
extraction ventilator to maintain reasonable engine room
temperatures. High temperature of intake air reduces
engine performance and increases engine coolant
temperatures. Air temperatures above 40°C reduce the
engine power by 2% for each 5°C of rise. To minimise
these effects the engine room temperature must not be
more than 15ºC 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 Battery POS 5 By-pass air vent 9 Fuel in 13 Cable fuel lift pump.
2 Fuel return 6 Water return 10 Remote cable
3 Exhaust 7 Water in 11 Battery NEG
4 Water out 8 Oil strainer 12 AC cable
Figure. 2:

INSTALLATION
EN / WHISPER 3.5 / October 2009 / Copyright © 2009 Mastervolt 5
1.4 CONNECTIONS
The generating set comes supplied with all supply lines
and output cable (i.e. electric cables, cooling water
connections, exhaust, fuel lines etc.) already connected to
the engine and generator. The supply lines are fed through
the capsule’s front base. The connections are marked as
shown in figure 2.
All electrical connections, cable types and sizes must
comply with the appropriate national regulations. Supplied
cables are rated for ambient temperatures up to 70°C. If
the cables are required to meet higher temperature
requirements, they must be run through conduits.
ATTENTION!
Before working (installation) on the system
read the section safety instructions
1.4.1 Fuel supply
1 FUEL TANK
Fuel tanks should be made of appropriate material such as
(stainless) steel or plastic. Steel tanks should not be
galvanised or painted inside. Condensation can occur in
metal tanks when temperature changes. Therefore, water
accumulates at the bottom of the tank and provisions
should be made for the drainage of this water.
The tank will need a filling connection, a return connection
and an air ventilation connection which will require
protection against water entry.
Some official regulations do not allow connection points at
the base of the fuel tank; 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 1 m.
If the pump has to lift the fuel higher than one meter an
external fuel lift pump must be installed. The control board
is already prepared to connect an extra fuel pump.
3 FUEL PIPES
When the tank is above the generating set we recommend
ending the return line on the top of the tank (A).
When the return is on the top - in case of a leakage the
return line cannot overflow because of siphoning. One will
only need a fuel cock in the fuel supply line.
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 to discharge under the lowest
fuel level. This prevents air getting into the fuel line. Here
also one needs a fuel cock only in the supply line
Both supply and return fuel pipe lines should be
appropriate material and 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 8
mm pipe. This fuel lines fulfils CE standards and are
according to ISO 7840 A2. It is important to avoid bends in
the pipes, as they could trap air bubbles. The return pipe
should never be connected to the suction pipe. Other
consumers of diesel fuel, such as the propulsion engine
and heaters, have to be connected to separate suction
and return pipes
4 FUEL FILTERS
A fine fuel filter is installed which requires maintenance.
Mastervolt advises to install an extra fuel filter/ water fuel
separator near the fuel tank.
Before starting your generating set for the first time follow
the fuel system bleeding procedure in the users manual.

INSTALLATION
6Copyright © 2009 Mastervolt / October 2009 / WHISPER 3.5 / EN
Figure 3: Fuel supply (fuel tank is above the generating set)
Figure. 4: Fuel supply (fuel tank is above the generating set)
> 1m
1
2
3
4
5
67
1 Fuel return;
2 Fuel supply;
3 Prefilter / water separator (optional);
4 Extra fuel lift pump (optional);
5 Fuel tank;
6 Standard fuel lift pump;
7 Standard fuel filter.
1
2
3
5
67
1 Fuel return;
2 Fuel supply;
3 Prefilter / water separator (optional);
5 Fuel tank;
6 Standard fuel lift pump;
7 Standard fuel filter.

INSTALLATION
EN / WHISPER 3.5 / October 2009 / Copyright © 2009 Mastervolt 7
Figure 5: Internal cooling system
1.4.2 Cooling
Intercooling is based on a raw water pump, heat
exchanger and water-injected 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 RAW WATER SUPPLY
For raw water supply the following installation materials
are required: -a skin fitting - a sea cock - a water strainer -
hoses and clamps. In order to keep the suction resistance
in the line at a minimum, the sea water intake system (i.e.
sea cock, tru-hull fitting, inlet filter, etc.) must have an
inner diameter of at least 12.5 mm diameter (1/2"). 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 8 to 12 litres /min.
2 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!
Figure 6 Installing water intake
MIN. 60CM (24")
MAX. 150CM (60")
5
6
2
MAX. 10CM (4")
MIN. 3CM (1,2")
3
1
47
5CM (2")
1 Water level 5 Air vent;
2 Water/exhaust separator 6 Water strainer;
3 Seacock 7 Seacock.
4 Waterlock
SAILING DIRECTION
SAILING DIRECTION
FLOW DIRECTION
FLOW DIRECTION

INSTALLATION
8Copyright © 2009 Mastervolt / October 2009 / WHISPER 3.5 / EN
On motorboats and on sailing boats the water scoop for a
generating set should be fitted with the opening faced
backwards to prevent water being forced in during sailing.
Use a sealant when mounting the skin fitting.
3 WATER STRAINER
Use an appropriate water strainer with connections of 12.5
mm (1/2"). Install the water strainer in a well accessible
position, (refer to figure. 5, ref 6) 5 cm above the waterline.
4 SIPHON BREAKER (AIR VENT)
When the point of water injection is below the waterline,
then -when the engine is stopped -there is a risk that the
cooling water may enter the engine as a result of
siphoning. To avoid this happening, the generating set is
designed to accommodate a siphon breaker (air vent). In
the standard delivery the connections are bypassed. Hose
of 12.5 mm (1/2") 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 600 mm above waterline and install an air vent.
Ideally, the air vent should be mounted above the yacht
keel center line (i.e. to minimize the influence of swaying
on the water intake). The hose of the drain should go
downwards. Water must flow out freely and air has to flow
in freely as well (refer to figure 7).
Fast motorboats will lay deeper when sailing at large
speed and can cause pressure on the waterinlet. This
should be avoided to prevent fleeding the engine.
If the air vent is clogged the water hoses will
not be vented when the generating set has
stopped and water can be forced into the
engine. This leads to immediate engine
problems and eventually severe damage!
DAMAGE CAUSED BY THE INGRESS OF WATER IN
THE ENGINE IS NOT COVERED BY WARRANTEE
On the valve is a little hose to drain a little water that could
be spilled from the valve. This hose should go down and
may not end under water, because it should ventilate air
into the valve to break the siphoning (figure 7).
OPEN
Figure 7: Wrong siphon breaker hose routing
Check the air vent at regular intervals. Open, clean and
lubricate the valve as required (figure 8).
Figure 8

INSTALLATION
EN / WHISPER 3.5 / October 2009 / Copyright © 2009 Mastervolt 9
1.4.3 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
figure 9, ref. 1). The exhaust hose must have an inner
diameter of 40 mm no less, no more-. The exhaust system
must be installed so that the back pressure inside the
exhaust does not exceed 0,8 psi 60 cm. waterpressure
(refer to paragraph 5.4.3 of the users manual) and total
length up to the outlet or water separator does not exceed
2,5 m. The exhaust hose descends from the capsule to the
water lock. Then the hose rises maximum lift 120 cm via
the "goose neck" to the through-hull exhaust outlet,
situated minimum 50 mm above the water line (refer to
figure 9, ref. 5). The "goose neck" must be vertical and
situated preferable along the ship’s keel center line. It is
recommended to install an extra muffler (see figure 9, ref.
2) close to the through-hull fitting.
Because of the small gas flow of the small
engine it is very important to keep strictly to
the instructions above. Some mufflers and
water locks cause too high back pressure.
You are advised to use a Mastervolt
installation kit or check the back pressure
(refer to paragraph 5.4.3 of the users manual).
Too high back pressure causes the system to
fill up with water that affects the outlet valve
and valve seat.
Figure 9: Standard exhaust system
33
4
2
5
6
A
Minimum 60cm (24")
Maximum 120cm (48")
5 cm (2")
B
1
Max. length A - B = 2.5m (8 ft.)
1 Exhaust water lock; 4 Goose neck;
2 Exhaust outlet muffler; 5 Through-hull exhaust outlet Ø 40 mm;
3 Exhaust line Ø 40 mm; 6 Water level.

INSTALLATION
10 Copyright © 2009 Mastervolt / October 2009 / WHISPER 3.5 / EN
Figure 10: Super silent exhaust system
Figure 11: Only after the exhaust / water separator the exhaust hose may have a length up to 7,5m
MAX. 10CM (4")
MIN. 60CM (24")
MAX. 120CM (48")
MIN. 3CM (1,2")
1
2
34
Ø 40 mm
Ø 40 mm
Ø 40 mm
1 Water level 3 Seacock
2 Water/exhaust separator 4 Waterlock
A
B
Max. length A - B = 2.5 m. (8 ft)
Ø 40 mm Ø 40 mm Ø 40 mm
Ø 40 mm

INSTALLATION
EN / WHISPER 3.5 / October 2009 / Copyright © 2009 Mastervolt 11
2 "SUPER SILENT" EXHAUST SYSTEM
See figure 10. In order to reduce the noise level of the
generating set to a minimum, an option to reduce the
exhaust noise further (especially exhaust water splashing)
is an exhaust/water separator. The exhaust/water
separator allows the cooling water to be ejected through a
line separate from the exhaust fumes and also functions
as a goose neck to prevent water from flooding the engine.
The exhaust/water separator is mounted more than 60 cm
above the water level.
See figure 11. 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 2,50 m.) The sea water from the
separator must run down along the shortest possible path
to the through-hull outlet.
Only when using an exhaust /water separator the exhaust
may have a length up to 7,5m after the water/gas-
separator.
However watertraps should be avoided as the fumes still
contains water and this should not accumulate in bents
(refer to figures 12 and 13). An additional outlet exhaust
muffler close to the hull outlet will help further to reduce
noise emission
Fig.12: Water trap in exhaust system
Figure 13: Water will collect in the hanging bend of the exhaust gas hose and will cause back pressure
OK! WRONG
OK!
WRONG

INSTALLATION
12 Copyright © 2009 Mastervolt / October 2009 / WHISPER 3.5 / EN
If the generating set and the exhaust system have been
installed correctly, neighbouring boats will not be disturbed
by generating set noise, With the "super silent" exhaust
system, generating set noises are almost inaudible. For
optimal noise reduction, the sea water outlet from the
exhaust/water separator (center outlet on the unit) should
be installed below the water level to eliminate noisy
splashing of the effluent sea water.
The through-hull outlet for the exhaust fumes should not
direct the fumes directly toward the water surface as this
will cause excessive noise (refer to figure 14).
Do not direct the outlet directly toward the
water surface.
Figure 14
1.4.4 Control system
1 DC 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 prior to despatch from the factory. Operation of the
engine is controlled by a microprocessor based control
system called “Digital Diesel Control”. The Digital Diesel
Control Panel is integrated in the generating set.
MasterBus
The generating set is compatible with MasterBus: a fully
decentralized data network for communication between
the different Mastervolt system devices such as the
inverter, battery charger, generator, batteries and many
more. See chapter 4 for details
The generating set as well as the rest of the electrical
system can be monitored and controlled by any MasterBus
compatible remote control panel. The MasterView Easy is
a MasterBus compatible monitoring and control panel that
is standard included in the delivery of the generating set.
Important to know:
This generating set is only feasible for the connection of
MasterBus compatible remote control panels. Connection
of other remote control panels such as the Digital Diesel
Control panel, the System Manager AC + Whisper panel
and the Power System Control Panel is not possible.
The Masterview Easy must be mounted on an easy
accessible location, protected against rain, moist, dust and
condensation. For good visibility avoid installing the panel
in direct sunlight
Installation of the MasterView Easy
Below mentioned steps describe a basic installation of the
MasterView Easy in combination with the generating set.
Refer to the separate user’s manual of the Masterview
Easy if you want to add any other Mastervolt system
devices to the MasterBus network (see
www.mastervolt.com)
Figure 15
DIGITAL DIESEL CONTROL PANEL
MasterBus terminating device
MasterBus communication cable
OK!
WRONG!

INSTALLATION
EN / WHISPER 3.5 / October 2009 / Copyright © 2009 Mastervolt 13
1 See figure 15 Insert a MasterBus terminating device
into one of both communication ports (it doesn’t
matter which one) of the Digital Diesel Control Panel
on the generating set. Insert the communication cable
in the other communication port
Figure 16
2 See figure 16. Connect the other end of the
communication cable to one of both communication
ports of the MasterView Easy. Insert a MasterBus
terminating device into the other communication port.
3 The Masterview Easy can be flush mounted or panel
mounted on a wall or board:
Figure 17
oFlush mounting (see figure 17):
•Remove the outer housing and remove the front
from the panel.
•Make a cut out in the mounting wall and drill the
holes using the saw template in the box or using
the dimensions at the back of the front plate.
•Mount the MasterView Easy onto the panel (1)
and then reattach the front (2).
Figure 18
oPanel mounting (see figure 18):
•Remove the outer housing and remove the front.
•Drill the holes using the dimensions at the back of
the front plate and fasten the outer housing (1).
•Click the panel into the outer housing (2).
•Reattach the front (3)
During first commissioning the generator set will be
recognized by the MasterBus network automatically. This
may take a few seconds. Then the Masterview Easy will
show the initial screen
Refer to the operation manual of the MasterView Easy for
initial settings and operating instructions
Event based commands
One of the main features of MasterBus is the possibility of
programming for interactive operation of the connected
devices, including automatic starting and stopping of the
generator set. This is done by means of event based
commands. Refer to the operation manual of the
MasterView Easy for details about programming these
event based commands.
Mastervolt cannot be held responsible for
damage caused by unattended running of
the generator due to the use of event
based commands
Using event based commands the
generator can start unexpectedly. When
working on the electrical system, the 30
Amp fuse must be removed from the Local
Control Panel and the battery plus cable
must be removed from the battery.
MasterBus
terminating device
MasterBus communication cable
Rear side MasterView
Easy

INSTALLATION
14 Copyright © 2009 Mastervolt / October 2009 / WHISPER 3.5 / EN
Connection of an 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 wires 13 and 14 that
come from the The Digital Diesel Control Panel.
See fig. 19. To do so, remove the top cover plate of the
connection box to get access to the wiring loom.
Figure 19: Location of the connection box
Disconnect the bypass between wires 13 and 14 and then
replace it by an emergency switch or a potential free fire
alarm switch with normally closed contacts (figure 20).
Fig. 20: Connection for emergency stop / fire alarm switch
2 STARTER BATTERY
For starting, the Whisper requires a 12V starter battery
with the following capacity:
Model Minimum capacity
Whisper 3.5 55Ah
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.
Figure 21: Installation of a 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.
The starter battery is charged by the standard internal
charger in the alternator. An additional battery charger will
help to keep the battery in good condition when the
generating set is not used. A battery charger is not
included in the standard supply. A high efficiency battery
charging unit can be ordered from Mastervolt which is able
to charge both the ship’s main battery and the starter
battery. Also a small charger can be used to charge the
starter battery only, such as the IVO SMART 12/10.
Normal operation
Alarm / emergency
13
14
230VAC
IVO 12/10
AB
12V
Top cover plate of
the connection box
Digital Diesel
Control Panel

INSTALLATION
EN / WHISPER 3.5 / October 2009 / Copyright © 2009 Mastervolt 15
3 OTHER RECOMMENDATIONS AND WARNINGS
The battery should be secured for seagoing conditions and
the terminals should be insulated. For extra safety the
battery can be enclosed in a wooden, plastic, Fiberglas
etc. (non metal) box. Even when the earth return system is
applied a negative battery cable should be used and the
vessel should not to be used as a conductor.
In the negative battery cable a 250 Amp starter battery
switch could be applied to switch off the battery. The
battery cables are supplied in a standard length of 1.5 m, if
longer cables are required a larger cross sectional area
should be considered to compensate for voltage reduction.
When two batteries are used in series to provide a 24 Volt
supply system, never take off 12 Volt (starting) power from
one of these batteries (figure 22). This will result in severe
damage to the batteries within a short time.
Figure 22
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.
1.4.5 AC power system (230 Volt)
Before working (installation) on the system
read the sections on safety in the users
manual.
Be sure that all electrical installations (including all safety
systems) comply with all required regulations of the local
authorities. All electrical safety/shutdown and circuit
breaking systems have to be installed onboard as the
generating set itself cannot be equipped with such
equipment for every possible variation.
The vessel’s power supply system should be suitable and
safe for the AC voltage which is applied and the power
that will be generated. Special attention has to be paid on
dividing the system in branches which are fused
individually.
It is absolutely essential that each and every circuit in the
on-board electrical system is properly installed by a
qualified electrician.
1 FUSE
An output fuse (from the generating set to the system)
should be installed to protect the installed electrical
system. The fuse should be sized such that the rated
generating set current is not exceeded by more than 15%.
The maximum single phase output current is as listed
below
Model Maximum output current
Whisper 3.5 – 3000 rpm 13 Amp
The fuses must be of the slow reacting type. For electrical
motors connected to the system, a motor protection switch
must be installed
12V12V
24V
12V

INSTALLATION
16 Copyright © 2009 Mastervolt / October 2009 / WHISPER 3.5 / EN
2 GROUNDING
The AC alternator windings are not grounded.
Measures against earth insulation failures are often
subject to local regulations. The housing of the alternator
and all other metal parts are grounded. For safety reasons
connect the main ships ground to negative point of the
generating set start battery. When an ungrounded return
DC system or positive grounded DC system is applied the
battery negative should not be connected to the main
ships ground.
To make a connection between “neutral” and “ground”
could be necessary as part of a specific insulation failure
protection system.
Small pleasure craft in Europe is submitted to The
Recreational Craft Directive 94/25/EC. The guidelines of
this directive refer to (ISO 13297).
When the installation comply to this standard the “neutral”
and “ground” should be connected on the generating set
by connecting the blue (neutral) wire with the terminal on
which the yellow/green wire is connected.
WARNING
In all situations the transfer switches between
shore, inverter and generator should switch all
connections, the phase line (L) as wel as
neutral (N). Of course this is the case when
using a Mastervolt Mass Systemswitch
Be aware that insulation protection systems can be
different for different applications and even within the ship
there could be different standards for different spaces. We
did refer to the Recreational Craft Directive that applies to
pleasure craft up to 24 m of length. Sometimes one has to
comply with other standards such as the rules of
certification societies like Lloyds Register of Shipping or
Veritas, regulations for the protection of personal, building
legislation, etc. It is of the greatest importance to have
expert advice on this issue.
3 CABLE
For the power cable we recommend the oil resistant cable
with the following cross sectional area:
Model cross sectional area
Whisper 3.5 – 3000 rpm 3x2.5 mm² (5m. included)
For very long cables it is recommended to apply cables
with a larger cross section than the mentioned above.
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 chattering.
Mastervolt advises the installation of a Mass Systemswitch
as the power source selector. This works automatically
when the generating set is not running the input remains in
the shore position and as soon as the generating set is
running the Mass Systemswitch switches automatically
after 10 seconds delay time over to the generating set
position.

INSTALLATION SPECIFICATIONS
EN / WHISPER 3.5 / October 2009 / Copyright © 2009 Mastervolt 17
2 INSTALLATION SPECIFICATIONS
2.1 WHISPER 3.5 INSTALLATION TABLE
Figure 23
1 Install a steel foundation plate between ship’s hull and
generating set, with 4 shock mounts (ref. to figure.
23).
2 Mount the generating set directly to the foundation
plate.
3 Connect the (sea) water inlet to the strainer.
4 Connect exhaust system.
5 Connect a siphon breaker or ‘air vent’ into the cooling
circuit, if necessary.
6 Connect ‘fuel supply line’ to the water separator/ fuel
filter.
7 Connect ‘fuel return line’ to the fuel tank.
8 Connect the MasterView Easy remote panel
9 Connect the AC cable from the AC box to the power
source selector or Mass SystemSwitch.
10 Connect plus and minus from the 12V starter battery
to the battery cables.
11 Install a Mastervolt battery charger. (optional)
2.2 COMMISSIONING TABLE
1 Check if a siphon breaker (air vent) is necessary and
has been installed and that the drain is without bents
and air can flow in freely.
2 Open the seawater inlet valve and check all water
connections. Check if the strainer is installed above
the seawater level.
3 Check if the exhaust system is properly installed. Also
check the minimum required height of 60 cm above
sea level of the exhaust loop (goose neck). Check
length of exhaust hose, diameter of exhaust hose,
position of the waterlock, maximum lift.
4 Open the seawater outlet valve and check all water
connections.
5 Check the AC cables and the grounding.
6 Check if an AC breaker is installed before or after the
power source selector. When there is only a circuit
breaker, use it to disconnect the generating set from
the grid.
7 Check all DC connections, check if the battery switch/
circuit breaker is closed.
8 Open the fuel valve and bleed the fuel system.
Ensure there is sufficient fuel. The Whisper 3.5 is self
bleeding. To check the well functioning release the
bleed screw on the high pressure fuel pump. Push the
start button activating the electric system and
activating the fuel pump. When more time is needed
to bleed, push “start” and hold on the local control
panel (so not on the MasterView Easy remote panel).
Hold as long as necessary to bleed the system.
Retighten the bleed screw when no further air bubbles
are expelled.
Check if there are no air leaks in the fuel supply line
and check if the lift of the fuel is less than 1 meter.
Check if there is no air in the water fuel separator.
9 Check if the air intake in the canopy is not blocked.
10 Check the oil level and color of the oil.
11 Start the engine by pushing the start button.
Foundation
plate
Shock mounts
Generating set

INSTALLATION SPECIFICATIONS
18 Copyright © 2009 Mastervolt / October 2009 / WHISPER 3.5 / EN
12 Check when the generating set is running, the delay
of 3 – 10 seconds in the power source selector
transfer.
13 Check voltage and frequency under ‘no load’
conditions.
14 Check voltage and frequency under ‘full load’
conditions.
15 Check if the battery charger of the generating set is
working (max. 14.5 Volt).
16 Close the sound shield and check the noise level.
17 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.
2.3 INSTALLATION SPECIFICATIONS WHISPER 3.5
TECHNICAL DATA
Article no 51200500
Dimensions WxDxH 505 x 400 x 500 mm
Weight 104 kg including sound shield
Max. operation angle 25°
Remote control: MasterView Easy (MasterBus)
Battery capacity min. 12V, 55 Ah
Fuel consumption 0,7-1,5 l/hr, load dependent
Lift fuel pump electric driven 12 V DC, max. lift 1 m
Cooling indirect cooling
Cooling pump raw water Mastervolt self priming impeller pump, PTO driven, type K
Minimum water supply 8-10 l/min
Crank case lube oil capacity 1.3 litre + 0.2 oil cooler, total 1.5 litre
Alternator synchronous brushless, maintenance free water cooled
Voltage regulation capacitor
Output power 230V - 50 Hz - 3kWatt @ cos phi = 1
Battery charger additional 12V winding including regulator (4 Amps)
2.4 SPECIFICATION OF THE ACCESSORIES
Water scoop min. 1/2” (recommended 3/4”)
Inlet valve min. 1/2" in 12.5 mm out (recommended 3/4” in 12.5 mm out)
Water strainer 12.5 mm in, 12.5 mm out
Air vent 12.5 mm
Inlet suction hose 12.5 mm
Fuel filter/water separator 30 micron
Fuel inlet and return 8 mm
Exhaust hose in/out Ø 40 mm (1 5/8”)
Water lock Ø 40 mm (1 5/8”)
Water/gas separator Ø 40 mm (1 5/8”)
Anti shock mounts art. nr. 50230552
Foundation plate min. 44 kg (97 Lbs)
Battery charger (optional) IVO SMART 12/10; 12V / 10 Amps

INSTALLATION SPECIFICATIONS
EN / WHISPER 3.5 / October 2009 / Copyright © 2009 Mastervolt 19
2.5 INSTALLATION MATERIALS WHISPER 3.5
Figure 24: Installation materials battery installation kit
BATTERY INSTALLATION KIT 55 Ah
pos. qty article no description
51 1 62000550 MV 12/55 Ah AGM Battery
52 1 43011000 IVO Smart 12/10 230V/50-60Hz IP65 battery charger
55 1 68230302 Terminal Cover RED 230N3V02
56 1 68230314 Terminal Cover BLACK 230N3V14
57 1 79006005 Battery switch ON/OFF with key 250A
58 2 6503001606 Cable lug 16mm² / M6
59 2 6503001610 Cable lug 16mm² / M10
TOTAL 50230208 BATTERY INSTALLATION KIT 55Ah
OPTIONAL INSTALLATION MATERIALS
•Additional installation parts
pos. qty article no description
60 6501208010 Cable 16mm² red per 100 meter
61 6501208020 Cable 16mm² black per 100 meter
Generator
battery positive (+) Generator
battery negative (–)

INSTALLATION SPECIFICATIONS
20 Copyright © 2009 Mastervolt / October 2009 / WHISPER 3.5 / EN
Figure 25: Installation materials fuel supply kit
FUEL SUPPLY KIT
pos. qty article no description
41 2 50221203 Straight coupling 8 mm
42 1 50230091 Filter head strainer fuel/water separator
43 2 50221618 Parallel male coupling M14- 8 mm
44 2 50221619 Parallel male coupling M14- 10 mm
45 2 50221620 Hose connection 8 mm outer cone
46 1 50230092 Filter for strainer fuel/water separator
47 2 50221252 Nipple hose pipe 8-8
48 4 50221522 Hose clamp stainless 10-16
49 2 50221632 Copper gasket ring 18x14x1,5 mm
TOTAL 50230205 FUEL SUPPLY KIT
Note: fuel pipes / fuel hoses are not included in the delivery of the fuel supply kit.
OPTIONAL INSTALLATION MATERIALS
•Additional installation parts
pos. qty article no description
48 50221522 Hose clamp stainless 10-16
50 50222020 Copper fuel pipe per meter
51 50220063 Fuel hose per meter
•Spare parts
pos. qty article no description
46 50230092 Filter for strainer fuel/water separator
Generator
fuel out
Generator
fuel in