Mastervolt Whisper 9.5 ultra User manual

USERS MANUAL U.S.A EDITION

WHISPER 9.5/11 ULTRA

- 1800 RPM -

Marine diesel generating set 120/240V / 60Hz

Digital Diesel Control

MASTERVOLT

Snijdersbergweg 93,

1105 AN Amsterdam

The Netherlands

Tel.: +31-20-3422100

Fax.: +31-20-6971006

www.mastervolt.com V3. August 2009

Art.nr. 50200227

TABLE OF CONTENTS

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.............................................................................................................................................................. 4

1.1 General .............................................................................................................................................................. 4

1.2 Service and maintenance................................................................................................................................... 4

1.3 Guarantee .......................................................................................................................................................... 4

1.4 Liability ............................................................................................................................................................... 5

1.5 Identification ....................................................................................................................................................... 6

1.5.1 General.............................................................................................................................................. 6

1.5.2 Identification plate ............................................................................................................................. 6

2INFORMATION................................................................................................................................................................ 7

2.1 Safety ................................................................................................................................................................. 7

2.1.1 General.............................................................................................................................................. 7

2.1.2 Electrical safety ................................................................................................................................. 7

2.1.3 Earth insulation failures ..................................................................................................................... 7

2.1.4 Installation ......................................................................................................................................... 7

2.1.5 Operation........................................................................................................................................... 8

2.1.6 Fire and explosion ............................................................................................................................. 8

2.1.7 Chemicals.......................................................................................................................................... 8

2.2 Transport, lifting and storage.............................................................................................................................. 9

2.3 The Whisper 9.5 / 11 ULTRA ............................................................................................................................. 9

2.3.1 Features ............................................................................................................................................ 9

2.3.2 Remote control .................................................................................................................................. 9

2.3.3 Documentation .................................................................................................................................. 9

2.3.4 Accessories included in the standard delivery...................................................................................9

2.4 Components ..................................................................................................................................................... 10

2.4.1 Main components to identify............................................................................................................ 10

2.4.2 Generator control panel................................................................................................................... 12

2.4.3 Remote control panel ...................................................................................................................... 12

2.5 Technical Information ....................................................................................................................................... 12

2.5.1 AC alternator ................................................................................................................................... 12

2.5.2 Engine ............................................................................................................................................. 12

2.5.3 Digital Diesel Control system........................................................................................................... 12

2.5.4 Battery charger................................................................................................................................ 12

2.5.5 Alarms and shut down ..................................................................................................................... 13

2.5.6 Control............................................................................................................................................. 13

2.5.7 Remote control ................................................................................................................................ 13

2.5.8 Hour counter.................................................................................................................................... 13

2.5.9 Load indicator.................................................................................................................................. 13

2.5.10 Fuel specification............................................................................................................................. 13

2.5.11 Oil information ................................................................................................................................. 13

2.5.12 Cooling liquid................................................................................................................................... 13

2.5.13 Technical data ................................................................................................................................. 14

2.5.14 Wiring codes and colours ................................................................................................................ 15

2.5.15 Lay out control wiring....................................................................................................................... 16

2.5.16 Electrical diagram 120V – 240 V AC / 60 Hz ................................................................................... 18

2.5.17 Diagram electronic governor Whisper 11 ULTRA............................................................................ 19

TABLE OF CONTENTS

3OPERATION.................................................................................................................................................................. 20

3.1 General ............................................................................................................................................................ 20

3.2 Operating Instructions ...................................................................................................................................... 20

3.2.1 Summarised operating instructions (daily use)................................................................................ 20

3.2.2 Extended operating instructions ...................................................................................................... 20

4MAINTENANCE............................................................................................................................................................. 23

4.1 Alternator.......................................................................................................................................................... 23

4.2 Engine .............................................................................................................................................................. 23

4.2.1 Preliminary instructions ................................................................................................................... 23

4.2.2 Bleeding fuel lines ........................................................................................................................... 23

4.2.3 Valve clearance............................................................................................................................... 23

4.2.4 Replacing fuel filter .......................................................................................................................... 23

4.2.5 Replacing oil filter ............................................................................................................................ 23

4.2.6 Readjustment V-beltplacing oil filter ................................................................................................ 24

4.3 Regular maintenance ....................................................................................................................................... 24

4.3.1 Maintenance schedule..................................................................................................................... 25

4.3.2 Putting out of service ....................................................................................................................... 26

5TROUBLE SHOOTING.................................................................................................................................................. 27

5.1 Alternator/ electrical faults ................................................................................................................................ 27

5.1.1 General............................................................................................................................................ 27

5.1.2 Trouble shooting table ..................................................................................................................... 27

5.2 Engine faults..................................................................................................................................................... 28

5.2.1 General............................................................................................................................................ 28

5.2.2 Trouble shooting table ..................................................................................................................... 29

5.2.3 Warnings ......................................................................................................................................... 31

5.2.4 Service address............................................................................................................................... 32

5.3 Special procedures alternator........................................................................................................................... 32

5.3.1 Residual voltage check / excitation procedure (Whisper 9.5 Ultra only) .......................................... 32

5.3.2 Testing rotary rectifier diodes .......................................................................................................... 32

5.3.3 Winding resistant values.................................................................................................................. 32

5.3.4 Meggering ....................................................................................................................................... 32

5.4 Special procedures engine ............................................................................................................................... 33

5.4.1 Setting the RPM .............................................................................................................................. 33

5.4.2 Adjusting valve clearance and retightening the cylinder head bolts. ............................................... 33

5.4.3 Measuring exhaust backpressure.................................................................................................... 34

5.4.4 Disassembling instructions .............................................................................................................. 35

6SPARE PARTS LIST..................................................................................................................................................... 36

MAINTENANCE LOG ............................................................................................................................................................... 38

INTRODUCTION

1 INTRODUCTION

1.1 GENERAL

The Whisper 9.5/11 ULTRA Marine Diesel Generating set

is manufactured and marketed by Mastervolt.

It is important to read this manual before installing and

operating the generating set. Both safety and durability

rely very much on the correct identification, installation and

a good understanding of ratings, features, design,

maintenance and operation procedures. The information,

specifications, illustrations and statements contained

within this publication are given with our best intentions

and are believed to be correct at the time of going to

press.

All of the specifications, provisions and instructions

contained in this manual apply solely to standard versions

of the Mastervolt Whisper 9.5/11 ULTRA generating set.

This manual is valid for the following models:

Part

number Description

51106055 Whisper 9.5 Ultra 120/240V 1800RPM

51106056 Whisper 9.5 Ultra 120/240V 1800RPM -

ungrounded

51189055 Whisper 11 Ultra 120/240V 1800RPM

51189056 Whisper 11 Ultra 120/240V 1800RPM -

ungrounded

For other models see other manuals available on our

website: www.mastervolt.com

Our policy is one of continued development and we re-

serve the right to amend any technical information without

prior notice.

Whilst every effort is made to ensure the accuracy of the

particulars contained within this publication neither the

manufacturer, distributor, or dealer in any circumstances

shall be held liable for any inaccuracy or the

consequences thereof.

Keep this manual at a secure place!

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.

1.2 SERVICE AND MAINTENANCE

Regular service and maintenance should be carried out

according to the directions in this manual. For service and

maintenance one can appeal to the manufacturer or the

dealers.

1.3 GUARANTEE

Mastervolt guarantees that this generating set has been

built according to good workmanship, according to the

specifications in this manual and according to European

Community safety regulations.

During production and prior to delivery, all of our

generating sets are tested and inspected.

The well functioning of this generating set is subject to

guarantee. The period and conditions of this guarantee are

laid down in the general conditions of delivery as

registered with the Chamber of Commerce and Industries

in Amsterdam number 33279951 and are available on

request. The guarantee period is two years, limited to

1000 running hours. For USA deliveries there are

additional conditions. These are available at Mastervolt

USA. Some aspects of our guarantee scheme are given

here in more detail:

Guarantee does not cover failures that are caused by

misuse, neglect or a faulty installation.

Example 1. Faulty installation:

Seawater entering the engine is the most common cause

of damage to combustion engines in boats (both to

propulsion and generator engines). The entry of water

must be avoided under all conditions. Be aware that the

conditions in blue water sailing can be extreme. Refer to

the installation manual for instructions but remember these

are for guidance only as many factors influence the

installation of a generator. The ultimate responsibility will

always be with the owner to ensure a safe and compliant

installation. If in doubt ask!

INTRODUCTION

DAMAGE CAUSED BY THE INGRESS OF

WATER IS NEVER COVERED BY

GUARANTEE

Example 2: Misuse:

Long term running with no load or too little load can cause

the exhaust to get choked with soot or carbon. Cleaning

the exhaust is not covered by guarantee.

Example 3: Neglect

Sometimes the seal of the raw water pump starts leaking.

Mostly this begins with a little drip and slowly gets worse.

Regular visual inspection of the generator is necessary to

prevent damage to occur from a leaking water pump.

When one find serious damage after weeks of neglect

guarantee claims will not be honoured.

Example 4: Neglect

Whisper generators have an option for an auto start/stop

mode or interval mode.

Mastervolt cannot be held responsible for damage caused

by the unattended running generator.

Guarantee means that faulty parts are repaired or

replaced free of charge. If necessary the whole generator

unit will be exchanged. Labour necessary to complete

repairs on board a vessel executed by an authorized

service engineer is covered, but is limited to a reasonable

number of hours and reasonable rates in relation to the

actual repair work that has to be done.

Travel expenses and travel hours are not covered. Also

not covered is the labour required to take a generator out

of a boat or for reinstallation. There is no cover for labour

needed to get access to the generator, for example to

remove equipment or bulkheads etc. For details refer to

Mastervolt U.S.A.

Goods to be delivered under guarantee will be invoiced.

Only after the faulty goods are returned will the invoice be

credited. Payment in advance may be required or

guaranteed by credit card. If after the faulty goods are

returned, it is indicated that the failure was not covered by

guarantee a credit will not be issued. For example if a

Printed Circuit Board is returned with clear damage

caused by seawater, guarantee will be refused.

Freight costs to deliver spares by normal mail or carriers is

covered under guarantee. Special services like express

mail, overnight delivery etc. are not covered. Taxes and

duties are not covered. For shipments to remote off shore

areas any additional costs incurred over normal carriage

will be invoiced to the customer.

The cost for returning faulty goods is not covered under

guarantee.

Additional agreements could be part of the contract of

delivery.

If any problem arises which could be subject of guarantee,

procedures should be followed as described in the

guarantee conditions, unauthorised repairs could lead to

further damage and violate the guarantee conditions.

Should work take place, which is not in

accordance with the guidelines, instructions

and specifications contained in this user’s

manual and the supplementary installation

manual, then damage may occur and the

generating set may not fulfil its specifications.

In all these cases the guarantee may become

invalid. Use original spareparts only!

1.4 LIABILITY

Mastervolt does not accept responsibility for damage,

injuries or casualties which are the result of operation of

the generating set in specific conditions which brings

dangers which could not be foreseen, or could be avoided

by additional measures. Mastervolt does not accept

liability for damage due to use of the generator, possible

errors in the manuals and the results thereof.

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.

INTRODUCTION

1.5 IDENTIFICATION

1.5.1 General

Before using this generating set it is very important to

identify the set correctly. To communicate for service or

ordering parts it is also essential to correctly identify the

generating set. Also for the daily operation of the genera-

ting set it is necessary that the operator knows the correct

specifications.

1.5.2 Identification plate

All required identification data are on the identification

plate. For location of the identification plate see figure 1

Fig. 1: Location identification plate.

1 The identity of the generating set is given by the

SERIAL NUMBER.

Example:

When this number is available the manufacturer can

trace the specifications of the generating set. On the

identification plate are also some basic features of the

set:

2 POWER

The identification plate gives the nominal maximum

continues load in kVA (= kW) calculated with power

factor one. When calculating a load one should

always take into account the power factor or cos phi

of this load. The power should never exceed the

nominal power as shown on the identification plate.

Power is rated at an ambient temperature of 104°F

(40°C) and a seawater temperature of 77°F (25ºC).

For higher temperatures the generating set has to be

derated.

3 VOLTAGE shows the nominal voltage.

This voltage should be within the specified tolerance

at the nominal frequency.

4 FREQUENCY is shown in Hz and is determined by

the speed of the engine (RPM). 60 Hz correlates with

1800 RPM.

5 CURRENT shows the maximum current that is

acceptable at the specified frequency, voltage and

power factor.

6 WEIGHT shows the net dry weight (approximately) in

kg. This is without fuel, oil, packing and external

installation equipment

7 CE-marking: the “CE” symbol shows that the

generating set is build according to European

Community safety regulations. This includes the

regulations regarding the safety of pleasure craft,

safety of machinery, electric safety and electric

magnetic compatibility (EMC) and other relevant

directives.

Safety also relies on the installation, application and

circumstances. See also the remarks in this manual under

SAFETY

Before changing a factory setting you are advised to

consult the manufacturer. When the generating set you

have to identify is not new you have to take into account

the possibility that former users may have changed the

settings. Check the settings (voltage, frequency, rpm)

when there is any doubt.

SERIAL NO: : WO22A001

version “A”

INFORMATION

2 INFORMATION

2.1 SAFETY

2.1.1 General

When correctly installed and used in normal

circumstances this generating set fulfils EC safety

regulations. This generating set could be part of an

installation or could be used in a way that additional

regulations of the EC or other authorities have to be taken

into account.

Circumstances could make it also necessary

to take additional measures. Be aware of wet

conditions and hazardous environments

caused by explosive gases etc

2.1.2 Electrical safety

The voltage of 120/240 Volt generated by this

generating set is dangerous and if instructions

and procedures are not strictly observed may

result in electrical shock which will result in

severe personal injury or loss of life.

•Check all wiring at least once a year. Defects,

such as loose connections, burned cables etc.

must be repaired immediately.

•Do not work on the electrical system if it is still

connected to a current source. Only allow

changes in your electrical system to be carried

out by qualified electricians.

•Connection and protection must be done in

accordance with local standards.

•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.

Warning signs indicate parts which could be

live.

2.1.3 Earth insulation failures

According to local regulations and depending on the

application it could be necessary to take measures for

protection against earth insulation failures.

With the USA versions “neutral” and “ground” are

connected with each other on the alternator. This requires

an insulation protection device as commonly used in the

U.S.A. This installation is beyond the influence of

Mastervolt and Mastervolt cannot be held responsible for

any consequence as a result of the installation.

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 Mass Systemswitch.

2.1.4 Installation

Whisper generating sets are not self contained and have

to be properly installed in enclosed areas such as a

machine room.

Installation includes measures to be taken to

outlet exhaust fumes which contain carbon

monoxide and are extremely dangerous.

Carbon monoxide (CO) is an invisible odourless gas.

Inhalation produces headache, nausea or death.

Installation includes measures for proper ventilation, safe

electric connections, safe installation of the starting

battery, proper fitting of the cooling system and fuel pipes

etc. Refer to the installation manual.

INFORMATION

2.1.5 Operation

External moving parts like fans and V-belts are covered by

the soundshield and therefore the Whisper 9.5 / 11 ULTRA

is very safe when the soundshield is closed.

Nevertheless take note of the signs on the

generating set which show symbols in a

triangle indicating danger.

When service has to be carried out while the

engine is running, be aware of moving parts

like V-belts.

•The generating set should be operated by

authorised personnel only.

•Be aware of hot parts and especially parts of the

exhaust system and the cooling system.

•If the generating set is unsafe, fit danger notices

and disconnect the battery positive (+) lead so

that it cannot be started until the condition is

corrected.

•Do not attempt to operate the generating set with

a known unsafe condition. Disconnect the battery

positive (+) lead prior to attempting any repairs or

cleaning inside the enclosure.

•Always consult the manual before carrying out

maintenance.

•Do not change the settings without consulting the

manufacturer. Keep a record of setting changes

in this manual.

2.1.6 Fire and explosion

Fuels can be flammable. Proper handling

limits the risk of fire and explosion.

•Avoid refilling the fuel tank while the engine is

running. When oil or fuel is leaking do not use the

generating set.

•Do not run the engine close to explosives or

gasses.

•Hydrogen gas generated by charging batteries is

explosive. Ensure for proper ventilation. Do not

smoke or allow sparks, flames, or other sources

of ignition around batteries.

•Keep a fire extinguisher on hand.

INCASEOFFIRE, DONOTOPENSOUNDSHIELD.

TOAVOID SERIOUS INJURY OR DEATH FROM FIRE

IMMEDIATELY DISCHARGE ENTIRE CONTENTS OF GASEOUS

SHUT DOWN ENGINES, GENERATOR SETS AND BLOWERS.

PORTABLE FIRE EXTINGUISHER THROUGH THIS PORT.

THROUGH

HERE

FIRE EXTINGUISHER PORT :

BREAK

Fig. 2: Fire extinguisher port.

•In case of fire do not open the soundshield. To

avoid serious injury or death from fire, shut down

engines, generator sets and blowers. Break

through the label which is indicated by BREAK

THROUGH HERE and then immediately

discharge entire contents of gaseous portable fire

extinguisher through the fire extinguisher port. On

the generating set this fire extinguisher port is

indicated by the label as shown in figure 2.

•Poor electrical connections or using wiring which

is not suited for the rated currents can cause

overheating and possibly fire.

2.1.7 Chemicals

•Fuels, oils, coolants, and battery electrolyte can

be hazardous to personnel if not treated properly.

Do not swallow or have skin contact with these

liquids. Do not wear clothing that has been

contaminated by fuel or lubricating oil.

•Gaskets may be manufactured from asbestos.

Particles of this material should not be inhaled as

this may result in fatal diseases.

•On no account allow any unprotected skin to

come into contact with the injector spray as the

fuel may enter the blood stream with fatal results.

•Engines may be fitted with seals or O-rings

manufactured from "viton" or similar material.

When exposed to abnormal high temperatures in

excess of 750°F (400°C) an extremely corrosive

acid is produced which cannot be removed from

INFORMATION

the skin. If signs of decomposition are evident, or

if in doubt, always wear disposable heavy duty

gloves.

2.2 TRANSPORT, LIFTING AND STORAGE

When lifting the generating set avoid any risk

of personal injuries, do not stand under the

generating set.

•Use soft slings to avoid damage

•On the engine are two hoist eyes which can be

used to take the generator out of the capsule.

They can also be used to lift the complete

generating set including the capsule.

•After transporting the generating set check for

damage before installation.

•Long term storage can have detrimental effects

on engine and alternator. The engine should be

put through an engine preservation procedure.

(Refer to the maintenance chapter)

•The alternator windings tend to condense. To

minimise condensation, store the generating set

in a dry and warm storage area.

•After removing the generating set from long term

storage perform an insulation check. (Refer to the

alternator maintenance paragraph for

procedures)

•While the battery is stored it should be recharged

every 12 weeks.

2.3 THE WHISPER 9.5 / 11 ULTRA

2.3.1 Features

This generating set includes a diesel engine which is

connected by close coupling to an alternator in a sound

attenuated capsule. The set is mounted on a steel base

frame and mounted securely on anti vibration mounting

pads to the capsule base. All cables and hoses are guided

through the capsule’s sides. The set is not self contained

and is only operable after proper installation using

additional accessories and installation materials.

Installation accessories are listed in the installation manual

and are available through the supplier of the generating

set. The full automatic Digital Control is based on

microprocessor technology. Several automatic start/stop

functions can be programmed and monitored (refer to

Digital Diesel Control users manual).

2.3.2 Remote control

The full automatic remote control panel including 15 mtr

cable comes as standard with the Whisper generating set.

2.3.3 Documentation

Included in the delivery is:

•This users manual (number: 50200227)

•An installation manual (number: 50200237)

•A users manual for DCC (number: 50200261).

•A quick reference guide for DDC (number

50200275)

Not included in the standard delivery but available as

options are:

•Parts manual; number: 50200185

•Workshop manual; number: 50200172

However in this manual there is a list of important parts for

maintenance and spare parts as well as a chapter on

maintenance and problem solving.

2.3.4 Accessories included in the standard

delivery

•Expansion tank, hose and fittings

•Special hose connector for measuring exhaust

back pressure (refer to paragraph 5.4.3)

INFORMATION

2.4 COMPONENTS

2.4.1 Main components to identify

Fig. 3 Front View main components Whisper 9.5 Ultra and 11 Ultra

Fig. 4: Rear view main components Whisper 9.5 Ultra and 11 Ultra.

01 Temperature switch

exhaust

02 Cooling water injection

bend

03 Exhaust manifold (water-

cooled)

04 Starter motor solenoid

05 Heat exchanger

05a Starter motor

06 Alternator (12VDC)

07 Rubber engine mounting

08 Bypass cooling water in

09 Expansion tank

10 Bypass cooling water out

11 Exhaust hose Ø51mm

12 Remote control

13 AC power output

14 Power take off (PTO)

15 Injection pump air

bleeding screw

16 Hoist eye front

17 Fuel injection pump

18 Engine speed adjusting

screw

19 Fuel solenoid (Whisper

9.5 Ultra)

20 Electronic governor

(Whisper 11 Ultra)

21 Fuel filter

22 Engine oil filter

23 Fuel lift pump

24 Oil sump hand pump

INFORMATION

Fig. 5: Rear view main components Whisper 9.5 Ultra and 11 Ultra

Fig. 6: Top View main components Whisper 9.5 Ultra and 11 Ultra

25 Digital Diesel Control

(DDC)

26 Control panel

26a Identification plate

27 Fuses

27a Air cleaner element

28 Fuel injector (3x)

29 Glow plug (3x)

30 V-belt

31 Engine coolant pump

32 Raw water pump

33 Engine serial number

34 Filler cap engine oil

35 Battery -

36 Battery +

37 Raw water inlet

38 Fuel in

39 Fuel out

40 Coolant drain plug

41 Engine oil pressure switch

42 Engine oil dipstick

43 Hoist eye rear

44 Filler cap engine coolant

45 Rocker cover

46 Filler cap engine oil

47 Temperature switch

48 Thermostat housing

49 Failsafe

50 Rubber engine mounting

INFORMATION

2.4.2 Generator control panel

Start / Stop

Remove fuse

Internal fuel pump

Fuse 3A

before maintenance

Digital Diesel Control

Fuse 3A

Auxiliary

Fuse 10A External Fuel Pump

Fuse 3A

Observe instructions in the manual

Replace fuseswith same type and rating

Whisper Digital Diesel OperationUnit

Fig: 9 Control panel.

Fig. 10 Digital Diesel Control unit

Fig. 11: Digital Diesel remote control panel

2.4.3 Remote control panel

1 Start button;

2 Stop button;

3 Select button;

4 Set button;

5 Failure lamp;

6 Generator load indicator.

7 Display

2.5 TECHNICAL INFORMATION

2.5.1 AC alternator

The single phase alternator is directly coupled, one

bearing, brushless, rotating field design, four poles (1800

RPM) and self regulating.

Residual magnetism causes a small voltage over the

stator windings and allows a current to flow in the

windings, which is magnified because of the feed back

effect between rotor and stator. The field windings in the

rotor are short-circuited over a diode to rectify the current.

A capacitor over an additional winding in the stator which

is at an angle with the power-winding keeps the voltage

stable within 5 % at the specified rpm and provides voltage

fall off with speed, preventing over-excitation at low engine

speeds and softening the effect of load switching to relieve

the burden on the engine.

Further technical data on the design of the alternator can

be found in drawings and diagrams in this manual.

2.5.2 Engine

The Whisper 9.5 / 11 ULTRA generating set is based on

the Mitsubishi S3L2 3 cylinder diesel engine. The engine is

indirectly injected. The engine is water cooled and the

cooling liquid is cooled by a heat exchanger and raw

water. The heat exchanger and all other parts which are in

direct contact with the raw (sea) water are made of

seawater resistant material like naval brass and gunmetal.

The engine has been specially adapted for the Mastervolt

application and is very different from the standard engine

supplied for industrial applications!

The engine fulfills EPA emission standards and is certified

and labelled as such..

2.5.3 Digital Diesel Control system

The standard electrical engine control system is 12 Volt

negative earth, non earth return (ungrounded) is available

as optional. Check your identification data to determine

which system is applied. The system is designed

according to the "energise to run" system. The Digital

Diesel Control is a very advanced microprocessor based

full automatic system. Besides automatic start the system

offers many monitoring options. Refer to the separate

Digital Diesel Control users manual.

The microprocessor unit is located in the black box on top

of the alternator

2.5.4 Battery charger

On the engine is an alternator generating 50 Amp 12V.

This current is rectified to charge the battery. The voltage

is regulated at ±14.4V.

1 26 5

347

INFORMATION

2.5.5 Alarms and shut down

In the event of malfunctioning this will be indicated by the

failure light, details will be shown on the display and the

engine will be shut down. There are three functions

guarded: oil pressure, oil temperature and exhaust

temperature.

Exhaust temperature too high indicates the cooling water

to be blocked.

All alarm switches are closed when no malfunction occur.

A contact is cut in the event of an alarm. This means that

the generating set will not work when the alarm switches

are broken or there is a loose wire. The system therefore

is intrinsically safe. The panel will display details about the

alarm.

2.5.6 Control

The generating set can be operated by push buttons on

the panel on the alternator or by the remote control. By

pushing the START button the control system is activated

and will start the engine automatically. Pushing the STOP

button will stop the engine and the electrical system will be

deactivated.

2.5.7 Remote control

All wiring connections from the remote control to the board

are made by plug in connectors.

An intermediate communication cable is in the standard

supply. If necessary an optional longer 8 wire

communication cable can be connected if the standard

length does not suit the required distance. Numerous

remote control units can be put in parallel by using the

connectors on the back of the units. (Refer to installation

instructions)

2.5.8 Hour counter

The remote control offers several timer functions that

helps to schedule maintenance.

2.5.9 Load indicator

On the remote control the load will be indicated on the

display and by the LED-bar. The load is measured by a

current transformer on the alternator.

2.5.10 Fuel specification

The engine must only be used with diesel fuel oil which

conforms to the standards for use in modern diesel

engines. Fuel free from water and contaminants is of the

utmost importance.

2.5.11 Oil information

1 Specification:

The oil must be suitable for oil changes as specified in

the maintenance chapter. The Mitsubishi engine must

be run on heavy duty lubricating oil meeting the

requirements of API class CC, CD, CF or CF_4.

It is very important to use the correct oil

specification. Very often local oil suppliers

recommend a higher class, because they

assume that a higher class is allowed. This is

not the case. One should not follow these

recommendations.

Using the wrong specification will cause high

oil consumption.

2 Oil viscosity:

We recommend a multigrade oil 15W40.

3 Oil capacity:

Excluding the oil filter the content of the crankcase is

3.9 U.S.qts (3.7 l). Including the oil filter it is 4.4

U.S.qts (4.2 l). Note that the engine may contain

some residual oil due to testing at the factory.

While filling, check the lubricating oil level by means

of the engine oil dipstick. Do not overfill with

lubricating oil as this may have a detrimental effect on

engine performance

4 Oil pressure

•Minimum at idle 98kPa (1 kgf/cm² - 14psi) (1 bar).

•Normal at 1800 RPM ±350kPa (3.5 kgf/cm² - 50

psi) (3.5 bar).

2.5.12 Cooling liquid

The engine is cooled by cooling liquid. The capacity of this

system of the Whisper 9.5 / 11 ULTRA is 3,7 US qts. (3.5

litres).

Always use coolant which is compatible with

aluminum components of the cooling system.

Do not mix coolants with different kinds of

chemical compound, as this may cause

congelation of the coolant. In case of doubt

refresh the content of the entire cooling

system.

We recommend not using water but cooling liquid that is

marketed for the use in combustion engines. Cooling liquid

protects the engine against frost to minus 13 °F (minus

25°C). Also it protects the engine block against corrosion.

One can fill the engine via the filling cap on the exhaust

manifold. Fill up till the level is just below the filling cap.

INFORMATION

When the engine is on temperature the liquid will expand

and the redundant liquid will be pressed into the expansion

tank. This tank has to be filled up till the mark. When

cooling liquid is not available clean fresh water could be

used with an additive of anti freeze. When using water with

anti freeze the right mixture has to be calculated according

to the information of the supplier of the anti freeze. When

the cooling is based on keel cooling or radiator cooling the

capacity of these coolers and piping has to be taken into

account calculating the right mixture.

The cooling liquid in the engine is pressurised and has a

boiling point above 212°F (100°C). The temperature

switch in the thermostat housing switches at 230°F

(110°C). When keel cooling or radiator cooling is applied

the cooling system is not pressurised. There should be a

special cap on the manifold without valves leaving the

connection to the expansion tank open. Refer to the

manual on keel cooling and radiator cooling.

2.5.13 Technical data

GENERAL

Model WHISPER 9.5ULTRA WHISPER 11 ULTRA

RPM 1800 1800

Alternator water cooled, synchronous water cooled, synchronous

Engine Mitsubishi diesel, model S3L2 (Japan) Mitsubishi diesel, model S3L2 (Japan)

Number of cylinders 3 3

Displacement 80.4 cubic inches (1318 cm3) 80.4 cubic inches (1318 cm3)

Bore X stroke 3.07 x 3.62 inches (78x92 mm) 3.07 x 3.62 inches (78x92 mm)

Combustion air consumption 46 cf/m (1.3 m³/min.) 46 cf/m (1.3 m³/min.)

Continuous power engine 9.5 kW 11 kW

Cooling system indirect cooling by raw water, 4.8 – 6 US gpmin (18-22 l/min.)

Cooling water pump PTO driven Mastervolt self priming impeller pump, type M12

Fuel lift pump engine electric pump (12 V DC), additional pump available upon request

Starting battery (optional) 70 Ah 12V 70 Ah 12V

Fuel consumption 0.53 – 1.2 US gph 2-4.5 litre/hour, load dependent

Control Digital Diesel Control including automatic start/stop

ELECTRICAL SPECIFICATIONS

Model WHISPER 9.5ULTRA WHISPER 11 ULTRA

Output voltage 120V/240V 60 Hz alternating current (AC) single phase – dual voltage

Output rating at power factor cos phi = 1 9.5 kVA = 9.5kW 11 kVA = 11kW

Voltage tolerance ± 5% ± 5%

Frequency tolerance ± 5% ± 1%

Alternator Brushless, four pole, synchronous Brushless, four pole, synchronous

Voltage regulation: Capacitor Capacitor

MECHANICAL SPECIFICATIONS

Supply includes Sound shield with steel base, mounted on rubber anti vibration mounts. (Generator

set without sound shield is optional)

Dimensions hxwxd 25.0 x 35.4 x 22.6 inch (640 x 900 x 575 mm)

Colour Metallic silver / grey

Weight 340 kg including sound shield

Max. installation angle 25 degrees

Standard supplies Digital remote panel (approx.45 feet / 15m cable), fuel filter, fuel lift pump, user and

installation manuals

Optional: Installation kits, mobile (vehicle) version, non earth return (ungrounded), spare part

kits, PTO to drive a hydraulic pump

INFORMATION

2.5.14 Wiring codes and colours

number colour AWG cross section

battery > starter motor red 2 25 mm2

starter motor > DDC 1 red 10 6 mm2

starter motor > LCP 13 red 14 2,5 mm2

battery > ground black 2 25 mm2

ground > LCP ground (GND) 2 black 12 4 mm2

DDC > glow plug 3 brown 12 4 mm2

DDC > starter solenoid 4 yellow 14 2,5 mm2

LCP > fuel lift pump + 5 grey 16 1,5 mm2

LCP > fuel lift pump – 15 black 16 1,5 mm2

DDC > LCD 5 grey 16 1,5 mm2

DDC > oil pressure switch 6 purple 17 1 mm2

LCP > oil pressure switch 6 purple/black 17 1 mm2

DDC > water temperature switch 7 blue 17 1 mm2

LCP > water temperature switch 7 blue/black 17 1 mm2

DDC > exhaust temperature switch 8 blue/green 17 1 mm2

DDC > fuel solenoid (hold) 9 green 16 1,5 mm2

DDC > fuel solenoid (pull) 20 pink 16 1,5 mm2

DDC > fuel solenoid (com.) 17 black 16 1,5 mm2

B+ terminal alternator > starter motor 21 red 10 6 mm2

DDC >R terminal alternator 18 white 16 1,5 mm2

DDC > L terminal alternator 19 orange 16 1,5 mm2

DDC > current measuring transformer 11 black 17 1 mm2

DDC > current measuring transformer 11 red 17 1 mm2

DDC > current measuring transformer 22 black 17 1 mm2

DDC > current measuring transformer 22 red 17 1 mm2

DDC > LCP 12 black 16 1,5 mm2

DDC > LCP 14 red 16 1,5 mm2

DDC > LCP 16 red/green 16 1,5 mm2

DDC > generator AC output 33 brown 17 1 mm2

DDC > generator AC output 33 blue 17 1 mm2

DDC > generator AC output 44 brown 17 1 mm2

DDC > generator AC output 44 blue 17 1 mm2

DDC=Digital Diesel Control Unit

LCP=Local Control Panel

INFORMATION

2.5.15 Lay out control wiring

Fig 12a: Electrical Diagram control wiring Whisper 9.5 Ultra

INFORMATION

Fig 12b: Electrical Diagram control wiring Whisper 11 Ultra

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