Mastervolt whisper 6, whisper 10 Installation Manual

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INSTALLATION MANUAL FOR MOBILE APPLICATIONS

WHISPER 6 /10

- 3000 RPM -

Mobile diesel generating set 230V / 50Hz

Digital Diesel Control

MASTERVOLT Snijdersbergweg 93, 1105 AN Amsterdam The Netherlands Tel.: +31-20-3422100 Fax.: +31-20-6971006 www.mastervolt.com

V5 August 2009

Art.nr. 50261121

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TABLE OF CONTENTS

Copyright © 2009 Mastervolt. All rights reserved. Reproduction, transfer, distribution or storage of part or all of the contents in this d ocument in an y form wit hout the prior written permission of Mastervolt is prohibited.

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TABLE OF CONTENTS

TABLE OF CONTENTS:

INTRODUCTION..............................................................................................................................................................4

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

1.2 Generating sets for vehicles............................................................................................................................... 4

1.2.1 Marine and mobile generators...........................................................................................................4

1.2.2 Why two radiators:............................................................................................................................. 5

1.2.3 Why the alternator should be cooled by water...................................................................................5

2 INSTALLATION............................................................................................................................................................... 6

2.1 General .............................................................................................................................................................. 6

2.2 Location..............................................................................................................................................................6

2.3 Instructions for optimal sound and vibration insulation....................................................................................... 7

2.3.1 Further recommendations .................................................................................................................7

2.4 Ventilation........................................................................................................................................................... 7

2.4.1 General..............................................................................................................................................7

2.4.2 Air strainer element ........................................................................................................................... 8

2.5 Connections .......................................................................................................................................................8

2.5.1 Fuel supply...................................................................................................................................... 10

2.5.2 Radiator cooling ..............................................................................................................................12

2.5.3 Dry exhaust system.........................................................................................................................16

2.5.4 Electrical installation (12 Volt) ......................................................................................................... 18

2.5.5 AC power system (230 Volt)............................................................................................................21

3 INSTALLATION SPECIFICATIONS.............................................................................................................................. 22

3.1 General ............................................................................................................................................................ 22

3.2 Commission table............................................................................................................................................. 22

3.3 Technical data..................................................................................................................................................23

3.4 Installation materials.........................................................................................................................................24

4 DIAGRAMS & DRAWINGS ........................................................................................................................................... 29

4.1 Layout generator control with 230VAC fan....................................................................................................... 29

4.2 Layout generator control with 12VDC fan......................................................................................................... 30

4.3 Layout generator control with 24VDC fan......................................................................................................... 31

4.4 Wiring colours................................................................................................................................................... 32

4.5 AC wiring diagram 230V / 50Hz .......................................................................................................................33

4.6 Electrical diagram radiator fan control 230VAC................................................................................................34

4.7 Electrical diagram radiator fan control 12 / 24 VDC.......................................................................................... 35

4.8 Wiring diagram electronic governor.................................................................................................................. 36

4.9 Remote control panel drawings........................................................................................................................ 37

4.10 Dimensions....................................................................................................................................................... 38

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INTRODUCTION

1 INTRODUCTION

1.1 GENERAL

This installation manual applies to the installation of the Mastervolt Whisper 6 / 10 -3000RPM mobile diesel generating set, first launched in August 2008. This manual is valid for the following models:

Part number Description

51102020 Whisper 6, 230V 3000rpm

Mobile / keel cooling

51102026 Whisper 6, 230V 3000rpm

Mobile / keel cooling -ungrounded

51104020 Whisper 10, 230V 3000rpm

Mobile / keel cooling

51104026 Whisper 10, 230V 3000rpm

Mobile / keel cooling -ungrounded

For other models see our website: www.mastervolt.com

WARNING

A warning symbol draws attention to special warnings, instructions or procedures which, if not strictly observed, may result in damage or destruction of equipment, severe personal injury or loss of life.

DANGER

This danger symbol refers to electric danger and draws attention to special warnings, instructions or procedures which, if not strictly observed, may result in electrical shock which will result in severe personal injury or loss of life.

WARNING! Before working (installation) on the system read the section safety instructions in the user’s manual

1.2 GENERATING SETS FOR VEHICLES

1.2.1 Marine and mobile generators

Whisper Generators originate from the marine sector. But there are also specially designed Whispers available for mobile applications, suitable for supplying power on board of vehicles to use professional apparatus and equipment, strong lightning and air conditioning etc. The cooling system and exhaust system on vehicles is completely different from standard marine systems. Standard marine generators are cooled by seawater that nowhere exceeds 30° Celsius and is seldom warmer than 20° Celsius in the northern territories. Cold seawater is pumped through the alternator, through the heat exchanger and is injected in the exhaust. The exhaust gasses are therefore cooled and rubber exhaust hose can be used.

On vehicles the engine and alternator are individually cooled by radiator with an electric (12V/24V or 230V) driven fan. The radiators can be fitted below, on top or in the side of the vehicle.

The exhaust is of the dry type and includes a stainless flexible bellow and high quality mufflers.

Never use rubber exhaust hose, neither fibreglass nor plastic exhaust parts in a dry exhaust system as applied on vehicles.

Figure 1: Typical vehicle application radiator side mounted

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INTRODUCTION

Figure 2: Typical vehicle application radiator top mounted

Figure 3: Typical vehicle application radiator bottom mounted

1.2.2 Why two radiators:

The optimum engine operating temperature is between 87° and 92° Celsius. The radiator reduces the temperature of the cooling liquid by only 5°C to 12°C. The returning “cold” coolant therefore has a minimum temperature of approx. 75° Celsius. The alternator should be kept as cool as possible. In practice an alternator starts getting less efficient above 40° Celsius. It is hardly possible to cool down the cool ant of the alternator below 40° by using a radiator. When a vehicle is in the sun on a parking place the ambient temperature itself could be 40° Celsius. Because of the divergence in the working temperature of engine and alternator it will be clear that it is not possible to combine the cooling of the engine and alt ernator in one radiator system. Furthermore it will be clear that it is very difficult to cool an alternator optimally with the aid of a radiator in conditions with high ambient temperatures.

1.2.3 Why the alternator should be cooled by water

For normal industrial use alternators are cooled by air. This requires a flow of air through the alternator of many m3 per minute. With the air, the noise comes out into the open. Generators on vehicles can only made silent by full enclosure in a sound shield canopy. The o nly opening in the Whisper canopy is the inlet for combustion air. For that reason the alternator is cooled by water. Although coolin g the alternator by circulating water through a radiator is not ideal; it is much better than by air. Therefore aircooled alternators are rarely used in vehicles

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INSTALLATION

2 INSTALLATION

Figure 4: Schematic installation diagram

2.1 GENERAL

To ensure reliability and durability of the equi pment, it is very important that the installation is carried out with the utmost care and attention. To avoid problems, such as temperature problems, noise levels, vibration, etc. the instructions set out in this manual must be followed and all installation work must be carried out professionally.

2.2 LOCATION

When looking for a proper place for a generator in a vehicle all relevant aspects have to be taken into account

• Accessibility

• Solid foundation

• Space to mount the radiator (Refer to par. 2.5.2)

• Space to mount the exhaust (Refer to par. 2.5.3)

• A way to fit the fuel lines

Since Whisper generating sets have extremely compact dimensions, they can be installed in tight locations. Please consider that even almost maintenance-free machinery must still remain accessible. When selecting the location area in which to mount the generating set, make sure there is sufficient room to carry out any maintenance work. The unit must be easily accessible on the service side and on the distribution si de to have access to the V-belt All models can be serviced from one side. Oil filling can b e done on the service side and on the top. Cooling liquid can be filled via the expansion tanks. The top of the engine (rocker cover) has to be accessible for adjustment of the valve clearance.

Please also note that in spite of the automatic oil pressure sensor it is still essential that the oil level is checked regularly.

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INSTALLATION

2.3 INSTRUCTIONS FOR OPTIMAL SOUND AND VIBRATION INSULATION

Position the generating set as low as possible in the vehicle. The generating set is secured to the base frame by means of flexible engine mountings. This frame is mounted in the vehicle with additional vibration dampers. When it is possible to mount the unit directly on the chassis of the vehicle this has advantages in preventing vibrations by resonance.

2.3.1 Further recommendations

Whisper generating sets are standard equipped with a sound cover. This sound cover has been designed to give effective sound insulation. For optimum sound and vibration dampening, the following factors should be considered.

1 Most important is the structure on which the generator

is placed to be stiff. Directly below the rubber mountings the structure should be supported vertically to the chassis of the vehicle.

2 In larger vehicles a separate and insulated space for

the generator will help to damp the noise even further

3 Avoid mounting the generating set in close proximity

to thin walls or floors that may cause resonance.

4 Sound dampening is extremel y poor if the generating

set is mounted on a light weight flimsy surface such as plywood which will only amplify vibrations. If mounting on a thinner surface cannot be avoided, this should be at least be reinforced with stiffening struts or ribbing. If possible, holes should be drilled or cut through the surface to help reduce the resonance. Covering the surrounding walls and floors with a heavy coating plus foam will certainly improve the situation.

5 Never connect the base of the generating set directly

to walls or tanks.

2.4 VENTILATION

2.4.1 General

The generating set normally draws air from the engine room. Engine rooms with natural ventilation must have vent openings of adequate size and location to ena ble 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 cm2 is required. A "sealed" engine compartment must have a good extraction ventilator to maintain reasonable engine room temperatures. High temperature of intake air reduces engine performance and increases engine coolant temperatures. Air temperatures above 40°C reduce the engine 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 mentioned temperature limit by using machine room ventilation, connections are to be made for an air inlet directly to the enclosure. With these connections the generating set can be directly connected to an air duct. Air inlets should be louvered, where appropriate, to protect the engine room and to protect the generating set from water spray. As an extra precaution, the fitting of a cowl ventilator with a cover box located as high as possible, is recommended.

Figure 5: Mounting of the Whisper generating set. X = wrong, V = OK

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INSTALLATION

Figure 6: Mounting of the air strainer element

2.4.2 Air strainer element

Applying a generator in a vehicle, where combustio n air is taken in from below the vehicle, there is often much dust, sand and dirt in the air. For these applications Mastervolt prescribes the installation of an air strainer element. This air strainer element is in the standard suppl y, but not yet mounted as often the best place to mount it will be different in any installation. To install the air strainer element one has to find the best place somewhere on the canopy. Figure 6 shows the recommended place, but the filter can be mounted everywhere, even on the bottom, hanging down. Use sealant or kit between the flange and the surface.

ATTENTION!

In any case it is necessary to open a hole for air inlet!

2.5 CONNECTIONS

The generating set comes with all supply lin es and output cable (i.e. electric cables, coolant connections, exhaust, fuel lines etc.) already connected to the engine and generator. The supply lines are fed through the capsule’s front base. The connections are marked as shown in figure 7 All electrical connections, cable types and sizes must comply with the appropriate national regulations. Supplied cables are rated for ambient temperatures up to 70°C. If the cables are required to meet higher temperature requirements, they must be run through conduits.

ATTENTION!

Before working (installation) on the system read the section safety instructions

50230006 A IR CLEA NER + ADAPTER

50230005 A DAPTER

50230003 A IR CLEANER

WHEN NO T USING THE FILTER, THIS HOLE SHOULD BE OPENED

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INSTALLATION

Fig. 7 Connections Whisper 6 and 10 for mobile applications

01 Coolant generator in 02 Battery positive (+) 03 Fuel out Ø8mm 04 Fuel in Ø8mm 05 Battery negative (–) 06 Coolant engine out 07 Coolant engine in 08 Coolant generator out

10 Expansion tank 11 Exhaust 1½” 12 AC power output 13 Remote control

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INSTALLATION

2.5.1 Fuel supply

1 FUEL TANK

Fuel tanks should be made of appropriate material such as (stainless) steel or plastic. Steel tanks should not be galvanised or painted inside. Condensation can occur in metal tanks when temperature changes. Therefore, water accumulates at the bottom of the tank and provisions should be made for the drainage of this water. The tank will need a filling connection, a return connection and an air ventilation connection which will require protection against water entry. Some official regulations do not allow connection points at the base of the fuel tank; connections are to be made at the top of the tank with internal tubing down to a few cm above the bottom of the tank. Using the existing fuel tank of the car-engine the fitting should be carried out with extra care. Both a supply line and a return line should be installed and go into the tank from the top. Interference of the two systems (car engine and generator engine) shou ld be avoided.

Do NOT connect the fuel lines to the lines of the vehicles engine fuel supply.

Driving the tank empty below the level of the suction pipe of the generator could make it necessary to bleed the fuel system.

2 FUEL LIFT PUMP

The generating set itself is equipped with a fuel lift pump; therefore the tank can be installed at a lower level than the generating set. See figure 8. The maximum suction he ight is 1 m. If the pump has to lift the fuel higher than one meter an external fuel lift pump must be installed. The control board is already prepared to connect an extra fuel pump. When using a second electric fuel supply pump, it is recommended to mount a loose supplied pump close to the tank and mount it in an angle or vertical to prevent air bubbles to block the system. The pump will become quite hot and should be mounted out of touch. (Refer to fig. 13) The pump makes clicking noises and therefore could be mounted on rubber mountings. When the clicking noises of the pump are not acceptable an other noiseless pum p is available as an option

Figure 8: Fuel supply (fuel tank is above the generating set)

1 Fuel return 2 Fuel supply 3 Prefilter / Water separator (optional) 5 Fuel Tank

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INSTALLATION

Figure 9: Fuel supply (fuel tank is below the generating set)

1 Fuel return 2 Fuel supply 3 Prefilter / Water separator (optional) 4 Extra fuel lift pump (optional) 5 Fuel tank

Figure 10: Fuel line assembly with vertical mounted pump and fuel lift pump mounted in an angle

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INSTALLATION

3 FUEL PIPES

When the tank is above the generating set (figure 8) we recommend ending the return line on the top of the tank. When the return is on the top - in case of a leakage the return line cannot overflow because of siphoning. One will only need a fuel cock in the fuel supply line. When the tank is below the generating set we recommend ending the return line on the bottom of the tank (A) below the inlet of the supply line.

Both supply and return fuel pipe lines should be appropriate material and 8 mm outer diamet er tubing. The quality of the tubing of fuel pipes could be submitted to local regulations depending on the application of the vehicle. The fuel pipes can be plumbed to the flexible hoses which are on the generating set and have a conn ection 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. The return line should be of 8 mm diameter and go straight back via the top to the bottom of the tank. When the return is too narrow, has too many bents and goes back to the bottom of the fuel tank, the back-pressure could be too high. This results in irregular running of the engine. When the engine runs irregular, one can check if back-pressure is the problem by disconnecting the return line just outside the canopy and draining it in a canister. When the engine runs smooth now, the return piping has to be changed. It could also help to install a second (electrical 12V) fuel lift pump.

4 FUEL FILTERS

A fine fuel filter is installed which requires maintenance. Mastervolt advises to install an extra fuel filter/ water fuel separator near the fuel tank. Before starting your generating set for the first time follow the fuel system bleeding procedure in the users manual.

2.5.2 Radiator cooling

1 GENERAL INSTRUCTIONS

The radiators can be mounted below the floor, in the side or on the roof of the vehicle. Wherever the radiators are mounted the well functioning of the system depends on the well circulation of the coolant. Roof mounted radiators bring the most risk for circulation problems, because air trapped in the radiators or a low level of the coolant, will immediately affect the cooling capacity of the radiators. It is recommended to keep the radiators as close as possible to the unit. The piping should be fitted as direct as possible. When the radiators are above the engine, the piping should be fitted below the top of the radiators! (refer to figure 11). Bents in the piping, that can trap air bubbles, should be avoided or ventilated (refer to figure 12)

Figure 11: Air traps should be avoided

Piping should not be fitted above the radiator!

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INSTALLATION

Figure 12: Ventilating an air trap

Special attention should be paid to the ventilation of the systems. Each installation system is standard supplied with an expansion tank for the coolant, which is also use d to release air bubbles and makes it possible to add coolant into the system in an easy way. This expansion tank should be at the highest point of the system and mounted as high as possible.

Most cooling problems originate from air traps blocking the circulation of the engine coolant.

Figure 13. Alternator cooling system: open expansion tank with overflow pillar.

For the alternator cooling system we use an open -non pressurised- system. Therefore the 12 mm overflow pillar on the expansion tank should stay open (figure 13). A piece of hose can be used to drain redunda nt liquid that is thrown out because of the expansion of the liquid in the system. When open the expansion tank can easily releas e air that is ventilated by the different connections. As the capacity of the alternator cooling system is very small, also the initial filling can be done via the expansion tank. It could be necessary to refill the tank a few times. The pump of the alternator cooling system is self-priming and this makes the system less sensitive for air traps.

For the engine we use a pressurised system. The 12 mm connection on the top is closed. Wherever the radiators are mounted it is necessary to ventilate the exhaust manifold of the engine. The exhaust manifold has a 8 mm connection to ventilate the manifold. There is an 8 mm high pressure and high temperature resistant hose in the delivery to connect the hose connection on the side of the manifold with the expansion tank (refer to figure 7).

Initially the engine cooling system can be filled via the cap on the exhaust manifold of the engine. However when the radiator is above the engine one can only fill the system to the level of the manifold. Additional filling has to be done via the expansion tank. For large engine cooling systems with long pipes or for extra reserve there is an extra large expansion tank with a content of 7 litres and an alarm for low coolant level th at can be supplied as an option (refer to figure 14).

Figure 14: 7 litres optional expansion tank with low level alarm.

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INSTALLATION

When mounting the radiators it is important to take care that the outgoing connection, which is the connection to the engine inlet, is on the top position (refer to figure 15 detail A) and is connected to the expansion tank. Also when the radiator is mounted flat at the bottom of the vehicle the outgoing connection is connected to the expansion tank. This is the best way to have the system release air and to add liquid when necessary.

The expansion tank must be fitted in the outlet of the radiator = the inlet pipe of the engine

Figure 15. Outgoing connection connected to the expansion tank

When both radiators are flat mounted on the roof, the expansion tanks should be mounted a little higher. (refer to figure 16 detail B).

Figure 16: Low profile radiator assembly on the roof

Most cooling problems originate from air traps blocking the circulation of the engine coolant.

It is very important to use good quality heat resistant hose and fittings. Therefore it is strongly advised to use Mastervolt installation kits

side mount

bottom mount

top mount

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INSTALLATION

2 HOW AND WHERE TO MOUNT THE RADIATORS

The radiator kit includes rubber mountings to prevent vibrations to be transferred to the body of the vehicle (figure 17). Due to the difference between vehicles general instructions are not available. One has to find out where the best place for mounting is. For OEM customers Mastervolt can supply a special customised installation kit.

Figure 17. Radiator on rubber mountings

Bottom mounted radiators

When bottom mounted the radiator should not be the lowest point of the vehicle to avoid damage. A free flow of air should be guaranteed. When horizontal mounted, the fan should be on top, which causes a flow of air downwards. Often it is possible to find a place where extra space above the fan helps to create a free flow of air. It is recommended to make a shield below the radiator to catch stones and dirt and operates as a spoiler. The distance between the radiator and the shield should be at least 50 mm. Sometimes it is possible to build the radiators and shield on a sub frame that is mounted below the vehicle as a module.

Measures have to be taken to prevent the hot air circulating and reducing the capacity of th e radiators. Refer to figure 18

Figure 18: Bottom mounted radiators with shield

Figure 19. Making use of the space below the floor to get an optimal flow of air through the radiators.

Side mounted radiators

Most effective and easy is to mount the radiator in the side of the vehicle, if possible below the level of t he top of the engine. A louvered grid should protect the radiator from rain and objects, but must not block the airflow. The fan should be inwards which causes the air to blo w outwards. A disadvantage of having the radiator in the side is possibly more noise of the electric fan and a flow of air that could be felt by people passing by. A free flow of air should be guaranteed. The ventilation connection of the cooling system that goes to the expansion tank, should be in the outgoing coolant flow on top of the radiator.

Figure 20: Side mounted radiator

side mounted

air flo

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INSTALLATION

Roof mounted radiators

The radiators on the roof is often the best option from the point of view of keeping the noise of the fans away from people and it will give the best result in dissipating the heat. However, often this option conflicts with the possible need to keep the vehicle as low as possible. An other disadvantage is that the piping has to go through the roof which requires provisions to be waterproof. Also negative is that roof mounted radiators are more sensitive for air traps (see figure 11). When having enou gh space it would be ideal to have the radiators vertically mounted on the roof. Note that the expansion tank should be above the radiator. When having the radiators horizontally mounted on the roof (refer to figure 21) enough space (50 mm) should be between the roof and the radiator fan to have a free flow of air. When the radiators are roof mounted there should be protection against weather conditions. To avoid damage while the vehicle is driving at high speed, the use of a spoiler could be necessary.

Figure 21: Two examples of top mount radiators

3 TWO SPEEDS FAN (OPTIONAL)

To keep the noise as low as possible the fans of the radiators can run at two different speeds. As option a control box is available which can be used to drive the fans with two speeds, depending on the load of the generator. When using 12/24V DC to drive the fans (see chapter 4.7), in normal mode the electric motors of the fans are connected in series and run at low speed. In this mode they almost produce no noise. Only when necessary

- this is controlled by thermostat switches - the fans are

switched in parallel and will blow at full speed.

The same is achieved with 230 V fans with help of a transformer (refer to the connection diagrams in paragraph

4.6).

However, when not strictly necessary, we recommend using the standard fan control instead of the t wo speeds fan control, in order to keep the system as simple as possible.

2.5.3 Dry exhaust system

1 GENERAL REMARKS

A dry exhaust muffler system should be as effective in silencing the exhaust as a wet marine exhaust system when applying the right mufflers. However noise could be generated by vibrations in the mufflers and be transferred to the chassis. Tacit factors like the length of specific pipe sections could be important. It is very difficult to take these factors into account.

Figure 22: Dry exhaust systems on vehicles

The standard Mastervolt exhaust kit contains the materials to perform a professional installation. In the kit is a stainless steel flexible bellow (hose) to allow for expansion and to prevent vibrations to be transferred. Rubbers are supplied to mount the mufflers flexible. The insulation blanket for the flexible bellow and the resonance muffler are also very effective in damping vibrations. Still it could be that additional measures has to be taken like an e xtra clamp in a vibrating section of pipe, insulation bl ankets on other parts of the system and possibly even additional mufflers.

When the exhaust is led through the roof of a vehicle, measures has to be taken to prevent rainwater to enter the system. Special rain caps are available as an option.

Figure 23. Ways to prevent water to get in

horizontal

vertical

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INSTALLATION

A negative feature of a dry exhaust system is the heat radiated by its components. Measures are taken to overcome the heat problem: The exhaust bent to bring the exhaust out of the canopy is cooled by water. Insulation blankets are included in the exhaust kit to insulate the flexible bellow and the first muffler. When a dry exhaust has its outlet on the roof, all the pip es inside the vehicle has to be insulated.

The exhaust pipes will be very hot and all accessible pipes and mufflers are dangerous to people when not insulated.

There are companies that are specialised in insulating hot pipes and fancy systems are available to make it good looking. However it is also possible to do it yourself by winding fibreglass or Rockwool around the pip es and seal it with aluminium tape.

2 THE STANDARD DRY EXHAUST SYSTEM

The standard exhaust system contains:

On the generator set:

• An insulated exhaust bent

In the exhaust installation kit:

• A stainless steel shielded flexible bellow.

• One resonance muffler

• One absorption muffler

• Clamps and rubbers to mount the system flexible

• Fittings, bents and pipes to make the different

connections

• Blankets for thermal and sound insulation.

The mufflers are high quality industrial mufflers that are much more effective, robust and durable than mufflers made for automotive use.

3 INSTALLATION OF THE EXHAUST

Before determining the location of the generator set one has to consider how to get away with the exhaust. Often one can find space below the vehicle between the chassis to mount the mufflers. The outlet should blow the fumes away from the doors to avoid a nasty smell. When the gasses are in the flow of air blowing from the radiators this will help to avoid the fumes to be noticed. Under no condition the fumes should be sucked into the flo w of air into the radiators. In wind still conditions a light smell of exhaust fumes around the vehicle will not be avoidable. To bring the exhaust to the top of the vehicle gives the best results on noise and smell. However, when the pipes go through the vehicle they should be insulated and around the hole in the roof should be a col lar to prevent rainwater to leak in. Both mufflers could be on the roof or one of them or both could be below the vehicle. In general it is better to have the mufflers wide apart: the resonance muffler close to the generator and the absorption muffler on the end of the line. A short pipe (30cm) should be on the far end after the absorption muffler. The absorption muffler has no flow direction and could be mounted both ways. The resonance muffler should be mounted according to the indication on the muffler itself.

The resonance muffler should be fitted according to direction of the gas flow indicated.

In the kit are clamps to mount the exhaust pipes to stainless steel bars. These bars should be mounted to the chassis of the vehicle. It is recommend to use rubber mountings whenever possible. However take care that the heat conducted through the brackets will not affect the rubber. Refer to figure 24 how to mount the rubber in a safe way. When any doubt an extra safe guard could b e constructed from steel wire or chain.

Figure 24. Mounting bracket in rubber with safe guard

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INSTALLATION

2.5.4 Electrical installation (12 Volt)

1 DIGITAL DIESEL CONTROL SYSTEM

The electrical control system is standard in 12 Volt with negative earth. Non- earth return is available as an option.

All electrical wiring has been prepared on the generating set to the control panel prior to despatch from the factory. The engine is controlled by a very advanced microprocessor based system: Digital Diesel Control. The “black box” containing the microprocessor is located on top of the alternator. A local control panel is on the generating set.

Remote control

A remote control panel also containing a microprocessor is in the delivery. A 15 m intermediate 8-pole communic ation cable is in the standard supply as well (refer to figure 25). If necessary an optional longer (up to 30m / 100ft) intermediate cable can be connected if the standard lengt h does not suit the required distance. When a longer distance than 30m / 100ft is required, consult the Mastervolt service department for advice.

Figure 25 Remote control cable

One can mount the control panel after drilling a hole in the dashboard using the plastic cover. Refer to the dimensional drawings in chapter 4. The panel without the plastic cover fits the Mastervision modular panel system.

More remote control panels (slave panels) can b e 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 figure 26 when fitting cable to the green connector. Some software versions in old system panels (supplied before Ma y 2004) could conflict with the software in the DDC and an update of the software of the system panel could be necessary. When this is the case consult to the Mastervolt service department for advice.

When using the factory settings, installation is very simple: just plug the remote cable into the remote and the generator is ready to use. Refer to figure 26.

WIRING C OLOURS

RED GREEN BROWN YELLOW PINK PURPLE BLUE WHITE

GREY/ PI NK GREY

RED/BLUE

BLACK

MAX. 150 m A

WARNING RELAY

REMOTE CABLE

SENSE BAT. 2

121110987654321

Whisper Re mote Panel

WRP/2

Figure 26 Remote box terminals

Acoustic alarm or warning lamp

One can connect an external max.150 mA 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 figure 26.

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INSTALLATION

Connection for emergency stop / fire alarm switch

To connect an emergency stop button or to stop the generator automatically in case of a fire alarm, you can use the bypass connection between fastons J7 and J18 on the backside of the local control panel. See figure 27. To do so, remove this bypass connection and then replace it by an emergency switch or a potential free fire alarm switch with normally closed contacts

Fig. 27: Connection for emergency stop / fire alarm switch

Automatic starting and stopping

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.

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 de-blocking and setting up this options refer to the APPENDIX of the DDC user’s 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 belo w 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). A sense wire to monitor the second battery should be connected (attention polarity!) to the connector on the back of the remote panel. Refer to fig. 29. 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.

2 STARTER BATTERY

For starting, the Whisper requires a 12V starter battery with the following capacity:

Model Minimum capacity

Whisper 6 60Ah Whisper 10 60Ah

The generating set can be connected with the main engine battery or have its own battery. We strongly recommend the use of a separate battery for the generating set and to keep the wiring system for the vehicle engine and the domestic DC supply system completely separate and individually connected to separate batteries.

230VAC

IVO 12/10

12V

Figure 28: Starter battery

However, the negative of all the batteries on the vehicle should be interconnected to avoid difference in the voltage level of the earth on different places causing trouble to electronic devices which might be in the system. The above recommendation is not valid for vehicles having the starter battery of the vehicle engine or other auxiliary

Remove bypass between J7 - J18

Normal operation

Alarm / emergency

local control panel (rear view)

Page 20

INSTALLATION

equipment positive grounded. When this is the case an expert should be consulted. A battery switch may be used to interrupt the positive connection. The starter battery is charged by the alternator on the engine. An additional battery charger will help to keep the battery in good condition when the generating set is not used. A battery charger is not included in the standard supply. A high efficiency battery charging unit can be ordered from Mastervolt which is able to charge both the vehicles’s main battery and the starter battery. Also a small charger can be used to charge the starter battery only, such as the IVO SMART 12/10. A battery switch and a charger are included in the battery installation kits, art. no. 50230210 (70Ah) or 50230220 (160Ah)

3 12V OR 24V DC TO DRIVE THE FAN

When applying 12V or 24 V DC to drive the fan of the radiators the fan should be wired with minimum 4 mm2 cable according to the wiring diagram. The negativ e return wire should be of the same diameter. The return current should never be lead over the chassis. The consumption of power by the 12V DC powered fan makes it necessary to install an additional 30 Amps battery charger to prevent the starter battery to be drained. A much larger battery (170Ah at least) is required. The battery charging winding in the generating set is not capable of powering the fan. Neither is the small charger that is included in the battery kit. Mastervolt supplies high quality battery chargers that continuously supply the rated power. Chargers of other suppliers are often rated to other standards and give the rated current (Amps) only for a short period if at all. To avoid the need of an extra heavy battery charger a 230 Volt fan on the radiator is recommended. One should realize that the power for the fan must be decucted from the output power of the generating set.

4 OTHER RECOMMENDATIONS AND WARNINGS

The battery should be secured for poor road conditions 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 cable should be use d and the vehicle should not to be used as a conductor. The battery cables are supplied in a standard length of 1.5 m, if longer cables are required a larger cross sectional area should be considered to compensate for voltage reduction.

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 severe damage to both batteries within a 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 may be 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.

Page 21

INSTALLATION

2.5.5 AC power system (230 Volt)

The electric power supplied by the generator is of a high voltage and dangerous to people. Before working (installation) on the system read the sections on safety in the users manual.

Realise hat people are not used to have 230V available on a vehicle. Put warning signs on wall sockets and on junction boxes. Instruct non-regular users of the vehicle. Warn maintenance personal of garages that do service on the vehicle.

Generators used on vehicles that are operated in a hazardous environment have often to fulfil special regulations and additional measures have to be taken accordingly.

Be sure that all electrical installations (including all safety systems) comply with all required regulations of the local authorities. All electrical safety/shutdown and circuit breaking systems have to be installed onboard as the generating set itself cannot be equipped with such equipment for every possible variation. The vehicle’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.

1 FUSE

An output fuse (between the generating set and the electrical installation) should be installed to protect the installed electrical system. The following maximum single phase output current applies:

Model Maximum single phase

output current

Whisper 6 25 Amps Whisper 10 40 Amps

The fuses must be of the slow reacting type. For electrical motors connected to the system, a motor protection switch must be installed

2 GROUNDING

The AC alternator windings are not grounded. The housing of the alternator and all other metal parts are grounded To make a connection between “neutral” and “ground” is necessary as part of a specific insulation failure protection system. It is possible that the electric installation in the vehicle must be protected against insulation failures. Methods of protection are subjected to rules that can be different depending on the use of the vehicle and local standards. In the standard marine manual is more information, but this is according CE regulations for boats. Vehicles are subject to different regulations depending on the application of the vehicle. Experts in this field should be consulted

3 CABLE

For the power cable we recommend the use of 3 wire single phase oil resistant cable with a sufficient cross sectional area. One wire for earth is included. For long cables it is recommended to apply cables with a larger cross section (refer to ISO 13297 annex A)

4 TRANSFER SWITCH

A power source selector switch much be installed bet ween the generating set and the vehicle’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 vehicle or from generating set to inverter - should be well designed to switch over all wires including neutral (and not only phases or line) and there should be provisions with the aid of timers to prevent relays from clattering.

Mastervolt recommends the installation of a Mass Systemswitch as the 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 Mass Systemswitch switches automatically after 10 seconds delay time over to the generating set position.

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.

Page 22

INSTALLATION SPECIFICATIONS

3 INSTALLATION SPECIFICATIONS

3.1 GENERAL

1 Make a hole for combustion air in the sound shield.

Mount an air inlet filter (if required)

2 Mount the generating set directly, without additional

vibration dampers, on a solid surface. 3 Mount the cooling system for the engine 4 Mount the cooling system for the alternator 5 Connect exhaust system. 6 Connect ‘fuel supply line’ to the water separator/ fuel

filter. 7 Connect ‘fuel return line’ to the fuel tank. 8 Connect remote panel (just plug in). 9 Connect the AC cable from the AC box to the power

source selector (or Mass Systemswitch). 10 Connect the positive and negative poles from the 12V

starter battery to the battery cables. 11 Connect the power supply of the radiators 12 Install a Mastervolt battery charger. (optional)

3.2 COMMISSION TABLE

1 Check if a hole for combustion air intake is in the

sound shield. Also check if an air inlet filter for

combustion air is necessary and has been installed 2 Check if the cooling system for the engine is properly

installed. Note that air traps must be avoided. 3 Check if the cooling system for the alternator is

properly installed. Note that air traps must be avoided. 4 Check if the exhaust system is properly installed.

Check maximum length of exhaust hose, diameter of

exhaust piping. 5 Check all coolant connections. 6 Check the AC cables and the grounding. 7 Check if an AC breaker is installe d before or after the

power source selector. When there is only a circuit

breaker, use it to disconnect the generating set from the grid.

8 Check all DC c onnections, check if the battery switch/

circuit breaker is closed.

9 Open the fuel valve. C heck 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. 10 Check if the air intake in the canopy is not blocked. 11 Check the oil level and colour of the oil. Check the

coolant level of both the alternator cooling and the

engine cooling 12 To bleed the fuel system: push the “Start” button on

the local control (not on the remote panel) and hold at

least 5 seconds and as long as necessary to bleed

the system. 13 Start the engine by pushing the start button 14 Check when t he generating set is running, the delay

of 5 to 10 seconds in the power source selector

transfer. 15 Check voltage and frequency under ‘no load’

conditions. 16 Check voltage and frequency under ‘full load’

conditions. 17 Check if the battery charger of the generating set is

working (max. 14.5 Volt). 18 Close the sound shield and check the noise level. 19 Stop the generating set and check th e engine again

for leakages of oil, fuel or coolant.

Installation checklist available on our website: www.mastervolt.com. Commissioning form available on our website: www.mastervolt.com..

Page 23

INSTALLATION SPECIFICATIONS

3.3 TECHNICAL DATA

WHISPER 6 AND 10

Model Whisper 6 Whisper 10

Dimensions (l x w x h) 69.0 x 52.5 x 58.0 cm 80.5 x 52.5 x 58.0 cm Weight including sound shield 200 kg (440Lbs) 240kg (530Lbs) Max. operation angle 25° 25° Remote panel 15 m cable Digital Diesel Control System Battery capacity min. 12V / 60Ah 12V / 60Ah Fuel consumption 1-2.5 litre/hour, load dependent 1-4 litre/hour, load dependent Combustion air consumption 0.95 m3/min. 1.43 m3/min. Model fuel pump Electrical driven 12V Electrical driven 12V Max lift fuel pump 1m 1m Cooling Radiator cooling Radiator cooling Cooling pump Mastervolt self priming raw water impeller pump, PTO driven Model cooling pump M M Alternator synchronous brushless, maintenance free, water cooled Voltage regulation capacitor capacitor Output power at 50Hz, power factor cos phi = 1 5 kW* 9 kW* Battery charger (alternator including regulator): 40 Amps 40 Amps * Note that this value must be reduced by the power to drive the cooling fans of the radiators.

Page 24

INSTALLATION SPECIFICATIONS

3.4 INSTALLATION MATERIALS

BATTERY INSTALLATION KIT 70 Ah

no qty article no description dimensions 51 1 62000700 Mastervolt AGM Battery 12V/70Ah 70Ah 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 switch 250 Amp 58 4 6503002508 cable connectors M8x25

TOTAL 50230210 BATTERY INSTALLATION KIT 70 Ah

FUEL KIT

no qty article no description dimensions 41 2 50221203 Straight coupling 8 mm 42 1 50230090 Fuel strainer/water separator M14x1.5 mm 43 2 50221618 Parallel male stud coupling M14 - 8 mm 44 2 50221644 Reducing male nipple M14-M16 60 gr. 45 2 50221615 Hose connection 8 mm 46 2 50221616 Nut coupling M16x1.5 mm 47 1 50221252 Nipple hose pipe 8 mm 48 4 50221522 Hose clamps 10-16 mm 49 2 50221632 Gasket ring 14x20x1.5 mm

TOTAL 50230205 FUEL KIT

OPTIONAL INSTALLATION MATERIALS

no qty article no description dimensions 50 1 50222020 copper fuel pipe 6x8 mm 51 1 50220063 fuel hose 8x16 mm

Page 25

INSTALLATION SPECIFICATIONS

Included are all fittings to fit copper pipes 8 mm outer diameter or rubber fuel hoses 8 mm inner diameter, or both

Figure 29: Installation materials battery and fuel kit

Page 26

INSTALLATION SPECIFICATIONS

DRY EXHAUST KIT 1½”

no qty article no description 61 1 50220043 Exhaust hose SS 500mm fem./male 1½” 62 1 50220042 Insul. blanket 3 5x60 exhaust hose 1½’ 63 1 50230523 Absorbtion muffler steel 1½” 64 1 50230524 Ressonance muffler steel 1½” 65 1 50230525 Insul. blanket 8 0x75 muffler SDHC 1½” 66 2 50221403 Pipe nipple 1½”x300mm galvanised 67 2 50221423 Parallel male coupling 1½” galvanised 68 2 50221413 Straigt coupling f/f 1½” galvanised 69 3 50221663 U-clamp 48 mm M10 70 3 50221664 Bracket U-clamp 25cm M10/48mm passivated 71 6 50211406 Washer SP M10 72 6 50211447 Washer spring SP M10 73 6 50211466 Nut hexogonal SP M10 75 1 50221473 Elbow 90 degr m/f gavalvanised 1½”

TOTAL 50201875 DRY EXHAUST KIT 1½”

RADIATOR COOLING KIT ALTERNATOR 230VAC

no qty article no description 31 1 50230304 Radiator cooler AP 300/2 E 230VAC 32 2 50221103 Straight reducer m/f 1”-3/4” 33 1 50221063 Male nipple 3/4” 34 1 50221043 TEE fittings 3/4” 35 3 50221004 Male hose co nnection 3/4x20 38 1 50212405 Temperature switch 35-45 degr 39 4 50201121 Vibration mounting 30x25 40 4 50211152 Bolt he xagonal ZP M8x16 41 8 50211465 Nut hexogonal SP M8 42 8 50211405 Washer SP M8 43 8 50211445 Washer spring SP M8 44 8 50220011 Hose vac um SAE100 R4 (3/4”) 19x31,5mm 45 6 50221502 Hose clamp stainless19-29 46 8 50221599 Hose support 35x15 mm galvanised 47 1 50230529 Bracket expansion tank for 50230531 47 1 50230531 Expansion tank 20 mm 47 1 50230532 Cap tank 0502 30531

TOTAL 50201878 RADIATOR COOLING KIT ALTERNATOR 230VAC

RADIATOR COOLING KIT ALTERNATOR 12VDC Same as article no. 50201878, except:

no qty article no description 31 1 50230302 Radiator cooler AP 300/2 E 12VDC

TOTAL 50201872 Radiator cooling kit alternator 12VDC

RADIATOR COOLING KIT ALTERNATOR 24VDC Same as article no. 50201878, except:

no qty article no description 31 1 50230303 Radiator cooler AP 300/2 E 24VDC

TOTAL 50201868 Radiator cooling kit alternator 24VDC

Page 27

INSTALLATION SPECIFICATIONS

Figure 30: radiator cooling kit engine, exhaust kit and radiator cooling kit alternator

Page 28

INSTALLATION SPECIFICATIONS

RADIATOR COOLING KIT ENGINE 230VAC no qtt article no description 1 1 50230304 Radiator cooler AP 300/2 E 230VAC 2 2 50221502 Hose clamp stainless19-29 3 1 50221064 “Male nipple 1” 4 1 50221044 “TEE fitting 1” 5 2 50221010 Male hose connection 1x25 6 1 50221103 “Straight reducer m/f 1”-3/4” 7 1 50221004 Male hose connection 3/4x20 8 1 50212409 Temperature switch 87-82 degr 9 4 50201121 Vibration mounting 30x25 10 4 50211152 Bolt he xagonal ZP M8x16 11 4 50211465 Nut hexogonal SP M8 12 8 50211405 Washer SP M8 13 8 50211445 Washer spring SP M8 14 6 50220012 “Hose vac um SAE100 R4 (1”) 25,4x38mm” 15 4 50221503 Hose clamp stainless 26-38 16 8 50221599 Hose support stainless 35x12 mm 17 1 50230529 Bracket expansion tank for 50230531 17 1 50230531 Expansion tank 20 mm 17 1 50230532 Cap tank 0502 30531 18 1.5 50220011 “Hose vacum SAE100R4 (3/4”) 19x31,5mm 21 1 50221532 Hose clamp stainless mini 9-11

TOTAL 50201879 Radiator cooling kit engine 230VAC

RADIATOR COOLING KIT ENGINE 12VDC Same as article no. 50201879, except:

no qtt article no description 31 1 50230302 Radiator cooler AP 300/2 E 12VDC

TOTAL 50201871 Radiator coolin g kit engine 12VDC

RADIATOR COOLING KIT ENGINE 12VDC Same as article no. 50201879, except:

no qtt article no description 31 1 50230303 Radiator cooler AP 300/2 E 24VDC

TOTAL 50201880 Radiator coolin g kit engine 24VDC

Page 29

DIAGRAMS & DRAWINGS

4 DIAGRAMS & DRAWINGS

4.1 LAYOUT GENERATOR CONTROL WITH 230VAC FAN

Figure 31: Layout generator control for with 230VAC radiator fan

Optional control for two speeds fans.

See chapter 4.6

ALTERNATOR TEMP.

WIT

Page 30

DIAGRAMS & DRAWINGS

4.2 LAYOUT GENERATOR CONTROL WITH 12VDC FAN

Figure 32: Layout generator control with 12VDC radiator fan

ALTERNATOR TEMP.

SWITCH

Optional control for two speeds fans.

See chapter 4.7

Page 31

DIAGRAMS & DRAWINGS

4.3 LAYOUT GENERATOR CONTROL WITH 24VDC FAN

Figure 33: Layout generator control with 24VDC radiator fan

ALTERNATOR TEMP.

SWITCH

Optional control for two speeds fans. See chapter 4.7

Page 32

DIAGRAMS & DRAWINGS

4.4 WIRING COLOURS

Cable code number colour cross section

battery > starter motor red 25 mm2 starter motor > DDC 1 red 6 mm2 starter motor > LCP 13 red 2,5 mm2 battery > ground black 25 mm2 ground > LCP ground (GND) 2 black 4 mm2 DDC > glow plugs 3 brown 4 mm2 DDC > starter solenoid 4 yellow 2,5 mm2 LCP > fuel lift pump + 5 brown 1,5 mm2 LCP > fuel lift pump - 15 black 1,5 mm2 DDC > LCD 5 grey 1,5 mm2 DDC > oil pressure switch 6 purple 1 mm2 LCP > oil pressure switch 6 purple/black 1 mm2 DDC > water temperature switch 7 blue 1 mm2 LCP >water temperature switch 7 blue/black 1 mm2 DDC > exhaust temperature switch 8 blue/green 1 mm2 LCP > exhaust temperature switch 8 blue/rose 1 mm2 DDC > fuel solenoid (hold) 9 green 1,5 mm2 DDC > fuel solenoid (pull) 20 pink 1,5 mm2 DDC > fuel solenoid (com.) 17 black 1,5 mm2 B+ terminal alternator > starter motor 21 red 6 mm2 DDC >R terminal alternator 18 wit 1,5 mm2 DDC > L terminal alternator 19 orange 1,5 mm2 DDC > current measuring transformer 11 black 1 mm2 DDC >current measuring transformer 11 red 1 mm2 DDC > LCP 12 black 1,5 mm2 DDC > LCP 14 red 1,5 mm2 DDC > LCP 16 red/green 1,5 mm2 DDC > generator AC output 33 brown 1 mm2 DDC > generator AC output 33 blue 1 mm2

Page 33

DIAGRAMS & DRAWINGS

4.5 AC WIRING DIAGRAM 230V / 50HZ

Figure 34: AC wiring diagram

Page 34

DIAGRAMS & DRAWINGS

4.6 ELECTRICAL DIAGRAM RADIATOR FAN CONTROL 230VAC

TERMINAL BLOCK

GENERATOR CONTACT

PUMP (PCB)

THERMOSTAT GENERATOR

THERMOSTAT ENGINE

RADIATOR COOLER

GENERATOR

BATTERY

230VAC

ENGINE

RADIATOR COOLER

GENERATOR

12VDC

230VAC

CU1,5

+1-

CU0,75

80-70?C

CU0,75

45-35?C

CU0,75

35A45 87

CU1,5

230VAC

CU1.5

6,3A116,3A

12 1413 15

CU1.5

DIMENTION BOX: 270x270x180 MM

JUNCTION BOX AIR FANS

12VDC K1 K2

230/115VAC 200VA

TRAFO

230VAC

Figure 36: Electrical diagram fan control using 230V AC radiator fans – with two speeds fans (optional)

FUSE 5A

FUSE 6.3A

FUSE 5A

15 16

5 6

13 14

BAT. +12V

PUMP

+12V

GENERATOR 230VAC (L1)

BAT.

–12V

GENERATOR 230VAC (N)

230VAC

45-35°C80-70°C

THERMOSTAT COOLER

ENGINE GENERATOR

RADIATOR COOLER

ENGINE

RADIATOR COOLER

GENERATOR

A2A2

A1 A1

230V

120V

115V

110V

TRANSFORMER

230V/115VAC

200VA

400V

M M

GENERATOR

MAIN CIRCUIT BREAKER

AC LOAD

CIRCUIT BREAKER

AIR FANS

Figure 35: Electrical diagram for standard fan

control using 230V AC radiator fans

Page 35

DIAGRAMS & DRAWINGS

4.7 ELECTRICAL DIAGRAM RADIATOR FAN CONTROL 12 / 24 VDC

PUMP (PCB)

GENERATOR CONTACT

THERMOSTAT ALTERNATOR

THERMOSTAT ENGINE

ALTERNATOR

RADIATOR COOLER

ENGINE

BATTERY

TERMINAL BLOCK

CU0,75

80-70∞C

CU4

CU0,75

45-35∞C

CU0,75

+1-2-

356+7

CU2,5

CU2.5

-8+9-

JUCTION BOX AIR FANS

FUSE 20/40A

21435768

DIMENIONS BOX: 160x160x90 MM

Figure 37: Electrical diagram fan control using 12V or 24V DC radiator fans (optional)

FUSE 20/40A

+ BAT.

THERMOSTAT COOLER

ENGINE GENERATOR

CONTROL PANEL

PUMP 2

45-35°C

80-70°C

RADIATOR COOLER

ENGINE GENERATOR

– BAT.

Page 36

DIAGRAMS & DRAWINGS

4.8 WIRING DIAGRAM ELECTRONIC GOVERNOR

Figure 38: Electronic governer.

In addition to the mechanical governor, the W hisper 6 and 10 are standard equipped with an electronic governor. A governor keeps the speed (RPM=Rotations Per Minute) of the engine at a fixed value. The RPM of the engine correlates with the frequency of the electrical output (1500 RPM =50 Hz) of the alternator. Under full load the RPM of the Whisper models that have only a mechanical governor can drop 75 RPM (=2.5 Hz) at full load and will go further down or collapse when further loaded. However the engines with the electronic governor will keep the RPM and frequency at the set value. As the voltage is related to the frequency, the voltage will be more stable as well. The RPM represents power and the alternator performs better as well on a higher speed. Whisper models with an electronic governor will bring more power. So the electronic governor offers three advantages: a more stable frequency and voltage and more power.

The electronic governor system contains two parts:

1 The actuator controls the eng ine speed. This actuator

replaces the standard hold solenoid that is on all other

mechanical controlled Whisper engines. The actuator

controls the RPM directly on the fuel rack inside the

fuel pump without levers and other mechanical

transmissions. 2 A microprocessor keeps the speed at the set value by

controlling the actuator. The microprocessor is

programmed at the Mastervolt factory and many

parameters are set to perform well. It should not be

necessary to make adjustments. When adjustments

are necessary this can only be done with the he lp of

an interface to a computer and special software to get

access to the microprocessor.

The Mastervolt electronic governor does not need a pickup device in the flywheel housing that counts the passing tooth of the flywheel and determines the exact RPM of the engine, because the processor uses the 50 Hz of the AC output voltage as a reference.

Page 37

DIAGRAMS & DRAWINGS

4.9 REMOTE CONTROL PANEL DRAWINGS

Figure 39: Whisper remote panel

The remote panel comes in a carton that can be used as a template to drill the mounting hole

Page 38

DIAGRAMS & DRAWINGS

4.10 DIMENSIONS

Figure 40: Outer dimensions (mm) Whisper 6 and 10

CONNECTIONS WHISPER 6 WHISPER 10 BOX DIMENSIONS WHISPER WHISPER 6

• exhaust: 1 ½” 1 ½” • length 69.0 cm (26.0’)

• fuel hose: 5/16” (8 mm) 5/16” (8 mm) • width 52.5 cm (20.7’)

• radiator alternator: 3/4” (19 mm) 3/4” (19 mm) • height 58.0 cm (22.8’)

• radiator engine: 1” (25.4 mm) 1¼” (32 mm) • weight 200 kg (440 Lbs)

• battery +: AW G 2 (25 mm2) AWG 2 (25 mm2)

• battery -: AWG 2 (25 mm2) AWG 2 (25 mm2)

POWERCABLES ISO 13297 annex A BOX DIMENSIONS WHISPER WHISPER 10

• 3 x AWG 12 (4 mm2) (not included) • length 80.5 cm (31.7’)

• width 52.5 cm (20.7’) REMOTE CONTROL: • height 58.0 cm (22.8’)

• 15 meter (45 ft) 8 wire communication cable (included) • weight 240 kg (530 Lbs)

Page 39

NOTES

Page 40

Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands

Tel : + 31-20-3422100 / Fax : + 31-20-6971006

www.mastervolt.com / info@mastervolt.com