Mastervolt WHISPER 9 User manual

MASTERVOLT
Snijdersbergweg 93
1105 AN Amsterdam
The Netherlands
Tel.: [phone]
Fax: [phone]
http://www.mastervolt.com
INSTALLATION MANUAL
V1. September 2004
WHISPER 9,5 / 12,5 / 15 / 20
ULTRA
-1800 RPM-
Diesel generating set 120/240V-60Hz
Art.nr. 50200404

2Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / 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 230 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.1. DC wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.2. Codes and colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
3.3 Wiring diagram electronic governor Whisper 12,5 ULTRA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
3.4 AC wiring diagram Whisper 120/240V 60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
3.5 Whisper remote control panel drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
3.6 Whisper 9,5/12,5/15/20 ULTRA dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
CONTENTS

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 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, weighing 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.
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
be directly connected to an air duct.
INSTALLATION

4Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA
Water in (8)
25,4 mm
Battery + (5) 35 mm2
Battery - (7) 35 mm2
Fuel return (6) 8 mm
Fuel in (4) 8 mm Power cable (3)
Remote cable (2)
Airvent out (9)
25,4 mm
Airvent in (10)
25,4 mm
Exhaust (1)
51 mm
INSTALLATION
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.
ATTENTION!
Before working (installation) on the system
read the section safety instructions.
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 cm above the bottom of
the tank.
AWG 2 (25 mm2)
2" (51 mm)
EXHAUST (1)
REMOTE CABLE (2)
AC CABLE (3)
12xAW 22 (0,3 mm2)FUEL RETURN (6) WATER IN (8)
3/4" (19 mm)
BATTERY + (5)
AWG 2 (25 mm2)
5/16" (8 mm)
FUEL IN (4)
AIRVENT OUT (9)
3/4" (19 mm)
BATTERY - (7)
3/4" (19 mm)
AIRVENT IN (10)
5/16" (8 mm)
Fig. 1.
WHISPER 9,5 / 12,5 / 15 ULTRA
WHISPER 20 ULTRA

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 5
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.
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.
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.
Fig. 2.
1Fuel return;
2Fuel supply;
3Prefilter / water separator (optional);
5Fuel tank;
INSTALLATION

6Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA
INSTALLATION
When the tank is below the generating set we recom-
mend to end the return line on the bottom of the tank
(A) below the inlet of the supply line to discharge
under the lowest fuel level. This prevents air getting
into the fuel line. Here also one need only a fuel cock
in the supply line.
Both supply and return fuel pipe lines should be
appropriate material and 8 mm outer diameter tubing.
The quality of the tubing of fuel pipes could be 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 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.
Fig. 3.
1Fuel return;
2Fuel supply;
3Prefilter / water separator (optional);
4Extra fuel lift pump (optional);
5Fuel tank;

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 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 19 mm
diameter (3/4") Whisper 15 and 25,4 mm (1”) Whisper
20. The suction hose should be kept as short as pos-
sible. Raw water plumbing should avoid bends as
much as possible.
1
2
34
5
7
6
Min.
24"
60 cm
2"
5 cm
Max.
60"
150 cm
Min.
24"
60 cm
Fig. 4b. 1Water level;
2Water/exhaust separator;
3Seacock;
4Waterlock;
5Air vent;
6Water strainer;
7Seacock.
Afb. 4a.
INSTALLATION

8Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA
INSTALLATION
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 according to the data in the
users manual.
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" (19mm) Whisper 15 ULTRA and 1" (25,4mm)
Whisper 20 ULTRA. Install the water strainer in a well ac-
cessible position, (ref. to fig. 4 - 6) 15 cm 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)
Whisper 9,5/ 12,5/ 15 ULTRA and 1" (25,4 mm)
Whisper 20 ULTRA inner diameter should be used.
If the generating set cannot be mounted such that the
bottom of the generating set is placed above the
waterline, an air vent must be installed.
Extend the water hose of the by-pass 600 mm above
waterline and install an air vent. Ideally, the air vent
should be mounted above the yacht keel center line
(i.e. to minimize the influence of swaying on the water
intake).
If the air vent is clogged the water hoses
will not be vented when the generating set
has stopped and water can be forced into
the engine. This leads to immediate engine
problems and eventually severe damage!
DAMAGE CAUSED BY THE INGRESS OF WATER
IN THE ENGINE IS NOT COVERED BY
WARRANTEE
On the valve is a little hose to drain a little water that
could be spilled from the valve. This hose should go
down and may not end under water, because it
should ventilate air into the valve to break the
siphoning.
Check the air vent at regular intervals. Open, clean
and lubricate the valve as required.
flow direction
sailing direction
WRONG!
thru-vessel inlet
Fig. 5.
Fig. 6.

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 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 outside sea 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 2” (51
mm). The exhaust system must be installed so that
the back pressure inside the exhaust does not
exceed 0.7 bar (1 psi = 27 inches (70 cm)
watercolumn)(2 inches mercury) and total length
from generator to the top of the goose neck or
water/gasseparator does not exceed 10 ft. (3m).
(Refer to paragraph 5.4.3 of the users manual.
The exhaust hose descends from the capsule to the
water lock. Then the hose rises via the "goose neck"
to the through-hull exhaust outlet, situated minimum
2” (50 mm) above the water line (ref. to fig. 7-5. The
"goose neck" must be vertical and situated preferable
along the ship’s keel center line. If the generating set
is mounted less than 24” (600 mm) above the
waterline, a "goose neck" must be installed to prevent
the engine from overflowing. It is recommended to
install an extra muffler close to the through-hull fitting.
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 Ø 2” (51 mm);
4Goose neck
5 Through-hull exhaust outlet Ø 2” (51 mm);
6 Water level.
INSTALLATION

10 Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / 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. If the exhaust/water separator is
mounted more than 24 inches (600 mm) above the
water level an additional goose neck is not required.
If the through-hull exhaust outlet has to be mounted
far (total length exhaust piping from generator to top
of goose neck (waterseparator) is more than 10 ft.
(3 m)) from the generating set, an exhaust/water se-
parator must definitely be installed. The sea water
from the separator must then run down along the
shortest possible path to the through-hull outlet. Only
after the exhaust/water separator the exhaust hose
may have alength of over 25 ft. (7,5 m) if the exhaust
hose diameter is also increased from 2” (51 mm) to 2
1/2” (63 mm) in order to reduce the back pressure
(ref. to fig. 9).
However watertraps should be avoided as the fumes
still contains water and this shouldnot accumulate in
bents. (Referto fig 8a) An additional outlet exhaust
muffler close to the hull outlet will help further to
reduce noise emission.
2" (51 mm)
24 inch
1 5/8" (40 mm)
WATERLEVEL
2" (51 mm)
MAX. 4 inches (10 cm)
Fig. 8.
Fig. 8a.

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 11
ø 2" (51 mm)
up to 10 ft. (3 m) ø 2" (51 mm)
10-30 ft. (3-10 m) ø 2,5" (63 mm)
ø 1 5/8" (40 mm)
max. length
A - B = 10 ft. (3 m)
A
B
Wrong
Good
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 Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA
INSTALLATION
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 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.
Fig. 11.
J3
MASTERVOLT
WRP/2
Whisper Remote Panel
TAIL OR 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 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 13
In the delivery are warning stickers to stick
on several parts of the electric installation
(transfer switch, distribution box, etc.) to
warn for automatic start.
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 9,5 / 12,5 / 15 requires a
battery with a capacity of at least 85 Ah. The Whisper
16 ULTRA reguires 120 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 connected 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 char-
ger will help to keep the battery in good condition
when the generating set in not used.
Abattery 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 stater 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.
INSTALLATION
12V
12V
IVO 12/10
IVO 12/10
AB
230VAC
230VAC
Fig. 13.

14 Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA
INSTALLATION SPECIFICATIOINS
The battery cables are supplied in a standard length
of 1.5 m, if longer cables are required a larger cross
sectional area should be considered to compensate
for voltage reduction.
When two batteries are used in series to provide a 24
Volt supply system, never take off 12 Volt (starting)
power from one of these batteries. This will result in
sever damage to the batteries within 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 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 (120/240 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 62A (15), 83A (20). At 120V the maximum
single phase current is: 125A (15) 166A (20). 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 than the above mentioned. (refer to ISO
13297 anex A)
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.

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 15
2INSTALLATION
SPECIFICATIONS
2.1 WHISPER 15/20 ULTRA INSTALLATION
TABLE
1Install the generating set, direct or with 4 shock
mounts (ref. to fig. 12)
2Connect the (sea) water inlet to the strainer.
3Connect exhaust system.
4Connect a siphon breaker or ‘air vent’ into cooling cir-
cuit, if necessary.
5Connect ‘fuel supply line’ to the water separator/ fuel
filter.
6Connect ‘fuel return line’ to the fuel tank.
7Connect remote panel (just plug in).
8Connect the AC cable from the AC box to the power
source selector or masterswitch.
9Connect plus and minus from the 12V starter battery
to the battery cables.
10 Install a Mastervolt battery charger. (optional)
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 above
the seawater level.
3Check if the exhaust system is properly installed.
Check maximum lentgh of exhaust hose, diameter of
exhaust hose, position of waterlock, maximum lift.
Also check the minimum required height of 600 mm
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.
8Check 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 fuel system (refer to the users manual
§4.2.2)
12 The starting procedure is initialized by pushing the
START button.
13 Check when the generating set is running, the delay
of 5 to 10 seconds in the power source selector trans-
fer.
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
Commissioning form available on our website
www.mastervolt.com
INSTALLATION SPECIFICATIONS
Fig. 14.

16 Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA
2.3 INSTALLATION SPECIFICATIONS WHISPER 9,5 / 12,5 / 15 / 20 ULTRA
TECHNICAL DATA
9,5 / 12,5 ULTRA: 35,4 x 24,21 x 27,17 inches (900 x 615 x 690 mm)
Dimensions wxdxh. 15 ULTRA:41,73 x 24,21 x 27,17 inches (1060 x 615 x 690 mm)
20 ULTRA: 45,27 x 26,77 x 29,52 inches (1150 x 680 x 750 mm)
Weight 9,5 / 12,5 ULTRA: 640 lbs (290 kg)
15 705: lbs (320 kg)
20 ULTRA: 926 lbs (420 kg)
Max. operation angle 25°
Remote panel 45 ft.15 m cable, indicating: run, load, overload, failure, hour counter, glow-, start-, stop button.
Battery capacity min. 9,5 / 12,5 / 15 ULTRA: 12V, 85 Ah
20 ULTRA: 12V, 120 Ah
Fuel consumption 0,25-1,2 gl/hr (1-4,5 l/hr), load dependent
Fuel lift pump 9,5 / 12,5 / 15 ULTRA electric driven 12 V DC, max. lift 3 ft. (1 m)
Fuel lift pump 20 ULTRA mechanical driven; manually priming; lift 3 ft. (1 m).
Cooling indirect cooling
Cooling pump 9,5 / 12,5 / 15 ULTRA raw water Mastervolt self priming impeller pump,
PTO driven, type M12
20 ULTRA raw water Mastervolt self priming impeller pump,
PTO driven, type M16
Minimum water supply 9,5 / 12,5 / 15 ULTRA: 4,8 - 6,9 gl/min (18-22 l/min)
20 ULTRA: 5,3 - 6,6 gl/min (20-25 l/min)
Alternator synchronous brushless, maintenance free water cooled
Voltage regulation capacitor + AVR (optional)
Output power at 9,5 ULTRA: 9,5 kW 120/240V 60 Hz
power factor cos phi =1 12,5 ULTRA: 12,5 kW 120/240V 60 Hz
15 ULTRA: 15 kW, 120/240V 60 Hz
20 ULTRA: 20 kW, 120/240V 60Hz
Battery charger alternator including regulator (50 Amps)
2.4 SPECIFICATION OF THE ACCESSORIES
Whisper 9,5 / 12,5 / 15 ULTRA Whisper 20 ULTRA
Water scoop 3/4” 1”
Inlet valve 3/4" 1”
Water strainer 3/4" 1”
Air vent 3/4" 1”
Inlet suction hose 3/4" 1”
Fuel filter/water separator 30 micron 30 micron
Fuel inlet and return 5/16” (8 mm) 5/16” (8 mm)
Exhaust hose Ø 2” (51 mm) Ø 2” (51 mm)
Water lock Ø 2” (51 mm) Ø 2” (51 mm)
Water/gas separator Ø 2” (51) -1 5/8” (40) -2” (51 mm) Ø 2” (51) -1 5/8” (40) -2” (51 mm)
Anti shock mounts 50230550 50230550
Battery charger (optional) IVO SMART 12/10; 12V / 10 Amps
INSTALLATION SPECIFICATIONS

INSTALLATION MATERIALS
USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 17
2.5 INSTALLATION MATERIALS WHISPER 9,5/12,5/15/20 ULTRA
WATER INLET KIT 3/4”(20mm) 9,5/12,5/15 ULTRA
no qtt article no 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 1/2x20
71 50230060 Nickel plated brass intake strainer3/4
81 50230067 Mounting bracket waterstrainer
TOTAL 50230211 WATER INLET KIT 3/4” (20 mm)
WATER INLET KIT 1”(25,4 mm) 20 ULTRA
no qtt article no description dimensions
11 50230053 Intake strainer 1”
21 50230043 Lever operated ball valve FF 1”
31 50221010 Male hose connection 1”x25
34 50221503 Hose clamps 26-38 mm
53 50220050 Outboard cooling water hose 25x33 mm
62 50221008 Male hose connection 3/4x25
71 50230061 Nickel plated brass intake strainer 3/4
TOTAL 50230221 WATER INLET KIT 25 mm
AIR VENT KIT 3/4” (20mm) 9,5/12,5/15 ULTRA
no qtt article no description dimensions
44 50221502 Hose clamps 19-29 mm
53 50220056 Outboard cooling water hose 20x28 mm
11 2 50221031 Bend male type with hose connection 1/2x1/2
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” (20 mm)
AIR VENT KIT 1” (25,4 mm) 20 ULTRA
no qtt article no description dimensions
44 50221503 Hose clamps 26 - 38 mm
53 50220050 Outboard cooling water hose 25 x 33 mm
11 2 50221083 Bend male type with hose connection 3/4
12 1 50221043 TEE fittings 3/4
12 1 50221102 Straight reducer 3/4 x 1/2
13 1 50230001 Syphon breaker valve 1/2
11 2 50221008 Male hose connection 3/4 x 25
14 1 50221001 Male hose connection 3/8x13
15 1 50221521 Hose clamps 12-20 mm
16 1,5 50220055 Water hose 12x18,2 mm
TOTAL 50230222 AIR VENT KIT 25 mm

INSTALLATION MATERIALS
18 June 2002 / WHISPER 15/20 ULTRA / USA
EXHAUST KIT 2” (51 mm)
no qtt article no description dimensions
22 5 50221541 Hose clamps HD. 55-62 mm
23 3 50220035 Marine exhaust hose 2”
24 1 50230081 Waterlock 2”
25 1 50230034 Brass through hull fitting 1 1/2 x 70
26 1 50221024 Female hose connector 1 1/2 x 2”
TOTAL 50230213 EXHAUST KIT 2” (51 mm)
OPTIONAL INSTALLATION MATERIALS
no qtt article no description dimensions
21A 1 50230077 Elbow 90 degr adapter exhaust hose 2”
22 2 50221541 Hose clamps H.D. 55-62 mm
WATER SEPERATOR KIT 1 5/8” (40 mm)
no qtt article no description dimensions
21 2 50221506 Hose clamps 44-56 mm
22 2 50221541 Hose clamps H.D. 55-62 mm
23 2,5 50220035 Marine exhaust hose 2”
40 1,5 50220033 Marine exhaust hose 1 5/8”
31 1 50221015 Male hose connection 1 1/4 x 1 5/8”
32 1 50230044 Lever operated ball valve FF 1 1/4
33 1 50230033 Brass through hull fitting 1/1/4
34 1 50230080 Water exhaust fumes seperator 2” - 1 5/8” - 2” (51-40-51)
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
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.
OPTIONAL INSTALLATION MATERIALS
no qtt articleno description dimensions
51 1 50220063 Fuel hose 5/16” (8x16 mm)

BATTERY INSTALLATION KIT 85 Ah 9,5/12,5/15 ULTRA
no qtt articleno description dimensions
51 1 64000850 Battery 85Ah
52 1 43011030 Battery charger
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 switch 250 Amp
58 4 6503001608 Cable connectors M8x16
58 4 6503002508 Cable connectors M8x25
TOTAL 50230216 BATTERY INSTALLATION KIT 85 Ah
BATTERY INSTALLATION KIT 120 Ah 20 ULTRA
no qtt articleno description dimensions
51 1 64001200 Battery 85Ah
52 1 43011000 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 6503003508 Cable connectors M8x35
TOTAL 50230226 BATTERY INSTALLATION KIT 120 Ah
RUBBER MOUNTING KIT 420 kg. 9,5/12,5/15 ULTRA
no qtt articleno description dimensions
64 1 50230015 Fastener kit rubber mountings
61 4 50230551 Rubber mountings M12
TOTAL 50230231 RUBBER MOUNTING KIT 420 kg.
RUBBER MOUNTING KIT 520 kg. 20 ULTRA
no qtt articleno description dimensions
64 1 50230015 Fastener kit rubber mountings
61 4 50230550 Rubber mountings M12
TOTAL 50230232 RUBBER MOUNTING KIT 520 kg.
INSTALLATION MATERIALS
USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 19

INSTALLATIOJ MATERIALS
20 Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA
- Fuel kit
- Battery installation kit
- Mounting kit
included are all fittings to fit rubber fuel
hoses.
Fig. 15.