Mastervolt Whisper 6 User manual

MASTERVOLT
Snijdersbergweg 93
1105 AN Amsterdam
The Netherlands
Tel.: [phone]
Fax: [phone]
http://www.mastervolt.com
INSTALLATION MANUAL FOR MOBILE APPLICATIONS
V2. November 2004
WHISPER 6 / 12
-3000 RPM-
6/8/10/12/16 ULTRA
-1500 RPM-
Mobile diesel generating set 230V-50Hz
Digital Diesel Control
Art.nr. 50200369

2EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004
CONTENTS
1INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.2 Generating sets for vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.2 Instructions for optimal sound and vibration insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.2.1 Steel base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.2.2 Further recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.3 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.4 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.4.1 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.4.2 Radiator cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.4.3 Dry exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
2.4.4 Electric installation 12 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
2.4.5 AC power system 230 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
3INSTALLATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
3.2 Installation materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
4DIAGRAMS AND DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
4.1 Layout DC control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.2 Diagrams fan control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.3 Codes and colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
4.4 AC wiring diagram Whisper 230V 50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
4.5 Diagram electronic governov (W 10 Ultra) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
4.6.1 Drawing remote panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
4.6.2 Whisper 6/12/ 6 ULTRA dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
4.6.3 Whisper 12/16 ULTRA dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
CONTENTS

November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN 3
1INTRODUCTION
1.1 GENERAL
This manual applies to the installation of Mastervolt
Whisper generating sets in vehicles.
Special attention has to be given to the
chapter on safety that is in the users
manual.
Awarning symbol draws attention to
warnings and instructions or procedures
which, if not strictly observed, may result in
damage or destruction of equipment,
severe personal injury or loss of life.
This warning symbol refers to electric
danger and draws attention to special
warnings, instructions or procedures
which, if not strictly observed, may result in
electrical shock which will result in severe
personal injury or loss of life.
1.2 GENERATING SETS FOR VEHICLES
Marine and mobile generators
Whisper Generators originate from the marine sector. But
there are also specially designed Whispers available for
mobile applications, suitable for supplying power on
board of vehicles to use professional apparatus and
equipment, strong lightning and air conditioning etc.
The cooling system and exhaust system on vehicles is
completely different from standard marine systems.
Standard marine generators are cooled by seawater that
nowhere exceeds 30° Celsius and is seldom warmer
than 20° Celsius in the northern territories. Cold
seawater is pumped through the alternator, through the
heat exchanger and is injected in the exhaust. The
exhaust gasses are therefore cooled and rubber exhaust
hose can be used.
On vehicles the engine and alternator are individually
cooled by radiator with an electric (12V/24V or 230V)
driven fan. The radiators can be fitted below, on top or in
the side of the vehicle.
The exhaust is of the dry type and includes a stainless
flexible bellow and high quality mufflers.
Never use rubber exhaust hose, neither
fibreglass nor plastic exhaust parts in a dry
exhaust system as applied on vehicles.
Why two radiators:
The optimal engine operating temperature is 87° up to
92° Celsius. The radiator cools the temperature of the
cooling liquid in the engine only 5° to 12° down. The
returning “cold” coolant therefore has a minimum
temperature of 75° Celsius.
INTRODUCTION
Fig.1. Typical vehicle application radiator side mounted.
Fig.3. Typical vehicle application radiator bottom mounted.
Fig.2. Typical vehicle application radiator top mounted.

2INSTALLATION
To ensure reliability and durability of the equipment, it is
very important that the installation is carried out with the
utmost care and attention. To avoid problems, such as
temperature problems, noise levels, vibration, etc. the
instructions set out in this manual must be followed and
all installation work must be carried out professionally.
2.1 LOCATION
When looking for a proper place for a generator in a
vehicle all relevant aspects have to be taken into account
* Accessibility
* Solid foundation
* Space to mount the radiators (Refer to par. 2.4.3)
* Space to mount the exhaust (Refer to par. 2.4.2)
* A way to fit the fuel lines
Since Whisper generating sets have extremely compact
dimensions, they can be installed in tight locations. 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
access to the V-belt.
All models can be serviced from one
side. Oil filling can be done on the
service side and on the top (Exept for
Whisper 16000 Ultra that has the oil
filler cap only on top). Cooling liquid
can be filled via the expansion tanks.
The top of the engine (rocker cover)
has to be accesible for adjustment of
the valve clearance.
Please also note that in spite of the automatic oil pressu-
re sensor it is still essential that the oil level is checked
regularly.
2.2 INSTRUCTIONS FOR OPTIMAL SOUND
AND VIBRATION INSULATION
When it is possible to mount the unit directly on the
chassis of the vehicle this has advantages in preventing
vibrations by resonance.
2.2.1 Steel base plate
When it is not possible to fit the generator directly on the
chassis and the unit is on a light floor or other light
construction. Mastervolt recommends the use of an extra
set of rubber mountings and a heavy steel base plate if
the additional weight is no objection. To keep resonant
vibrations at a minimum, it is possible to mount the
generating set on a solid steel base plate, approx. 20 mm
(3/4") weighing approx. 50% of the weight of the
generating set. . A heavy base plate is available as an
optional installation kit for Whisper 6/3000 rpm. (ref. fig.
27, item 62).
4EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004
INSTALLATION
The alternator should be kept as cool as possible. In
practice an alternator starts getting less efficient above
40° Celsius. It is hardly possible to cool down the coolant
of the alternator below 40° using a radiator. When a
vehicle is in the sun on a parking place the ambient
temperature itself could be 40° Celsius.
Because of the divergence in the working temperature of
engine and alternator it will be clear that it is not possible
to combine the cooling of the engine and alternator in
one radiator system.
Furthermore it will be clear that it is very difficult to cool
an alternator optimally with the aid of a radiator in
conditions with high ambient temperatures.
Why should the alternator being cooled by water:
For normal industrial use alternators are cooled by air.
This requires a flow of air through the alternator of many
m3 per minute. With the air, the noise comes out into the
open. Generators on vehicles can only made silent by full
enclosure in a sound shield canopy. The only opening in
the Whisper canopy is the inlet for combustion air. For
that reason the alternator is cooled by water. Although
cooling the alternator by circulating water through a
radiator is not ideal; it is much better than by air.
Therefore aircooled alternators are rarely used in
vehicles.
Fig.4 Schematic installation diagram

November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN 5
2.2.2 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.
1In larger vehicles a separate and insulated space for
the generator will help to damp the noise even
further.
2Avoid mounting the generating set in close proximity
to thin walls or floors as that may resonate.
3Sound 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 drilled or cut
through the surface to help reduce the resonance.
Covering the surrounding walls and floors with a
heavy coating plus foam will improve the situation.
4Never connect the base of the generating set directly
to bulkheads, walls or tanks.
2.3 VENTILATION
The generating set normally draws combustion air from
the engine room. A full enclosure with natural ventilation
must have ventilation openings of adequate size and
location to enable the generating set to operate without
overheating. To allow an ample supply of air within the
temperature limits of the generating set an opening of at
least 100 cm2is required.
Air inlets should be louvered, where appropriate, to pro-
tect the generating set from water spray.
2.4 CONNECTIONS
The generating set comes with all supply lines and output
cables (i.e. electric cables, cooling water connections,
exhaust, fuel lines etc.) already connected to the engine
and alternator. The supply lines are led through the
capsule’s base. The connections are marked as shown in
fig. 5, 6, 7 and 8.
INSTALLATION
Fig. 5.
ATTENTION!
Before working (installation) on the system
read the section safety instructions.
WHISPER 6/3000RPM
Fig. 6
WHISPER 6 ULTRA / 12-3000 RPM

6EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004
INSTALLATION
All electrical connections, cable types and sizes must
comply to the appropriate national regulations. Supplied
cables are rated for ambient temperatures up to 70°C. If
the cables are required to meet higher temperature, they
must be run through conduits.
2.4.1 FUEL SUPPLY
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; connections are to
be made at the top of the tank with internal tubing
down to a few cm above the bottom of the tank. Using
the existing fuel tank of the car-engine the fitting
should be executed with extra care. Both a supply line
and a return line should be installed and go into the
tank from the top. Interference of the two systems (car
engine and generator engine) should be avoided.
19
35
19
Fig. 8.
WHISPER 8/10/12 ULTRA
WHISPER 16 ULTRA
Fig. 7.
Fuel line assembly with vertical mounted
pump and fuel lift pump mounted in an angle.
Fig. 9.

Do NOT connect the fuel lines to the
lines of the vehicles engine fuel supply.
Driving the tank empty below the level of
the suction pipe of the generator could
makes it necessary to bleed the fuel
system.
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 1 m. The Whisper 16 ULTRA has a
mechanical fuel lift pump, that should be primed
manually when the first time used.
If the pump has to lift the fuel higher than one meter
an external fuel lift pump must be installed. The con-
trol board is already prepared to connect an extra fuel
pump. When using a second electric fuel supply
pump, it is recommended to mount a loose supplied
pump close to the tank and mount it in an angle or
vertical to prevent air bubbles to block the system.
The pump will become quite hot and should be
mounted out of touch. (Refer to fig. 9)
The pump makes clicking noises and therefore could
November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN 7
INSTALLATION
1
2
3
5
67
6
Fig. 10.
1Fuel return;
2Fuel supply;
3Prefilter / water separator (optional);
5Fuel tank;
> 1m
1
2
3
4
5
67
6
1Fuel return;
2Fuel supply;
3Prefilter / water separator (optional);
4Extra fuel lift pump (optional);
5Fuel tank;
Fig. 11.

8EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004
INSTALLATION
be mounted on rubber mountings. When the clicking
noises of the pump are not acceptable an other
noiseless pump is available as an option.
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.
When the return is on the top - in case of a leakage -
the return line cannot overflow because of siphoning.
One will only need a fuel cock in the fuel supply line.
Both supply and return fuel pipe lines should be
appropriate material and 8 mm outer diameter tubing.
The quality of the tubing of fuel pipes could be sub-
mitted to local regulations depending on the applica-
tion of the vehicle.
The fuel pipes can be plumbed to the flexible hoses
which are on the generating set and have a connec-
tion to fit to 8 mm pipe. The fuel lines Mastervolt
supplies are according to ISO 7840 A2.
It is important to avoid bends in the pipes, as they
could trap air bubbles. The return pipe should never
be connected to the suction pipe. The return line
should be of 8 mm diameter and go straight back via
the top to the bottom of the tank. When the return is
too narrow, has too many bents and goes back to the
bottom of the fuel tank, the back-pressure could be to
high. This results in irregular running of the engine.
When the engine runs irregular, one can check if
back-pressure is the problem by disconnecting the
return line just outside the canopy and draining it in a
canister. When the engine runs smooth now, the
return piping has to be changed. It could also help to
install a second (electrical 12V) fuel lift pump.
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.
2.4.2 RADIATOR COOLING
1 General instructions
The radiators can be mounted below the floor, in the side
or on the roof of the vehicle.
Wherever the radiators are mounted the well functioning
of the system depends on the well circulation of the
coolant.
Roof mounted radiators bring the most risk for circulation
problems, because air trapped in the radiators or a low
level of the coolant, will immediately affect the cooling
capacity of the radiators.
It is recommended to keep the radiators as close as
possible to the unit. The piping should be fitted as direct
as possible.
When the radiators are above the engine, the piping should
be fitted below the top of the radiators! (refer to figure 12).
Bents in the piping, that can trap air bubbles, should be
avoided or ventilated (refer to figure 13).
Special attention should be paid to the ventilation of the
systems. Each installation system is standard supplied
with an expansion tank for the coolant, which is also
used to release air bubbles and makes it possible to add
coolant into the system in an easy way. This expansion
tank should be at the highest point of the system and
mounted as high as possible.
Most cooling problems originate from air
traps blocking the circulation of the engine
coolant.
No bent of piping above the radiator
Fig.12. Remove the air trap
Fig.13. Ventilating an air trap

November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN 9
For the alternator cooling system we use an open -non
pressurised- system. Therefore the 12 mm overflow pillar
on the expansion tank should stay open. A piece of hose
can be used to drain redundant liquid that is thrown out
because of the expansion of the liquid in the system.
When open the expansion tank can easily release air that
is ventilated by the different connections.
As the capacity of the alternator cooling system is very
small, also the initial filling can be done via the expansion
tank. It could be necessary to refill the tank a few times.
The pump of the alternator cooling system is self-priming
and this makes the system less sensitive for air traps.
For the engine we use a pressurised system. The 12 mm
connection on the top is closed.
Wherever the radiators are mounted it is necessary to
ventilate the exhaust manifold of the engine. The exhaust
manifold has a 8 mm connection to ventilate the
manifold. There is a 8 mm high temperature resistant
hose in the delivery to connect the hose connection on
the side of the manifold with the expansion tank. This
hose can go down first through a hole one has to drill in
the lower green part of the soundshield canopy and than
up again to the expansion tank. (refer to figure 14).
Initially the engine cooling system can be filled via the
cap on the exhaust manifold of the engine. However
when the radiator is above the engine one can only fill
the system to the level of the manifold. Additional filling
has to be done via the expansion tank.
For large engine cooling systems with long pipes or for
extra reserve there is an extra large expansion tank with
a content of 7 litres and an alarm for low coolant level
that can be supplied as an option. (refer to figure 15).
When mounting the radiators it is important to take care
that the outgoing connection, which is the connection to
the engine inlet, is on the top position (refer to figure 16
detail A) and is connected to the expansion tank. Also
when the radiator is mounted flat at the bottom of the
vehicle the outgoing connection is connected to the
expansion tank This is the best way to have the system
release air and to add liquid when necessary.
The expansion tank must be fitted in the
outlet of the radiator = the inlet pipe of the
engine
Fig.16. Outgoing connection connected to the expansion
tank
When both radiators are flat mounted on the roof, the
expansion tanks should be mounted a little higher.
(refer to figure 17 detail B).
INSTALLATION
Open to drain
expanded coolant
Mount expansion tank as high as possible
To radiator
Drill a hole where the hose can
be routed in the shortest way
to the expansion tank.
A
side mount
bottom mount
Fig.15. 7 litres optional expansion tank with low level alarm
Fig.14. The exhaust manifold to be ventilated into the
expansion tank

10 EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004
INSTALLATION
Fig.17. Low profile radiator assembly on the roof
Most cooling problems originate from air
traps blocking the circulation of the engine
coolant.
It is very important to use good quality heat
resistant hose and fittings. Therefore it is
strongly advised to use Mastervolt
installation kits.
2 How and where to mount the radiators
The radiator kit includes rubber mountings to prevent
vibrations to be transferred to the body of the vehicle (fig.
18). Due to the difference between vehicles general
instructions are not available. One has to find out where
the best place for mounting is. For OEM customers
Mastervolt can supply a special customised installation
kit.
Fig.18. Radiator on rubber mountings
When bottom mounted the radiator should not be the
lowest point of the vehicle to avoid damage.
Afree flow of air should be guaranteed. When horizontal
mounted the fan should be on top, that causes a flow of
air downwards. Often it is possible to find a place where
extra space above the fan helps to create a free flow of
air. It is recommended to make a shield below the
radiator to catch stones and dirt and operates as a
spoiler. The distance between the radiator and the shield
should be at least 50 mm. Sometimes it is possible to
build the radiators and shield on a sub frame that is
mounted below the vehicle as a module.
Measures has to be taken to prevent the
hot air circulating and reducing the
capacity of the radiators. Refer to figure.19
Figure 19. Bottom mounted with shield
Fig.20. Making use of the space below the floor to get an
optimal flow of air through the radiators.
Most effective and easy is to mount the radiator in the
side of the vehicle. (If possible below the level of the top
of the engine.) A louvered grid should protect the radiator
from rain and objects, but must not block the airflow. The
fan should be inwards which causes the air to blow
outwards. A free flow of air should be guaranteed. The
ventilation (connection to the expansion tank) should be
in the outgoing flow on top of the radiator.
Adisadvantage of having the radiator in the side is
possibly more noise of the electric fan and a flow of air
that could be felt by people passing by.
Fig.21.
The radiators on the roof is often the best option from the
point of view of keeping the noise of the fans away from
people and it give the best result in dissipating the heat.
However often this option conflicts with the possible need
to keep the vehicle as low as possible. An other
disadvantage is that the piping has to go through the roof
side mounted
air flo
w
B
top mount

November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN 11
that requires provisions to be waterproof.
Also negative is that roof mounted radiators are more
sensitive for air traps.
When having enough space it would be ideal to have the
radiators vertically mounted on the roof. The expansion
tank should be above the radiator.
When having the radiators horizontally mounted on the
roof (refer to figure 22) enough space (50 mm) should be
between the roof and the fan to have a free flow of air.
When the radiators are roof mounted there should be
protection against the weather. To avoid damage while
the vehicle is driving at high speed a spoiler could be
needed.
Fig.22. Two examples of top mount radiators
3 Two speeds fan.
To keep the noise as low as possible the fans of the
radiators can run at two different speeds. The radiator
installation kits includes a control box that is used to drive
the fans with two speeds depending on the load of the
generator. When using 12/24V DC to drive the fans in
normal mode the electric motors of the fans are in series
and run at low speed. In this mode they almost produce
no noise. Only when necessary - this is controlled by
thermostat switches - the fans are switched in parallel
and will blow at full speed.
The same is achieved with 230 V fans with help of a
transformer. (refer to the connection diagrams in
paragraph 4.3 ).
2.4.3 DRY EXHAUST SYSTEM
1 General remarks
Adry exhaust muffler system should be as effective in
silencing the exhaust as a wet marine exhaust system
when applying the right mufflers. However noise could be
generated by vibrations in the mufflers and be transferred
to the chassis. Tacit factors like the length of specific pipe
sections could be important. It is very difficult to take
these factors into account.
Fig.23. Dry exhaust systems on vehicles
The standard Mastervolt exhaust kit contains the
materials to perform a professional installation. In the kit
is a stainless steel flexible bellow (hose) to allow for
expansion and to prevent vibrations to be transferred.
Rubbers are supplied to mount the mufflers flexible. The
insulation blanket for the flexible bellow and the
resonance muffler are also very effective in damping
vibrations. Still it could be that additional measures has
to be taken like an extra clamp in a vibrating section of
pipe, insulation blankets on other parts of the system and
possibly even additional mufflers.
When the exhaust is led to the roof of a
vehicle, measures has to betaken to
prevent rainwater to enter the system.
Special rain caps are available as an
option.
Fig.24. Ways to prevent water to get in
Anegative feature of a dry exhaust system is the heat
radiated by its components.
Measures are taken to overcome the heat problem: The
exhaust bent to bring the exhaust out of the canopy is
cooled by water. Insulation blankets are included in the
exhaust kit to insulate the flexible bellow and the first
muffler.
When a dry exhaust has its outlet on the roof, all the
pipes inside the vehicle has to be insulated.
The exhaust pipes will be very hot and all
accessible pipes and mufflers are
dangerous to people when not insulated.
INSTALLATION
horizontal vertical

12 EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004
INSTALLATION
There are companies that are specialised in insulating
hot pipes and fancy systems are available to make it
good looking. However it is also possible to do it yourself
by winding fibreglass or rockwool around the pipes and
seal it with aluminium tape.
2 The standard dry exhaust system
The standard exhaust system contains:
On the generator set:
Awater-cooled exhaust bent
In the exhaust installation kit:
Astainless steel shielded flexible bellow.
One resonance muffler
One absorption muffler
Clamps and rubbers to mount the system flexible
Fittings, bents and pipes to make the different
connections
Blankets for thermal and sound insulation.
The mufflers are high quality industrial mufflers that are
much more effective, robust and durable than mufflers
made for automotive use.
3 Installation of the exhaust
Before determining the location of the generator set one
has to consider how to get away with the exhaust. Often
one can find space below the vehicle between the
chassis to mount the mufflers. The outlet should blow the
fumes away from the doors to avoid a nasty smell. When
the gasses are in the flow of air blowing from the
radiators this will help to avoid the fumes to be noticed.
Under no condition the fumes should be sucked into the
flow of air into the radiators. In wind still conditions a light
smell of exhaust fumes around the vehicle will not be
avoidable.
To bring the exhaust to the top of the vehicle gives the
best results on noise and smell. However when the pipes
go through the vehicle they should be insulated and
around the hole in the roof should be a collar to prevent
rainwater to leak in. Both mufflers could be on the roof or
one of them or both could be below the vehicle.
In general it is better to have the mufflers wide apart: the
resonance muffler close to the generator and the
absorption muffler on the end of the line. A short pipe
(30cm) should be on the far end after the absorption
muffler. The absorption muffler has no flow direction and
could be mounted both ways. The resonance muffler
should be mounted according to the indication on the
muffler itself.
The resonance muffler should be fitted
according to direction of the gas flow
indicated.
In the kit are clamps to mount the exhaust pipes to
stainless steel bars. These bars should be mounted to
the chassis of the vehicle. It is recommend to use rubber
mountings whenever possible. However take care that
the heat conducted through the brackets will not affect
the rubber. Refer to figure 18 how to mount the rubber in
a safe way. When any doubt an extra safe guard could
be constructed from steel wire or chain.
Fig.25. Mounting bracket in rubber with safe guard
2.4.4 ELECTRIC INSTALLATION (12 VOLT)
1DC control system
The electrical control system is standard in 12 Volt
with negative earth. Non-earth (ungrounded) return is
available as an option. All electrical wiring has been
prepared on the generating set and control panel
prior to despatch from the factory.
The engine is controlled by a printed circuit board
(PCB) that is located directly behind the control pa-
nel. The PCB incorporates exchangeable relays and
connector sockets.
Aremote control panel is in the delivery. An interme-
diate cable is in the standard supply too. If necessary
an optional longer intermediate 12 wire cable can be
connected if the standard length does not suit the
required distance.
Numerous remote control units (slave panels) can be
put in parallel by using the connectors on the back of
the units.
2Starter battery
For starting, the Whisper requires a battery with a
capacity of at least 85 Ah (Whisper 16000 : 120 Ah).
The generating set can be connected with the 12V
main engine battery or with its own battery, however
we strongly recommend to use a separate battery for
the generating set and to keep the wiring system for
the vehicles 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
vehicle should be interconnected to avoid difference
in the voltage level of the earth on different places
causing trouble to electronic devices which might be
in the system.
Abattery switch is recommended to be used to
interrupt the positive connection.
The starter battery is charged by the alternator on the
generator engine. An additional battery charger will
help to keep the battery in good condition when the
generating set in not used.
312V or 24V DC to drive the fans
When applying 12V or 24 V DC to drive the fans of
the radiators the radiators should be wired with
minimum 4 mm2 cable according to the wiring
diagram. The negative return wire should be of the
same diameter. The return current should never be
lead over the chassis.
The consumption of power by the DC powered fans
makes it necessary to install an additional 30 Amps
battery charger to prevent the starter battery to be
drained. The alternator on the generating set is not
capable of powering the fans. Neither is the small
charger that is included in the battery kit. Mastervolt
supplies high quality battery chargers that
continuously supply the rated power. Chargers of
other suppliers are often rated to other standards and
give the rated current (Amps) only for a short period if
at all.
To avoid the need of an extra heavy battery charger
230 Volt fans on the radiators are recommended.
( Refer to paragraph 4.3.2)
4Other recommandations and warnings
The battery should be secured for poor road 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 vehicle should not to be
used as a conductor.
The battery cables are supplied in a standard length
of 1.5 m, if longer cables are required a larger cross
sectional area should be considered to compensate
for voltage reduction.
Never take off 12 Volt from one battery off
a 24-Volt battery bank (12-Volt batteries
that are in series). This will cause serious
damage to the batteries in short time
Disconnect the battery leads if electrical welding is to
be carried out, otherwise damage will be caused to
the diodes of the alternator.
As explosive hydrogen gases are dischar-
ged 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 du-
ring or shortly after charging as sparking
can occur, which may ignite the hydrogen
gasses.
2.4.5 AC POWER SYSTEM (230/ VOLT)
The electric power supplied by the
generator is of a high voltage and
dangerous to people.
Refer to the instructions and warnings in
the standard installation manual.
Realise hat people are not used to have
230V available on a vehicle. Put warning
signs on wall sockets and on junction
boxes. Instruct non-regular users of the
vehicle. Warn maintenance personal of
garages that do service on the vehicle.
Generators used on vehicles that are
operated in a hazardous environment have
often to fulfil special regulations and
additional measures have to be taken
accordingly.
Be sure that all electrical installations (including all safety
systems) comply with all required regulations of the local
authorities. All electrical safety/shutdown and circuit
breaking systems have to be installed onboard as the
generating set itself cannot be equipped with such equip-
ment for every possible variation.
The vehicles power supply system (grid) should be
suitable and safe for the AC voltage which is applied and
the power that will be generated. Special attention has to
be paid on dividing the system in branches which are
fused individually. Wire colors should comply with AC
standards. It is absolutely essential that each and every
November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN 13
INSTALLATION

14 EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004
INSTALLATION
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 230V is 25A (W 6), 32A (W 8), 40A (W 10),
48A (W 12) or 75A (W 16).
The fuses must be of the slow reacting type. For elec-
trical motors connected to the system, a motor pro-
tection switch must be installed.
2Insulation failures
The AC alternator windings are not grounded.
The housing of the alternator and all other metal parts
are grounded.
To make a connection between “neutral” and “ground”
could be necessary as part of a specific insulation
failure protection system.
It is possible that the electric installation in the vehicle
must be protected against insulation failures.
Methods of protection are subjected to rules that can
be different depending on the use of the vehicle and
local standards.
In the standard marine manual is more information,
but this is according CE regulations for boats.
Vehicles are subject to different regulations
depending on the application of the vehicle. Experts
in this field should be consulted.
3Cable
For the power cable in single phase installations we
recommend the use of flexible 3 wire oil resistant
cable with a sufficient cross sectional area. One wire
for earth is included. For very long cables it is
recommended to apply cables with a larger cross
section. Refer to the installation specifications to
select the proper cabling (page 34).
4Transfer switch
Apower source selector switch much be installed
between the generating set and the vehicles 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
vehicle or from generating set to inverter - should be
well designed to switch over all wires including
neutral (and not only phases or line) and there should
be provisions with the aid of timers to prevent relays
from clattering.
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 over automati-
cally after 10 seconds delay time to the generating
set position.
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.
12V
12V
IVO SMART 12/10
AB
230VAC
230VAC
Fig. 26.

November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN 15
INSTALLATION SPECIFICATIONS
3INSTALLATION SPECIFICATIONS
3.1 TECHNICAL DATA W6/12 W6 ULTRA
Dimensions wxdxh. W 6: 660 x 495 x 550, W 12/6 ULTRA: 810 x 525 x 615
Weight W 6: 178 kg / 12: 210 kg / 6 ULTRA: 225 kg
including soundshield
Max. operation angle 25°
Remote panel 15 m cable, indicating: run, load, overload, failure, hour counter, glow-, start-, stop button.
Battery capacity min. 12V, 85Ah
Fuel consumption 1.5-4 l/hr, load dependent
Fuel lift pump 12 ULTRA electric driven 12 V DC, max. lift 1 m
Cooling radiator cooling
Crank case lube oil capacity, 6: 2.4 l. + 0.5 oil filter, total 2.9 l.;
12/6 ULTRA: 3.6 l. + 0.5 oil filter, total 4,1 l.
Alternator synchronous brushless, maintenance free water cooled
Voltage regulation capacitor (AVR optional)
Output power at W 6: 5.2 kW, 230V 50 Hz
power factor cos phi =1 W 6 ULTRA: 5.7 kW, 230V 50Hz
W 12: 10 kW, 230V 50Hz
Battery charging alternator including regulator (40 Amps)
TECHNICAL DATA W8/10/12/16 ULTRA
Dimensions wxdxh. W 8/10 ULTRA: 900x610x690, 12 ULTRA:1060 x 615 x 690,
W 16 ULTRA: 1150 x 680 x 750
Weight W 8/10/12 ULTRA: 310 kg
W 16 ULTRA: 420 kg
Max. operation angle 25°
Remote panel 10 m cable, indicating: run, load, overload, failure, hour counter, glow-, start-, stop button.
Battery capacity min. W 12 12V, 85 Ah W 16 12V 120Ah
Fuel consumption 1-6 l/hr, load dependent
Fuel lift pump W 8/10/12 ULTRA electric driven 12 V DC, max. lift 1 m
Fuel lift pump W 16 ULTRA mechanical driven; manually priming; lift 1m.
Cooling radiator cooling
Alternator synchronous brushless, maintenance free water cooled
Voltage regulation capacitor + AVR (optional)
Output power at W 8 ULTRA: 1 kW, 230V 50 HZ W 12 ULTRA: 12 kW, 230V 50 Hz
power factor cos phi =1 W 10 ULTRA: 1 kW, 230V 50 HZ W 16 ULTRA: 16 kW, 230V 50Hz
Battery charging alternator including regulator (50 Amps)

INSTALLATION SPECIFICATIONS
16 EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004
Fig. 27.
3.2 INSTALLATION MATERIALS

INSTALLATION SPECIFICATIONS
November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN 17
50230216 Battery installation kit 85 Ah Whisper 6-12/6-8-10-12Ultra
no qtt article no description
51 1 ST 064000850 Battery 85 ah
52 1 ST 043011000 Battery charger IVO Smart 12/10
53 1 ST 068060100 Battery terminal +
54 1 ST 068060200 Battery terminal -
55 1 ST 068456902 Isolation cap
56 1 ST 068456914 Isolation cap
57 1 ST 079009005 Battery swich
58 4 ST 6503002508 Cable connectors
50230226 Battery installation kit 120 Ah Whisper 16 Ultra
no qtt article no description
51 1 ST 064001200 Battery 120 Ah
52 1 ST 043011000 Battery charger IVO Smart 12/10
53 1 ST 068060100 Battery terminal +
54 1 ST 068060200 Battery terminal -
55 1 ST 068456902 Isolation cap
56 1 ST 068456914 Isolation cap
57 1 ST 079009005 Battery swich
58 4 ST 6503003508 Cable connectors
50230205 Fuel installation kit Whisper all models
no qtt article no description
41 2 ST 50221203 Straight coupling 8 mm
42 1 ST 50230091 Filter head strainer fuel/water separat.
42 1 ST 50230092 Filter for strainer fuel/water seperator
43 2 ST 50221618 Parallel male coupling M14- 8 mm
44 2 ST 50221619 Parallel male coupling M14- 10 mm
45 2 ST 50221620 Hose connection 8 mm outer cone
47 1 ST 50221252 Nipple hose pipe 8-8
48 4 ST 50221522 Hose clamp stainless 10-16
49 2 ST 50221632 Copper gasket washer 14x18x2 mm
Optional installation materials
50 M 50222020 Copper fuel pipe 6x8 mm
51 M 50220063 Fuel hose 8x16 mm
50230209 Base plate kit Whisper 6
no qtt article no description
61 4 ST 50230551 Rubber mounting up to 105 kg
62 1 ST 50230014 Base plate 6/8000 yellow sinc plated
63 4 ST 50211449 Washer spring SP M12
63 4 ST 50211250 Bolt hexagonal socket ZP M12x30
63 4 ST 50211241 Bolt hexagonal socket ZP M10x25
63 4 ST 50211447 Washer spring SP M10
63 4 ST 50211410 Washer SP M10 large outer diameter
50230217 Rubber dampening kit up to 250kg Whisper 6-12/6-8-10 Ultra
no qtt article no description
61 4 ST 50230552 Rubber mounting up to 70 kg
64 4 ST 50211449 Washer spring SP M12
64 4 ST 50211250 Bolt hexagonal socket ZP M12x30
64 4 ST 50211407 Washer SP M12
50230231 Rubber mounting kit up to 450kg Whisper 12-16 Ultra
no qtt article no description
61 4 ST 50230550 Rubber mounting up to 130 kg
64 4 ST 50211449 Washer spring SP M12
64 4 ST 50211250 Bolt hexagonal socket ZP M12x30
64 4 ST 50211407 Washer SP M12

INSTALLATION SPECIFICATIONS
18 EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004
Fig. 28.

INSTALLATION SPECIFICATIONS
November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN 19
50201320 Dry exhaust kit 1” Whisper 6”
no qtt article no description
61 1 ST 50220041 “Exhaust hose 500mm SS male/female 1”
62 1 ST 50220042 Insul. blanket 35x60 exhaust hose 1 1/2
63 1 ST 50230520 “Absorbtion muffler steel 1”
64 1 ST 50230521 “Ressonance muffler steel 1”
65 1 ST 50230522 “Insulation blanket R-muffler 1”
66 2 ST 50221401 “Pipe nipple 1”x300mm galvanised”
67 2 ST 50221421 “Parallel male coupling 1” galvanised”
68 2 ST 50221411 “Straigt coupling f/f 1”galvanised”
69 3 ST 50221661 U-clamp 42mm M10
70 3 ST 50221664 Bracket U-clamp 25cm M10/48mm passivated
71 6 ST 50211406 Washer SP M10
72 6 ST 50211447 Washer spring SP M10
73 6 ST 50211466 Nut hexogonal SP M10
75 1 ST 50221471 “Elbow 90 degr m/f gavalvanised 1””
50201875 Dry exhaust kit 1,5” Whisper 12/6-8-10-12-16 Ultra
no qtt article no description
61 1 ST 50220043 “Exh.hose SS 500mm fem./male 11/2”
62 1 ST 50220042 Insul. blanket 35x60 exhaust hose 1 1/2
63 1 ST 50230523 “Absorbtion muffler steel 11/2”
64 1 ST 50230524 “Ressonance muffler steel 11/2”
65 1 ST 50230525 “Insul. blanket 80x75 muffler SDHC 11/2”
66 2 ST 50221403 “Pipe nipple 11/2”x300mm galvanised”
67 2 ST 50221423 “Parallel male coupling 11/2” galvanised”
68 2 ST 50221413 “Straigt coupling f/f 11/2”galvanised”
69 3 ST 50221663 U-clamp 48 mm M10
70 3 ST 50221664 Bracket U-clamp 25cm M10/48mm passivated
71 6 ST 50211406 Washer SP M10
72 6 ST 50211447 Washer spring SP M10
73 6 ST 50211466 Nut hexogonal SP M10
75 1 ST 50221473 “Elbow 90 degr m/f gavalvanised 11/2”
50201878 Radiator cooling kit alternator 230VAC
Whisper 6,12/6,8,10,12 ULTRA
no qtt article no description
31 1 ST 50230304 Radiator cooler AP 300/2 E 230VAC
32 2 ST 50221103 “Straight reducer m/f 1”-3/4”
33 1 ST 50221063 “Male nipple 3/4”
34 1 ST 50221043 “TEE fittings 3/4”
35 3 ST 50221004 Male hose connection 3/4x20
38 1 ST 50212405 Temperature switch 35-45 degr
39 4 ST 50201121 Vibration mounting 30x25
40 4 ST 50211152 Bolt hexagonal ZP M8x16
41 8 ST 50211465 Nut hexogonal SP M8
42 8 ST 50211405 Washer SP M8
43 8 ST 50211445 Washer spring SP M8
44 8 M 50220011 “Hose vacum SAE100R4 (3/4”) 19x31,5mm
45 6 ST 50221502 Hose clamp stainless19-29
46 8 ST 50221599 Hose support 35x15 mm galvanised
47 1 ST 50230529 Bracket expansion tank for 50230531
47 1 ST 50230531 Expansion tank 20 mm
47 1 ST 50230532 Cap tank 0502 30531
50201872 Radiator cooling kit alternator 12VDC Whisper 6/6 ULTRA
50201868 Radiator cooling kit alternator 24VDC Whisper 6/6 ULTRA

INSTALLATION SPECIFICATIONS
20 EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004
50201888 Radiator cooling kit alternator 230VAC Whisper 16
no qtt article no
31 1 ST 50230307 Radiator AP 430 230VAC
32 1 ST 50221103 “Straight reducer m/f 1””-3/4”””
33 1 ST 50221064 “Male nipple 1”””
34 1 ST 50221044 “TEE fitting 1”””
35 2 ST 50221010 Male hose connection 1x25
35 1 ST 50221004 Male hose connection 3/4x20
38 1 ST 50212405 Temperature switch 35-45 degr
39 4 ST 50201121 Vibration mounting 30x25
40 4 ST 50211152 Bolt hexagonal ZP M8x16
41 4 ST 50211465 Nut hexogonal SP M8
42 4 ST 50211405 Washer SP M8
43 8 ST 50211445 Washer spring SP M8
44 6 M 50220012 “Cooling water hose smooth (1””) 25x34 mm”
44 1.5 M 50220011 “Cooling water hose smooth (3/4””)18x27 mm”
45 2 ST 50221502 Hose clamp stainless19-29
45 4 ST 50221503 Hose clamp stainless 26-38
47 8 ST 50221599 Hose support stainless 35x12 mm
47 1 ST 50230529 Bracket expansion tank for 50230531
47 1 ST 50230532 Cap tank 0502 30531
47 1 ST 50230531 Expansion tank 20 mm
50201879 Radiator cooling kit engine 230VAC Whisper 6/6 Ultra
no qtt article no description
11ST50230304 Radiator cooler AP 300/2 E 230VAC
22ST50221502 Hose clamp stainless19-29
31ST50221064 “Male nipple 1”
41ST50221044 “TEE fitting 1”
52ST50221010 Male hose connection 1x25
61ST50221103 “Straight reducer m/f 1”-3/4”
71ST50221004 Male hose connection 3/4x20
81ST50212409 Temperature switch 87-82 degr
94ST50201121 Vibration mounting 30x25
10 4 ST 50211152 Bolt hexagonal ZP M8x16
11 4ST50211465 Nut hexogonal SP M8
12 8 ST 50211405 Washer SP M8
13 8 ST 50211445 Washer spring SP M8
14 6 M 50220012 “Hose vacum SAE100R4 (1”) 25,4x38mm”
15 4 ST 50221503 Hose clamp stainless 26-38
16 8 ST 50221599 Hose support stainless 35x12 mm
17 1 ST 50230529 Bracket expansion tank for 50230531
17 1 ST 50230531 Expansion tank 20 mm
17 1 ST 50230532 Cap tank 0502 30531
18 1.5 M 50220011 “Hose vacum SAE100R4 (3/4”) 19x31,5mm
21 1 ST 50221532 Hose clamp stainless mini 9-11
50201871 Radiator cooling kit engine 12VDC Whisper 6/6 Ultra
50201880 Radiator cooling kit engine 24VDC Whisper 6/6 Ultra