Mastervolt Whisper 6 User manual

MASTERVOLT
Snijdersbergweg 93
1105 AN Amsterdam
The Netherlands
Tel : [phone]
Fax: [phone]
http://www mastervolt com
INSTALLATION MANUAL
V2 October 2004
WHISPER 6 / 8 / 12
6 ULTRA
-3000 / 1500 RPM-
Marine diesel generating set 230V-50Hz
Digital Diesel Control
Art nr 50200361

2October 2004 / WHISPER 6/8/12 & 6 ULTRA / EN
This manual applies to the Mastervolt Whisper 6/8/12 and 6 ULTRA Marine
Diesel Generating set controlled by Digital Diesel Control first launched in April
2004 For earlier models refer to other manuals available on our website: www
mastervolt com
CONTENTS
1 INSTALLATION 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 Digital Diesel Control system 12 Volt 12
1 4 5 AC power system 230 Volt (120 Volt) 13
2 INSTALLATION SPECIFICATIONS 15
2 1 Installation table 15
2 2 Commission table 16
2 3 Technical data 17
2 4 Specification of the accessories 17
2 5 Installation materials 18
3 DIAGRAMS AND DRAWINGS 22
3 1 DC wiring diagram 22
3 2 Codes and colors 23
3 3 Wiring diagram electronic governor (optional) 24
3 4 AC wiring diagram Whisper 230V 50Hz 25
3 5 Remote panel dimensions 26
3 6 Whisper 6/8/12 and 6 ULTRA dimensions 27
CONTENTS

EN / WHISPER 6/8/12 & 6 ULTRA / October 2004 3
1 INSTALLATION
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 S eel base pla e
However to keep resonant vibrations at a minimum, it is
possible to mount the generating set on a solid steel base
plate, approx 20 mm (3/4") weighing approx 60 kg or
50% of the weight of the generating set The engine
draws its inlet combustion air through several holes in the
capsule base Therefore the capsule must be fitted with
sufficient clearance between the capsule underside and
the base plate For the Whisper 6/8-3000rpm a steel
base plate is available with Mastervolt as an optional
accessory (ref fig 12, page 36)
1.2.2 Fur her recommenda ions
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
1 Avoid mounting the generating set in close proximity
to thin walls or floors as that may resonate
2 Sound 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
3 Never 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 100 cm2is re-
quired
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 40°C reduce the engi-
ne power by 2% for each 5°C of rise To minimise these
effects the engine room temperature must not be more
than 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 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

4October 2004 / WHISPER 6/8/12 & 6 ULTRA / EN
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 70°C If
the cables are required to meet higher temperature requi-
rements, they must be run through conduits
ATTENTION!
Before working (installation) on the system
read the section safety instructions
1.4.1 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 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
EXHAUST (1)
40 mm REMOTE CABLE (2)
12x0,3 mm2
AC CABLE (3)
FUEL RETURN (6)
16 mm2
BATTERY - (7)
8 mm
FUEL IN (4)
8 mm
16 mm2
BATTERY + (5)
AIRVENT IN (10)
19 mm
AIRVENT OUT (9)
WATER IN (8)
19 mm
19 mm
40 mm
40 mm
EXHAUST (1)
EXHAUST (1)
REMOTE CABLE (2)
AC CABLE (3)
12x0,3 mm2
FUEL RETURN (6)
WATER IN (8)
19 mm
8 mm
BATTERY + (5)
25 mm2
8 mm
FUEL IN (4)
AIRVENT OUT (9)
19 mm
BATTERY - (7)
25mm2
19 mm
AIRVENT IN (10)
Afb. 1.
WHISPER 6/8
WHISPER 12/6 ULTRA

EN / WHISPER 6/8/12 & 6 ULTRA / October 2004 5
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 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.
1 Fuel return;
2 Fuel supply;
3 Prefilter / water separator (optional);
5 Fuel tank;
INSTALLATION

6October 2004 / WHISPER 6/8/12 & 6 ULTRA / EN
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
4 FUEL FILTERS
A fine 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.
1 Fuel return;
2 Fuel supply;
3 Prefilter / water separator (optional);
4 Extra fuel lift pump (optional);
5 Fuel tank

EN / WHISPER 6/8/12 & 6 ULTRA / October 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
2 RAW 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") The suction hose should be kept as
short as possible 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. 1 Water level;
2 Water/exhaust separator;
3 Seacock;
4 Waterlock;
5 Air vent;
6 Water strainer;
7 Seacock
Afb. 4a.
INSTALLATION

8October 2004 / WHISPER 6/8/12 & 6 ULTRA / EN
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
3 INSTALLATION 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
4 WATER STRAINER
Use an appropriate water strainer with connections of
19 mm (3/4") Install the water strainer in a well ac-
cessible position, (ref to fig 4 - 6) 15 cm above the
waterline
5 SIPHON 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 19 mm (3/4") 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) The hose of the drain should go downwards
Water must flow out freely; air must flow in freely as
well
Fast motorboats will lay deeper when sailing at large
speed and can cause pressure on the waterinlet This
should be avoided to prevent fleeding the engine
If the air vent is clogged the water hoses
will not be vented when the generating set
has stopped and water can be forced into
the engine This leads to immediate engine
problems and eventually severe damage!
DAMAGE CAUSED BY THE INGRESS OF WATER
INTO THE ENGINE IS NEVER COVERED BY
WARRANTEE.
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
flow direction
sailing direction
WRONG!
thru-vessel inlet
Fig. 5.
Fig. 6.

EN / WHISPER 6/8/12 & 6 ULTRA / October 2004 9
Check the air vent at regular intervals Open, clean
and lubricate the valve as required
1.4.3 Exhaus sys em
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
1 STANDARD 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 40 mm
The exhaust system must be installed so that the
back pressure inside the exhaust does not exceed
0 07 bar (1 psi = 70 cm watercolumn) and total length
from generator to the top of the goose neck or
water/gasseparator does not exceed 3m (10 ft )
(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
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 600 mm (24") 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.
1 Exhaust water lock;
2 Exhaust outlet muffler;
3 Exhaust line Ø 40 mm;
4 Goose neck
5 Through-hull exhaust outlet Ø 40 mm;
6 Water level
INSTALLATION

10 October 2004 / WHISPER 6/8/12 & 6 ULTRA / EN
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 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 3 m)
from the generating set, an exhaust/water separator
must definitely be installed The sea water from the
separator must then run down along the shortest pos-
sible path to the through-hull outlet Only after the
exhaust/water separator the exhaust hose may have
alength of over 7,5 m if the exhaust hose diameter is
also increased from 40 mm to 50 mm in order to re-
duce the back pressure (ref to fig 9)
Hohwever watertraps should be avoided as the
fumes still contains water and this should not
accumulate in bents (Refer to fig 8a) An additional
outlet exhaust muffler close to the hull outlet will help
further to reduce noise emission
water
level
max
150 cm
min
60 cm
40 mm
40 mm
40 mm
A
max 10 cm
Fig. 8.
Fig. 8a.