Mastervolt WHISPER 7 ULTRA User manual

INSTALLATION MANUAL FOR MOBILE APPLICATIONS
U.S.A EDITION
WHISPER
7 / 9.5 / 15 / 20 ULTRA
- 1800 RPM -
Mobile diesel generating set 120/240V / 60Hz
Digital Diesel Control
MASTERVOLT
Snijdersbergweg 93,
1105 AN Amsterdam
The Netherlands
Tel.: [phone]
Fax.: [phone]
www.mastervolt.com V5. May 2009
Art.nr. 50200244

TABLE OF CONTENTS
2Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US
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.
TABLE OF CONTENTS:
1INTRODUCTION.............................................................................................................................................................. 3
1.1 General ..............................................................................................................................................................3
1.2 Generating sets for vehicles...............................................................................................................................3
1.2.1 Marine and mobile generators...........................................................................................................3
1.2.2 Why two radiators:.............................................................................................................................4
1.2.3 Why the alternator should be cooled by water...................................................................................4
2INSTALLATION............................................................................................................................................................... 5
2.1 General ..............................................................................................................................................................5
2.2 Location..............................................................................................................................................................5
2.3 Instructions for optimal sound and vibration insulation.......................................................................................6
2.3.1 Further recommendations .................................................................................................................6
2.4 Ventilation...........................................................................................................................................................6
2.4.1 General..............................................................................................................................................6
2.4.2 Air strainer element ...........................................................................................................................7
2.5 Connections ....................................................................................................................................................... 7
2.5.1 Fuel supply...................................................................................................................................... 12
2.5.2 Radiator cooling .............................................................................................................................. 14
2.5.3 Dry exhaust system......................................................................................................................... 18
2.5.4 Electrical installation (12 Volt) ......................................................................................................... 20
2.5.5 AC power system (120 / 240 Volt)................................................................................................... 23
3INSTALLATION SPECIFICATIONS.............................................................................................................................. 24
3.1 General ............................................................................................................................................................ 24
3.2 Commission table............................................................................................................................................. 24
3.3 Technical data.................................................................................................................................................. 25
3.4 Installation materials......................................................................................................................................... 26
4DIAGRAMS & DRAWINGS ........................................................................................................................................... 33
4.1 Layout generator control for Whisper 7, 9.5 and 15 Ultra with 120VAC fan ..................................................... 33
4.2 Layout generator control for Whisper 7 Ultra with 12VDC fan.......................................................................... 34
4.3 Layout generator control for Whisper 7 Ultra with 24VDC fan.......................................................................... 35
4.4 Layout generator control for Whisper 20 Ultra with 120VAC fan...................................................................... 36
4.5 Wiring colours Whisper 7 Ultra, 9 Ultra and 15 Ultra........................................................................................ 37
4.6 Wiring colours Whisper 20 Ultra....................................................................................................................... 38
4.7 AC wiring diagram 120-240V / 60Hz ................................................................................................................ 39
4.8 Electrical diagram radiator fan control 120VAC................................................................................................ 40
4.9 Electrical diagram radiator fan control 12 / 24 VDC.......................................................................................... 41
4.10 Wiring diagram electronic governor (Standard for Whisper 7, 9.5 and 15 Ultra) .............................................. 42
4.11 Remote control panel drawings........................................................................................................................ 43
4.12 Dimensions Whisper 7 Ultra............................................................................................................................. 44
4.13 Dimensions Whisper 9.5 Ultra.......................................................................................................................... 45
4.14 Dimensions Whisper 15 Ultra........................................................................................................................... 46
4.15 Dimensions Whisper 20 Ultra........................................................................................................................... 47

INTRODUCTION
US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt 3
1 INTRODUCTION
1.1 GENERAL
This installation manual applies to the installation of
Mastervolt Whisper gensets in vehicles. This manual is
valid for the following models:
Part number Description
51105025 Whisper 7 Ultra 120/240V 1800rpm
Mobile / keel cooling
51106025 Whisper 9.5 Ultra 120/240V 1800rpm
Mobile / keel cooling
51107025 Whisper 15 Ultra 120/240V 1800rpm
Mobile / keel cooling
51108025 Whisper 20 Ultra 120/240V 1800rpm
Mobile / keel cooling
For other models see our website: www.mastervolt.com
WARNING
A warning symbol draws attention to special
warnings, instructions or procedures which, if
not strictly observed, may result in damage or
destruction of equipment, severe personal
injury or loss of life.
DANGER
This danger symbol refers to electric danger
and draws attention to special warnings,
instructions or procedures which, if not strictly
observed, may result in electrical shock which
will result in severe personal injury or loss of
life.
WARNING!
Before working (installation) on the system
read the section safety instructions in the
user’s manual
1.2 GENERATING SETS FOR VEHICLES
1.2.1 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
86° Fahrenheit (30°C) and is seldom warmer than 68°F
(20°C) 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 120V)
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.
Figure 1: Typical vehicle application radiator side mounted

INTRODUCTION
4Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US
Figure 2: Typical vehicle application radiator top mounted
Figure 3: Typical vehicle application radiator bottom
mounted
1.2.2 Why two radiators:
The optimum engine operating temperature is between
189°F and 198°F (87°C and 92°C). The radiator reduces
the temperature of the cooling liquid by only 9°F to 22°F
(5°C to 12°C). The returning “cold” coolant therefore has a
minimum temperature of approx. 167°F (75°C).
The alternator should be kept as cool as possible. In
practice an alternator starts getting less efficient above
104°F (40°C). It is hardly possible to cool down the coolant
of the alternator below 104°F (40°C) by using a radiator.
When a vehicle is in the sun on a parking place the
ambient temperature itself could be 104°F (40°C).
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.
1.2.3 Why the alternator should be 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

INSTALLATION
US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt 5
2 INSTALLATION
Figure 4: Schematic installation diagram
2.1 GENERAL
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.
2.2 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 radiator (Refer to par. 2.5.2)
•Space to mount the exhaust (Refer to par. 2.5.3)
•A way to fit the fuel lines
Since Whisper generating sets have extremely compact
dimensions, they can be installed in tight locations. Please
consider that even almost maintenance-free machinery
must still remain accessible.
When selecting the location area in which to mount the
generating set, make sure there is sufficient room to carry
out any maintenance work. The unit must be easily
accessible on the service side and on the distribution side
to have access to the V-belt
All models can be serviced from one side. Oil filling can be
done on the service side and on the top (except for
Whisper 20 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 accessible
for adjustment of the valve clearance.
Please also note that in spite of the automatic oil pressure
sensor it is still essential that the oil level is checked
regularly.

INSTALLATION
6Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US
2.3 INSTRUCTIONS FOR OPTIMAL SOUND
AND VIBRATION INSULATION
Position the generating set as low as possible in the
vehicle. The generating set is secured to the base frame
by means of flexible engine mountings. This frame is
mounted in the vehicle with additional vibration dampers.
When it is possible to mount the unit directly on the
chassis of the vehicle this has advantages in preventing
vibrations by resonance.
2.3.1 Further recommendations
Whisper generating sets are standard equipped with a
sound cover. This sound cover has been designed to give
effective sound insulation. For optimum sound and
vibration dampening, the following factors should be
considered.
1 Most important is the structure on which the generator
is placed to be stiff. Directly below the rubber
mountings the structure should be supported vertically
to the chassis of the vehicle.
2 In larger vehicles a separate and insulated space for
the generator will help to damp the noise even further
3 Avoid mounting the generating set in close proximity
to thin walls or floors that may cause resonance.
4 Sound dampening is extremely poor if the generating
set is mounted on a light weight flimsy surface such
as plywood which will only amplify vibrations. If
mounting on a thinner surface cannot be avoided, this
should be at least be reinforced with stiffening struts
or ribbing. If possible, holes should be drilled or cut
through the surface to help reduce the resonance.
Covering the surrounding walls and floors with a
heavy coating plus foam will certainly improve the
situation.
5 Never connect the base of the generating set directly
to walls or tanks.
2.4 VENTILATION
2.4.1 General
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 15.5 sq inch (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 104°F (40°C)
reduce the engine power by 2% for each 9ºF (5°C) of rise.
To minimise these effects the engine room temperature
must not be more than 27ºF (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.
Figure 5: Mounting of the Whisper generating set. X = wrong, V = OK

INSTALLATION
US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt 7
Figure 6: Mounting of the air strainer element
2.4.2 Air strainer element
Applying a generator in a vehicle, where combustion air is
taken in from below the vehicle, there is often much dust,
sand and dirt in the air. For these applications Mastervolt
prescribes the installation of an air strainer element. This
air strainer element is in the standard supply, but not yet
mounted as often the best place to mount it will be
different in any installation.
To install the air strainer element one has to find the best
place somewhere on the canopy. Figure 6 shows the
recommended place, but the filter can be mounted
everywhere, even on the bottom, hanging down.
Use sealant or kit between the flange and the surface.
ATTENTION!
In any case it is necessary to open a hole for
air inlet!
2.5 CONNECTIONS
The generating set comes with all supply lines and output
cable (i.e. electric cables, coolant 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
figures 7 till 10
All electrical connections, cable types and sizes must
comply with 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 requirements, they must be run through
conduits.
ATTENTION!
Before working (installation) on the system
read the section safety instructions
50230006 AIRCLEANER+ ADAPTER
50230005 ADAPTER
50230003 AIRCLEANER
WHEN NOT USING
THE FILTER, THIS HOLE
SHOULD BE OPENED

INSTALLATION
8Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US
Fig. 7 Connections Whisper 7 Ultra for mobile application
01 Coolant generator in
02 Battery + (POS)
AWG3 (25mm2)
03 Fuel out Ø5/16’ (8mm)
04 Fuel in Ø5/16’ (8mm)
05 Battery – (NEG)
AWG3 (25mm2)
06 Coolant engine out
07 Coolant engine in
08 Coolant generator out
10 Expansion tank Ø5/16’
(Ø8mm)
11 Exhaust 1½”
12 AC power output
13 Remote control

INSTALLATION
US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt 9
Fig. 8a Connections Whisper 9.5 Ultra
Fig. 8b Connections Whisper 9.5 Ultra
01 Expansion tank Ø5/16’
(Ø8mm)
02 Exhaust 1½”
03 Remote control
04 AC power output
05 Coolant engine out
06 Coolant generator out
07 Battery – (NEG)
AWG3 (25mm2)
08 Fuel out Ø5/16’ (8mm)
09 Fuel in Ø5/16’ (8mm)
10 Battery + (POS)
AWG3 (25mm2)
11 Coolant generator in
12 Coolant engine in

INSTALLATION
10 Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US
Fig. 9a Connections Whisper 15 Ultra
Fig. 9b Connections Whisper 15 Ultra
05 Coolant engine out
06 Coolant generator out
07 Fuel out Ø5/16’ (8mm)
08 Fuel in Ø5/16’ (8mm)
09 Battery – (NEG)
AWG3 (25mm2)
10 Battery + (POS)
AWG3 (25mm2)
11 Coolant generator in
12 Coolant engine in
01 Expansion tank Ø5/16’
(Ø8mm)
02 Exhaust 1½”
03 Remote control
04 AC power output

INSTALLATION
US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt 11
Fig. 10a Connections Whisper 20 Ultra
Fig. 10b Connections Whisper 20 Ultra
01 Expansion tank Ø5/16’
(Ø8mm)
02 Exhaust 1½”
03 Remote control
04 AC power output
05 Coolant engine out
06 Coolant generator out
07 Coolant generator in
08 Coolant engine in
09 Battery + (POS)
AWG2 (35mm2)
10 Battery – (NEG)
AWG2 (35mm2)
11 Fuel in Ø5/16’ (8mm)
12 Fuel out Ø5/16’ (8mm)

INSTALLATION
12 Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US
2.5.1 Fuel supply
1 FUEL TANK
Fuel tanks should be made of appropriate material such as
(stainless) steel or plastic. Steel tanks should not be
galvanised or painted inside. Condensation can occur in
metal tanks when temperature changes. Therefore, water
accumulates at the bottom of the tank and provisions
should be made for the drainage of this water.
The tank will need a filling connection, a return connection
and an air ventilation connection which will require
protection against water entry.
Some official regulations do not allow connection points at
the base of the fuel tank; 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 carried out 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.
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 make it
necessary to bleed the fuel system.
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. See figure 12. The maximum suction
height is 3 feet (1 meter). The Whisper 20 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 control 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. 13)
The pump makes clicking noises and therefore could be
mounted on rubber mountings. When the clicking noises of
the pump are not acceptable an other noiseless pump is
available as an option
Figure 11 Fuel supply (fuel tank is above the generating set)
1 Fuel return
2 Fuel supply
3 Prefilter / Water separator (optional)
5 Fuel Tank

INSTALLATION
US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt 13
A
1
3
2
5
4
Figure 12 Fuel supply (fuel tank is below the generating set)
1 Fuel return
2 Fuel supply
3 Prefilter / Water separator (optional)
4 Extra fuel lift pump (optional)
5 Fuel tank
Figure 13: Fuel line assembly with vertical mounted pump and fuel lift pump mounted in an angle

INSTALLATION
14 Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US
3 FUEL PIPES
When the tank is above the generating set (figure 11) we
recommend ending the return line on the top of the tank.
When the return is on the top - in case of a leakage the
return line cannot overflow because of siphoning. One will
only need a fuel cock in the fuel supply line. 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.
Both supply and return fuel pipe lines should be
appropriate material and 5/16’ (8 mm) inner diameter
tubing. The quality of the tubing of fuel pipes could be
submitted to local regulations depending on the application
of the vehicle.
The fuel pipes can be plumbed to the flexible hoses which
are on the generating set and have a connection to fit to
5/16’ (8 mm) pipe. This fuel lines fulfils CE standards and
are according to ISO 7840 A2.
It is important to avoid bends in the pipes, as they could
trap air bubbles. The return pipe should never be
connected to the suction pipe. 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 too 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.
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.
2.5.2 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 14). Bents in the piping, that can trap air bubbles,
should be avoided or ventilated (refer to figure 15)
Figure 14: Air traps should be avoided
Piping should not be fitted above the radiator!
OK

INSTALLATION
US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt 15
Figure 15: Ventilating an air trap
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.
Figure 16. Alternator cooling system: open expansion tank
with overflow pillar.
For the alternator cooling system we use an open -non
pressurised- system. Therefore the ½” (12 mm) overflow
pillar on the expansion tank should stay open (figure 16).
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 cooling of the the engine we use a pressurised
system. The ½” (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 5/16’ (8 mm) connection to ventilate the
manifold. There is an 5/16’ (8 mm) high pressure and high
temperature resistant hose in the delivery to connect the
hose connection on the side of the manifold with the
expansion tank. (refer to figure 7 till 10).
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 1.8 gallon (7 litres) and an alarm for low coolant
level that can be supplied as an option (refer to figure 16).
Figure 17:
Optional 1.8 gallon expansion tank with low level alarm.

INSTALLATION
16 Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US
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 18
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
Figure 18.
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 19 detail B).
Figure 19:
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
A
side mount
bottom mount
B
top mount

INSTALLATION
US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt 17
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.
20). 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.
Figure 20. Radiator on rubber mountings
Bottom mounted radiators
When bottom mounted the radiator should not be the
lowest point of the vehicle to avoid damage.
A free flow of air should be guaranteed. When horizontal
mounted, the fan should be on top, which 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 have to be taken to prevent the hot
air circulating and reducing the capacity of the
radiators. Refer to figure 21
Figure 21: Bottom mounted radiators with shield
Figure 22. Making use of the space below the floor to get
an optimal flow of air through the radiators.
Side mounted 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 disadvantage 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.
A free flow of air should be guaranteed. The ventilation
connection of the cooling system that goes to the
expansion tank, should be in the outgoing coolant flow on
top of the radiator.
Figure 23: Side mounted radiator
side mounted
air flo
w

INSTALLATION
18 Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US
Roof mounted radiators
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 will 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 which requires provisions to be waterproof. Also
negative is that roof mounted radiators are more sensitive
for air traps (see figure 14). When having enough space it
would be ideal to have the radiators vertically mounted on
the roof. Note that the expansion tank should be above the
radiator.
When having the radiators horizontally mounted on the
roof (refer to figure 24) enough space (2 inches / 50 mm)
should be between the roof and the radiator fan to have a
free flow of air. When the radiators are roof mounted there
should be protection against weather conditions. To avoid
damage while the vehicle is driving at high speed, the use
of a spoiler could be necessary.
Figure 24: Two examples of top mount radiators
3 TWO SPEEDS FAN (OPTIONAL)
To keep the noise as low as possible the fans of the
radiators can run at two different speeds. As option a
control box is available which can be used to drive the
fans with two speeds, depending on the load of the
generator. When using 12/24V DC to drive the fans (see
chapter 4.9), in normal mode the electric motors of the
fans are connected 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.
However, when not strictly necessary, we recommend
using the standard 120V fan control instead of the two
speeds 12/24V fan control, in order to keep the system as
simple as possible.
2.5.3 Dry exhaust system
1 GENERAL REMARKS
A dry 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.
Figure 25: 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 through the roof of a
vehicle, measures has to be taken to prevent
rainwater to enter the system. Special rain
caps are available as an option.
Figure 26. Ways to prevent water to get in
horizontal vertical

INSTALLATION
US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt 19
A negative 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.
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:
•An insulated exhaust bent
In the exhaust installation kit:
•A stainless 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 (12
inch / 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 19 how to mount the rubber in a
safe way. When any doubt an extra safe guard could be
constructed from steel wire or chain.
Figure 27. Mounting bracket in rubber with safe guard

INSTALLATION
20 Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US
2.5.4 Electrical installation (12 Volt)
1 DIGITAL DIESEL CONTROL SYSTEM
The electrical control system is standard in 12 Volt with
negative earth. Non- earth return is available as an option.
All electrical wiring has been prepared on the generating
set to the control panel prior to despatch from the factory.
The engine is controlled by a very advanced
microprocessor based system: Digital Diesel Control.
The “black box” containing the microprocessor is located
on top of the alternator.
A local control panel is on the generating set.
Remote control
A remote control panel also containing a microprocessor is
in the delivery. A 49ft (15 m) intermediate 8-pole
communication cable is in the standard supply as well
(refer to fig. 28). If necessary an optional longer (up to
100ft / 30m) intermediate cable can be connected if the
standard length does not suit the required distance. When
a longer distance than 100ft / 30m is required, consult the
Mastervolt service department for advice.
Fig. 28 Remote control cable
One can mount the control panel after drilling a hole in the
dashboard using the plastic cover. Refer to the
dimensional drawings in chapter 4. 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 (like the
System Manager AC + Whisper or the CSCP4) can be
connected by means of the green connector.
Pay attention to the colour codes as indicated in fig. 29
when fitting cable to the green connector. Some software
versions in old system panels (supplied before May 2004)
could conflict with the software in the DDC and an update
of the software of the system panel could be necessary.
When this is the case consult to the Mastervolt service
department for advice.
When using the factory settings, installation is very simple:
just plug the remote cable into the remote and the
generator is ready to use. Refer to fig. 29.
WIRINGCOLOURS
RED
GREEN
BROWN
YELLOW
PINK
PURPLE
BLUE
WHITE
GREY/ PI NK
GREY
RED/BLUE
BLACK
MAX. 150 mA
WARNING RELAY
REMOTE CABLE
REMOTE CABLE
2
1
5
4
3
8
7
6
11
10
9
12
SENSE BAT. 2
121110987654321
Whisper Remote Panel
WRP/2
J3
Fig. 29 Remote box terminals