Mastervolt Whisper 6 User manual

MASTERVOLT
Snijdersbergweg 93
1105 AN Amsterdam
The Netherlands
Tel.: [phone]
Fax: [phone]
http://www.mastervolt.com
INSTALLATION MANUAL U.S.A. EDITION
V1. June 2004
WHISPER 6 / 8 / 12
-3600 RPM-
WHISPER 7 ULTRA
-1800 RPM-
Marine diesel generating set 120/240V-60Hz
Digital Diesel Control
Art.nr. 50200364

2June 2004 / WHISPER 7 ULTRA/6/8/12 / USA
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.4 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.4.1 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.4.2 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
1.4.3 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
1.4.4 DC control system 12 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
1.4.5 AC power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
2INSTALLATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.1 Installation table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2.2 Commission table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.4 Specification of the accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.5 Installation materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
3DIAGRAMS AND DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.1. DC wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
3.2. Codes and colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.3 Diagram Electrical Governor (Whisper 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3.4 AC wiring diagram 120V/240 60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3.5 Remote Control panel drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
3.6 Whisper 6/8/12/7 ULTRA dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
CONTENTS

USA / WHISPER 7 ULTRA/6/8/12 / June 2004 3
1INSTALLATION
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. Plea-
se consider that even almost maintenance-free machi-
nery must still remain accessible.
When selecting the location area to mount the generating
set, make sure there is sufficient room to carry out any
maintenance work. The unit must be easily accessible on
the service side and on the distribution side to have ac-
cess to the V-belt.
Please also note that in spite of the automatic oil pressu-
re 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 already has secured to the
base frame by means of flexible engine mountings, the
frame can be mounted directly to the vessel’s main struc-
ture.
1.2.1 Steel base plate
However to keep resonant vibrations at a minimum, it is
possible to mount the generating set on a solid steel base
plate, approx. 3/4" (20 mm) weighing approx. 60 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. For the Whisper 6/8-3600rpm a steel
base plate is available with Mastervolt as an optional
accessory (refer fig. 12).
1.2.2 Further recommendations
Whisper generating sets are standard equipped with a
"GRP" (Glass Reinforced Plastic) sound cover. The ca-
nopy has been designed to give an effective sound insu-
lation. For optimum sound and vibration dampening, the
following factors should be considered.
1Avoid mounting the generating set in close proximity
to thin walls or floors as that may resonate.
2Sound dampening is extremely poor if the generating
set is mounted on alight 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 drilled or cut
through the surface to help reduce the resonance.
Covering the surrounding walls and floors with a
heavy coating plus foam will certainly improve the
situation.
3Never 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 15 square
inches (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 tem-
peratures. Air temperatures above 104°F (40°C) reduce
the engine power by 2% for each 90°F (5°C) of rise. To
minimise these effects the engine room temperature
must not be more than 30°F (15°C) 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 mentio-
ned temperature limit by using machine room ventilation,
connections are to be made for an air inlet directly to the
enclosure. With these connection the generating set can
INSTALLATION

4June 2004 / WHISPER 7 ULTRA/6/8/12 / USA
be directly connected to an air duct.
Air inlets should be louvered, where appropriate, to pro-
tect the engine room and to protect the generating set
from water spray. As an extra precaution, the fitting of a
cowl ventilator with dorade box located as high as possi-
ble, is recommended.
1.4 CONNECTIONS
The generating set comes supplied with all supply lines
and output cable (i.e. electric cables, cooling water con-
nections, exhaust, fuel lines etc.) already connected to
the engine and generator. The supply lines are fed through
the capsule’s base. The connections are marked as shown
in fig. 1.
All electrical connections, cable types and sizes must comply
to the appropriate national regulations. Supplied cables are
rated for ambient temperatures up to 158°F (70°C). If the
cables are required to meet higher temperature require-
ments, they must be run through conduits.
1.4.1 Fuel supply
1FUEL 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 con-
nection 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 inches above the
bottom of the tank.
INSTALLATION
EXHAUST (1)
1 5/8" (40 mm) REMOTE CABLE (2)
12xAW22 (0,25mm2)
AC CABLE (3)
FUEL RETURN (6)
AW2 (25 mm2)
BATTERY - (7)
5/16" (8 mm)
FUEL IN (4)
5/16" (8 mm)
AW2 (25 mm2)
BATTERY + (5)
AIRVENT IN (10)
3/4" (19 mm)
AIRVENT OUT (9)
WATER IN (8)
3/4" (19 mm)
3/4" (19 mm)
1 5/8" (40 mm)
EXHAUST (1)
REMOTE CABLE (2)
AC CABLE (3)
12xAW22 (0,25mm2)
FUEL RETURN (6)
WATER IN (8)
3/4" (19 mm)
5/16" (8 mm)
BATTERY + (5)
AW2 (25mm
2
)
5/16" (8 mm)
FUEL IN (4)
AIRVENT OUT (9)
3/4" (19 mm)
BATTERY - (7)
AW2 (25mm
2
)
3/4" (19 mm)
AIRVENT IN (10)
Afb. 1.
WHISPER 6/8
WHISPER 12/7 ULTRA

USA / WHISPER 7 ULTRA/6/8/12 / June 2004 5
ATTENTION!
Before working (installation) on the system
read the section safety instructions.
2FUEL LIFT PUMP
The generating set itself is equipped with a fuel lift
pump; therefore the tank can be installed at a lower
level than the generating set. The maximum suction
height is 3 ft. (1 m)
If the pump has to lift the fuel higher than 3 ft (1 m)
an external fuel lift pump must be installed. The con-
trol board is already prepared to connect an extra fuel
pump.
3 FUEL PIPES
When the tank is above the generating set we recom-
mend to end the return line on the top of the tank
(fig. 2). 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.
INSTALLATION
Fig. 2.
1Fuel return;
2Fuel supply;
3Prefilter / water separator (optional);
5Fuel tank;

6June 2004 / WHISPER 7 ULTRA/6/8/12 / USA
When the tank is below the generating set we recom-
mend to end the return line on the bottom of the tank
fig. 3 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 need only a fuel cock
in the supply line.
Both supply and return fuel pipe lines should be
appropriate material and 5/16 inner diameter tubing.
The quality of the tubing of fuel pipes could be sub-
mitted to local regulations depending on the applica-
tion of the vessel.
The fuel pipes can be plumbed to the flexible hoses
which are on the generating set and have a connec-
tion to fit to 5/16” (8 mm) pipe. This fuel lines fulfils
CE standards and are according to ISO 7840 A2.
It is important to avoid bends in the pipes, as they
could trap air bubbles. The return pipe should never
be connected to the suction pipe. Other consumers of
diesel fuel, such as the propulsion engine and hea-
ters, have to be connected to separate suction and
return pipes
4FUEL FILTERS
Afine fuel filter is installed which requires maintenan-
ce. 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
Fig. 3.
1Fuel return;
2Fuel supply;
3Prefilter / water separator (optional);
4Extra fuel lift pump (optional);
5Fuel tank;

USA / WHISPER 7 ULTRA/6/8/12 / June 2004 7
1.4.2 Cooling
Intercooling is based on a raw water pump, heat exchan-
ger and water-injected exhaust. Cooling liquid in the
internal cooling system is cooled in a heatexchanger by
outboard water (raw water or seawater). After the raw
water is warmed up in the heatexchanger it is dumped
overboard by injecting it in the exhaust.
The generating set should have its own sea water
(coolant water) inlet and should not be connected to any
other engine systems. A properly installed cooling system
is critical to keep engine temperatures within an accepta-
ble range. Ensure that the installation complies to the
following installation instructions.
1 THE INTERNAL COOLING SYSTEM
The internal cooling system should be filled with
cooling liquid. (Refer to the users manual 2.5.12)
When the engine becomes hot the liquid expands and
the system is pressurised. After the pressure becomes
to high the release valve in the filling cap on the
manifold opens and the expanding liquid is pressed
into the expansion tank that is in the delivery. Also the
air in the system that is collected at the top of the
manifold is released in this way. When the liquid cools
down there will be underpressure. An other valve
opens and the liquid is sucked into the manifold again.
This system works only when there is enough liquid
initially. This has to be checked when commissioning
the generator set. By filling up the expansion tank
when necessary there will always be enough liquid in
the system. The hose that is in the delivery has to be
connected to the connection on the side of the filling
cap. This hose is made of heat resistant plastic and is
not sensitive for kinks.
The hose goes through a hole that has to be drilled in
the lower part of the canopy close to the place where
the tank is mounted.
The tank has to be placed close to the generator.
When it is mounted above the top of the manifold the
liquid in the tank will be drained when the cap on the
manifold is taken off.
When keel cooling or radiator cooling is applied the
system will not be pressurised. A cap without release
valve should be applied. Refer to the special manual
for these applications.
2RAW WATER SUPPLY
For raw water supply the following installation mate-
rials are required: -a skin fitting - a sea cock - a water
strainer - hoses and clamps. In order to keep the suc-
tion 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 3/4"
diameter (19 mm). The suction hose should be kept
as short as possible. Raw water plumbing should
avoid bends as much as possible.
INSTALLATION
1
2
34
5
7
6
60 cm
Fig. 4b. 1Water level;
2Water/exhaust separator;
3Seacock;
4Waterlock;
5Air vent;
6Water strainer;
7Seacock.
Afb. 4a.

8June 2004 / WHISPER 7 ULTRA/6/8/12 / USA
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 2,65-3,5 U.S. qph (10 to 14
liters /min).
3INSTALLATION OF THROUGH HULL FITTING
It is good practice for yachts to use a hull inlet fitting
with an integrated strainer (water scoop). For propul-
sion 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 ailing at higher
speeds, water will be forced into the inlet
and your generating set will overflow!
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.
4WATER STRAINER
Use an appropriate water strainer with connections of
3/4" (19 mm). Install the water strainer in a well ac-
cessible position, (ref. to fig. 4 - 6) on or just above
the waterline.
5SIPHON BREAKER (AIR VENT)
When the point of water injection is below the water-
line, 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 ge-
nerating set is designed to accommodate a siphon
breaker (air vent). In the standard delivery the con-
nections are bypassed. Hose of 3/4" (19 mm) inner
diameter should be used.
If the generating set cannot be mounted such that the
bottom of the generating set is placed above the
waterline, an air vent must be installed.
Extend the water hose of the by-pass 24” (60 cm)
above waterline and install an air vent. Ideally, the air
vent should be mounted above the yacht keel center
line (i.e. to minimize the influence of swaying on the
water intake).
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
INTO THE ENGINE IS NEVER COVERED BY
WARRANTEE.
Check the air vent at regular intervals. Open, clean
and lubricate the valve as required.
INSTALLATION
flow direction
sailing direction
WRONG!
thru-vessel inlet
Fig. 5.
Fig. 6.

USA / WHISPER 7 ULTRA/6/8/12 / June 2004 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.
1STANDARD EXHAUST SYSTEM INSTALLATION
The generating set exhaust system must remain
completely independent and separate from the ex-
haust system of any other engine on board. A water
lock prevents the generating set from being flooded
by cooling water and should be installed as close to
the generating set as possible. The lock must be
large enough to hold the entire water volume held in
the hose from the top of the goose neck to the water
lock. The water lock must be installed at the lowest
point of the exhaust system (ref. to fig. 7-1). The ex-
haust hose must have an inner diameter of 1 5/8” (40
mm). The exhaust system must be installed so that
the back pressure inside the exhaust does not
exceed 1 psi (2 inches mercury, 27 inches (70 cm.)
watercolumn) (Refer to paragraph 5.4.3 of the users
mannual) and length from A to B does not exceed 10
ft (3 m.). The exhaust hose descends from the
capsule to the water lock. Then the hose rises
maximum lift 5 ft. (150 cm) via the "goose neck" to
the through-hull exhaust outlet, situated minimum 2
inches (50 mm) above the water line (ref. to fig. 7-5.
The "goose neck" must be vertical and situated 60
cm above the waterline preferable along the ship’s
keel center line. It is recommended to install an extra
muffler close to the through-hull fitting.
INSTALLATION
A
B
Minimal
24"
60 cm.
Maximal
60"
150 cm.
max. length A - B = 10 ft. (3 m.)
2"
5 cm.
Fig. 7.
1Exhaust water lock;
2Exhaust outlet muffler;
3Exhaust line 5/8” Ø 40 mm;
4Goose neck
5 Through-hull exhaust outlet 1 5/8” Ø 40 mm;
6 Water level.

10 June 2004 / WHISPER 7 ULTRA/6/8/12 / USA
INSTALLATION
2"SUPER SILENT" EXHAUST SYSTEM
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 sepa-
rator allows the cooling water to be ejected through a
line (A) 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 24” (60 cm.) above the water level and
replaces a goose neck.
If the through-hull exhaust outlet has to be mounted
far from the generating set, an exhaust/water separa-
tor must definitely be installed. Total length exhaust
piping from generator to top of goose neck (water
separator) is more than 10 ft. (3m.)) The sea water
from the separator must run down along the shortest
possible path to the through-hull outlet. (ref. to fig. 9).
Only after the exhaust/waterseparator the exhaust
may have a length of over 25 ft (7,5 m) if the exhaust
hose diameter is increased to 2” (50 mm). However
watertraps should be avoided as the fumes still
contain water and this should not accumulate in bents
(Refer to fig. 8a). An additional outlet exhaust muffler
close to the hull outlet will help further to reduce noise
emission.
max.
5 ft.
(150 cm.)
min.
24"
(60 cm.)
1 5/8" (40 mm)
1 5/8" (40 mm)
waterlevel
1 5/8" (40 mm)
A
max. 4 inches
Fig. 8.
Fig. 8a.

USA / WHISPER 7 ULTRA/6/8/12 / June 2004 11
A
B
WRONG
GOOD
Max.length
A - B =
10 ft. (3 m.)
up to 10 ft.(3 m) 1 5/8" (40 mm) Ø
10 ft - 30 ft (3 -10 m) 2" (50 mm) Ø
1 5/8" (40 mm) Ø
1 5/8" (40 mm) Ø
Fig. 9.
Fig. 10.
If the generating set and the exhaust system have
been installed correctly, neighboring boats will not be
disturbed by generating set noise, With the "super
silent" exhaust system, generating set noises are
almost inaudible. For optimal noise reduction, the sea
water outlet from the exhaust/water separator (center
outlet on the unit) should be installed below the water
level to eliminate noisy splashing of the effluent sea
water.
The through-hull outlet for the exhaust fumes should
not direct the fumes directly toward the water surface
as this will cause excessive noise (ref. to fig. 10).
Do not direct the outlet directly toward the
water surface.
INSTALLATION

12 June 2004 / WHISPER 7 ULTRA/6/8/12 / USA
1.4.4 DC control system (12 Volt)
1DC CONTROL SYSTEM
The electrical control system is standard in 12 Volt
with negative earth. Non- earth return (ungrounded)
is available as an option for aluminium vessels to
prevent corrosion.
All electrical wiring has been prepared on the genera-
ting set and control panel prior to despatch from the
factory.
The engine is controlled by a very advanced
microprocessor based system: Digital Diesel Control.
The “black box” containing the microprocessor is
located on top of the alternator.
Alocal control panel is on the generating set.
Remote control
Aremote control panel also containing a
microprocessor is in the delivery. A 45 feet (15 m)
intermediate 8-pole cross-wired communication cable
is in the standard supply too. If necessary an optional
longer max 90 feet (30 m) intermediate cable can be
connected if the standard length does not suit the
required distance. When a longer distance than 90
feet (30 m) is required, consult the Mastervolt service
department for advice. Refer to fig. 11.
One can mount the control panel after drilling a hole
in the dashboard using the plastic cover. Refer to the
dimensional drawing in paragraph 3.5. The panel
without the plastic cover fits the Mastervision modular
panel system.
More remote control panels (slave panels) can be put
in parallel by using the modular connectors on the
back of the units. As a slave one can use the same
panel offering all functions again. It is also possible to
use an old or new type slave panel only to start and
stop the generator.
Old type remote panels and system panels can be
connected by means of the green connector.
Pay attention to the colour codes as indicated in fig.
12 when fitting cable to the green connector. Some
software versions in old system panels (supplied
before may 2004) could conflict with the software in
the DDC and an up-date of the software of the
system panel could be necessary. When this is the
case consult to the Mastervolt service department for
advice.
When using the factory settings, installation is very
simple: just plug the remote cable into the remote and
the generator is ready to use. Refer to fig. 12.
Acoustic alarm or warning lamp
One can connect an external max.150 mAmp relay to
generate an acoustic warning or applying a warning
lamp etc. Be aware of polarity as some relays has a
diode inside and should be connected plus to plus en
minus to minus as indicated. Refer to fig. 12.
Automatic start/stop
Mastervolt cannot be held responsible for
damage caused by the unattended running
generator using the auto-start/stop mode or
interval mode.
Using the auto-start/stop (interval) mode the
generator can start unexpectedly. When working
on the electrical system, the 3 Amp fuse must be
removed from the control panel and the battery
plus cable must be removed from the battery.
INSTALLATION
Fig. 11.
J3
MASTERVOLT
WRP/2
Whisper Remote Panel
TAILOR MADE ENERGY
+-
123456789101112
+-
SENSE BAT. 2
12
9
10
11
6
7
8
3
4
5
1
2
REMOTE CABLE
REMOTE CABLE
WARNING RELAY
MAX. 150 mA
BLACK
RED/BLUE
GREY
GREY/PINK
WHITE
BLUE
PURPLE
PINK
YELLOW
BROWN
GREEN
RED
WIRING COLOURS
Fig. 12.

USA / WHISPER 7 ULTRA/6/8/12 / June 2004 13
INSTALLATION
The Mastervolt Digital Diesel Control system offers
several options for automatic starting and stopping.
Access to this menu and other menus could be
blocked. For blocking and setting up this options refer
to the APPENDIX of the DDC users manual.
One of these options is to monitor a second battery
(Not being the starter battery) to start the generator
automatically when the voltage of this battery drops
below a certain setting.
Other names for this second battery are “auxiliary
battery”, “service battery”, ”users battery” or
“consumers battery”. We will refer to this battery as
“the second battery”(BAT2). In some menus the
starter battery could be indicated as “the first battery”
(BAT1).
Asense wire to monitor the second battery should be
connected (Attention polarity!) to the connector on the
back of the remote panel. Refer to fig. 12. The sense
wires must be connected directly on the second
battery before a main switch and be protected by a 3
Amps fuse.
(Monitoring the generator starter battery does not
require an extra sense connection)
Settings
When one want to apply other settings than the
factory settings refer to the DDC users manual,
especially to the APPENDIX.
2STARTER BATTERY
For starting, the Whisper requires a battery with a
capacity of at least 85 Ah. The generating set can be
connected with the main engine battery or with its
own battery.
We strongly recommend to use 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 connec-
ted to separate batteries.
However the negative of all the batteries on the
vessel should be interconnected (when on earth) to
avoid difference in the voltage level of the earth on
different places causing trouble to electronic devices
which might be in the system.
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.
Abattery switch may be used to interrupt the positive
connection.
The starter battery is charged by the alternator on the
engine. An additional battery charger will help to keep
the battery in good condition when the generating set
in not used. A battery charger in 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 for the sta-
ter battery only, such as IVO SMART 12/10.
3OTHER RECOMMENDATIONS AND WARNINGS
The battery should be secured for seagoing condi-
tions 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 ca-
ble should be used and the vessel should not to be
used as a conductor.
The battery cables are supplied in a standard length
of 60” (150 cm), if longer cables are required a larger
cross sectional area should be considered to
compensate for voltage reduction.
When two batteries are used in series to provide a 24
Volt supply system, never take off 12 Volt (starting)
power from one of these batteries. This will result in
12V
12V
IVO 12/10
IVO 12/10
AB
230VAC
230VAC
Fig. 11.

14 June 2004 / WHISPER 7 ULTRA/6/8/12 / USA
sever damage to the batteries within short time.
Disconnect the battery leads if electrical welding is to
be carried out, otherwise damage could 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 (240/120 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 system have to be installed onboard as the
generating set itself cannot be equipped with such equip-
ment 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.
1FUSE
An input fuse (from the generating set to the system)
should be installed to protect the installed electrical
system.
For the Whispers the maximum single phase current
at 240V is 25A (6), 32A (8) or 48A(12).
At 120V the maximum single phase current is: 48A
(6) / 63A (8) / 96A (12). The fuses must be of the
slow reacting type. For electrical motors connected to
the system, a motor protection switch must be
installed.
2GROUNDING
In the U.S.A. models neutral of the AC
alternator windings is grounded.
The housing of the alternator and all other
metal parts are grounded as well.
The connection between “neutral” and “ground” is
necessary as part of a insulation failure protection
system as commonly used in the U.S.A.
Warnings:
In all situations the transfer switches
between shore, inverter and generator
should switch both neutral and L1. Of
course this is the case when using a
Mastervolt Masterswitch. For safety
reasons connect the main ships ground to
negative point of the generating set start
battery. When an ungrounded DC system
or positive grounded DC system is applied
the battery negative should not be
connected to the main ships ground.
3CABLE
For the power cable we recommend the use of 4 wire
oil resistant cable with a sufficient cross sectional
area. One wire for earth is included. For very long ca-
bles it is recommended to apply cables with a larger
cross section. (Refer to paragraph 3.5)
4TRANSFER SWITCH
Apower 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 de-
signed to switch over all wires including neutral (and
not only phases or line) and there should be provi-
sions with the aid of timers to prevent relays from
clattering.
Mastervolt advises to install a MASTERSWITCH as a
power source selector. This works automatically when
the generating set is not running the input remains in
the shore position and as soon as the generating set
is running the masterswitch switches automatically
after 10 seconds delay time over to the generating
set position.
INSTALLATION SPECIFICATIONS

1Install a steel foundation plate between ship’s hull
and generating set, with 4 shock mounts (ref. to
fig.12) ‘foundation plate’(optional for Whisper 6/8).
2Mount the generating set directly to the foundation
plate.
3Connect the (sea) water inlet to the strainer.
4Connect exhaust system.
5Connect a siphon breaker or ‘air vent’ into cooling cir-
cuit, if necessary.
6Connect ‘fuel supply line’ to the water separator/ fuel
filter.
7Connect ‘fuel return line’ to the fuel tank.
8Connect remote panel (just plug in).
9Connect the AC cable from the AC box to the power
source selector or masterswitch.
10 Connect plus and minus from the 12V starter battery
to the battery cables.
11 Install a Mastervolt battery charger. (optional)
USA / WHISPER 7 ULTRA/6/8/12 / June 2004 15
2.2 COMMISSION TABLE
1Check if a siphon breaker (air vent) is necessary and
has been installed.
2Open the seawater inlet valve and check all water
connections. Check if the strainer is installed just
above the seawater level.
3Check if the exhaust system is properly installed.
Check maximum length of exhausthose, diameter of
exhausthose, position of waterlock, maximum lift. Also
check the minimum required height of 2 ft (60 cm)
above sea level of the exhaust loop (goose neck).
4Open the seawater outlet valve and check all water
connections.
5Check the AC cables and the grounding.
6Check 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.
7Check all DC connections, check if the battery switch/
circuit breaker is closed.
8Open the fuel valve. Check if there are no air leaks in
the fuel supply line, and check if the lift of the fuel is
less than 1 meter. Check if there is no air in the water
fuel separator.
9Check if the air intake in the canopy is not blocked.
10 Check the oil level and color of the oil. Check the
coolant level.
11 Bleed the fuelsystem
(Refer to the users manual § 4.2.2)
12 The starting procedure is initiated by pushing the
start button.
INSTALLATION SPECIFICATIOINS
2INSTALLATION SPECIFICATIONS
2.1 WHISPER 6/8/12/7 ULTRA INSTALLATION TABLE
Fig. 12.

16 June 2004 / WHISPER 7 ULTRA/6/8/12 / USA
2.3 INSTALLATION SPECIFICATIONS WHISPER 6/8/12 - 3600 RPM/7 ULTRA - 1800 RPM.
TECHNICAL DATA
Dimensions wxdxh. 6/8: 26” x 19,5” x 21,7” (660 x 495 x 550 mm)
12/7 ULTRA: 31,9” x 20,7” x 24,2” (810 x 525 x 615 mm)
Weight 6 / 8:392 lbs. (178 kg) / 12: 463 lbs (210 kg) /
7 ULTRA: 496 lbs (225 kg) including sound shield
Max. operation angle 25°
Remote panel 10 m cable, indicating: run, failure, hour counter, glow-, start-, stop button.
Battery capacity min. 12V, 60 Ah
Fuel consumption 0,5 - 1 gl/h (1.5-4 l/hr), load dependent
Lift fuel pump electric driven 12 V DC, max. lift 3 ft. (1 m)
Cooling indirect cooling
Cooling pump raw water Mastervolt self priming impeller pump, PTO driven, type M
Minimum water supply 3 - 4 gl/min. (9-15 l/min)
Crank case lube oil capacity, 6/8; 2,5 U.S. qts(2.4 l.) + 0,5 U.S.qts(0.5 l) oil filter, total 3 U.S.qts(2.9 l.) ;
12/7 ULTRA; 3,7 U.S. qts(3.6l.) + 0,5 U.s.qts(0.5) oil filter.
total 4,2 U.S. qts (4.1l.)
Alternator synchronous brushless, maintenance free water cooled
Voltage regulation 6 capacitor, 8/12/7 ULTRA capacitor + AVR
Output power at 6: 6 kW 60Hz 7 ULTRA: 7 kW 60Hz
power factor cos phi =1 8: 8 kW 60Hz 12: 12 kW 60Hz
Battery charger alternator including regulator (40 Amps)
2.4 SPECIFICATION OF THE ACCESSORIES
Water scoop 3/4”
Inlet valve 3/4"
Water strainer 3/4"
Air vent 3/4"
Inlet suction hose 3/4"
Fuel filter/water separator 30 micron
Fuel inlet and return 5/16”
Exhaust hose in/out 1 5/8”
Water lock 1 5/8”
Water/gas separator 1 5/8”
Foundation plate min. 60 kg (only 6/8)
Battery charger (optional) IVO SMART 12/10; 12V / 10 Amps
Anti shock mounts art.no. 50230552
installation specifications
13 Check when the generating set is running, the delay of
5 to 10 seconds in the power source selector transfer.
14 Check voltage and frequency under ‘no load’ condi-
tions.
15 Check voltage and frequency under ‘full load’ condi-
tions.
16 Check if the battery charger of the generating set is
working (max. 14.2 Volt).
17 Close the sound shield and check the noise level.
18 Stop the generating set and check the engine again
for leakages of oil, fuel or water.
Installation checklist available on our website
www.mastervolt.com
Commission form available on our website
www.mastervolt.com

USA / WHISPER 7 ULTRA/6/8/12 / June 2004 17
2.5 INSTALLATION MATERIALS WHISPER 6/8/12/7 ULTRA
WATER INLET KIT 3/4 (20mm)
no qtt articleno description dimensions
11 50230052 Intake strainer 3/4
21 50230042 Lever operated ball valve FF 3/4
31 50221004 Male hose connection 3/4
34 50221502 Hose clamps 19-29 mm
53 50220056 Outboard cooling water hose 20x28 mm
62 50221007 Male hose connection 1/2
71 50230060 Nickel plated brass intake strainer 3/4
81 50230067 Mounting bracket waterstrainer
TOTAL 50230211 WATER INLET KIT 3/4
AIR VENT KIT 3/4 (20mm)
no qtt articleno description dimensions
44 50221502 Hose clamps 19-29 mm
53 50220056 Outboard cooling water hose 20x28 mm
11 2 50221031 Bend male hose connection 1/2
12 1 50221042 TEE fittings 1/2
13 1 50230001 Syphon breaker valve 1/2
14 1 50221001 Male hose connection 3/8x1/2
15 1 50221521 Hose clamps 12-20 mm
16 1,5 50220055 Outboard cooling water hose 12x18,2 mm
TOTAL 50230212 AIR VENT KIT 3/4
EXHAUST KIT 1 5/8 (40 mm)
no qtt articleno description dimensions
21 1 50221481 Hose connector 1 5/8 (40 mm)
22 5 50221506 Hose clamps 44-56 mm
23 3 50220033 Marine exhaust hose 1 5/8 (40 mm inw)
24 1 50230071 Waterlock 1 5/8 (40 mm)
25 1 50230038 Brass through hull fitting hose connection 1 1/4x1 5/8 (40 mm)
TOTAL 50230203 EXHAUST KIT 1 5/8 (40 mm)
OPTIONAL INSTALLATION MATERIALS
no qtt articleno description dimensions
21A 1 50201830 Elbow 90 degr adapter exhaust hose 1 5/8” (40 mm)
22 2 50221506 Hose clamps 44-56 mm
WATER SEPERATOR KIT 1 5/8 (40 mm)
no qtt articleno description dimensions
22 4 50221506 Hose clamps 44-56 mm
23 2,5 50220033 Marine exhaust hose 40 mm inw
31 1 50221015 Male hose connection 1 1/4 x 1 5/8 (40 mm)
32 1 50230044 Lever operated ball valve FF 1 1/4
33 1 50230033 Brass through hull fitting 1/1/4x70
34 1 50230080 Water exhaust fumes seperator 40-40-40
35 4 50201121 Vibration mounting 25x30 mm M8
36 4 50211152 Bolt M8x16
37 4 50211465 Nut M8
38 8 50211405 Washer M8
39 8 50211445 Lock washer M8
TOTAL 50230204 WATER SEPERATOR KIT 1 5/8 (40 mm)
INSTALLATION MATERIALS

18 June 2004 / WHISPER 7 ULTRA/6/8/12 / USA
FUEL KIT U.S.A.
no qtt articleno description dimensions
42 1 50230090 Fuel strainer/water seperator M14x1,5 mm
44 2 50221644 Reducing male nipple M14-M16 60 gr.
45 2 50221615 Hose connection 5/16” (8 mm)
46 2 50221616 Nut coupling M16x1,5 mm
48 4 50221522 Hose clamps 10-16 mm
TOTAL 50230206 FUEL KIT U.S.A.
OPTINAL INSTALLATION MATERIALS
no qtt articleno description dimensions
51 1 50220063 Fuel hose 5/16” (8x16 mm)
BATTERY INSTALLATION KIT 85Ah
no qtt articleno description dimensions
51 1 64000850 Battery 85Ah
52 1 43011030 Battery charger IVO - SMART 12/10
53 1 68060100 Battery terminal + M8
54 1 68060200 Battery terminal - M8
55 1 68456902 Isolation cap
56 1 68456914 Isolation cap
57 1 79009005 Battery swich 250 Amp
58 4 6503001608 Cable connectors M8x16
58 4 6503002508 Cable connectors M8x25
TOTAL 50230216 BATTERY INSTALLATION KIT 85 Ah
BASE PLATE KIT WHISPER6/8 (3600 rpm)
no qtt articleno description dimensions
61 4 50230552 Rubber mountings M12
62 1 50230014 Base plate Whisper 6/8
63 1 50230011 Fastener kit base plate
TOTAL 50230209 BASE PLATE KIT 6/8
RUBBER MOUNTING KIT
no qtt articleno description dimensions
64 1 50230015 Fastener kit rubber mountings
61 4 50230552 Rubber mountings M12
TOTAL 50230217 RUBBER MOUNTING KIT
INSTALLATION MATERIALS

INSTALLATION MATERIALS
USA / WHISPER 7 ULTRA/6/8/12 / June 2004 19
Whisper 6/8/12/7 ULTRA
- FUEL KIT
- BATTERY INSTALLATION KIT
- BASE PLATE KIT
Whisper 6/8 only

INSTALLATION MATERIALS
20 June 2004 / WHISPER 7 ULTRA/6/8/12 / USA
Whisper 6/8/12/7 ULTRA
- WATER INLET KIT
- AIR VENT KIT
- EXHAUST KIT
- WATER SEPERATOR KIT