Mastervolt WHISPER 15 ULTRA, WHISPER 12.5 ULTRA, WHISPER 20 ULTRA Installation Manual

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Page 1

INSTALLATION MANUAL

WHISPER 9.5 / 12.5 / 15 / 20

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

V1. September 2006

Art.nr. 50200234

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CONTENTS

2 September 2006 / WHISPER 9.5/12.5/15/20 ULTRA / US

CONTENTS:

INSTALLATION...............................................................................................................................................................3

1.1 General ..............................................................................................................................................................3

1.2 Location..............................................................................................................................................................3

1.3 Instructions for optimal sound and vibration insulation.......................................................................................3

1.4 Ventilation...........................................................................................................................................................4

1.5 Connections....................................................................................................................................................... 4

1.5.1 Fuel supply........................................................................................................................................8

1.5.2 Cooling.............................................................................................................................................. 9

1.5.3 Exhaust system...............................................................................................................................12

1.5.4 Digital Diesel Control system (12 Volt)............................................................................................ 15

1.5.5 AC power system (120/240 Volt).....................................................................................................17

2 INSTALLATION SPECIFICATIONS..............................................................................................................................19

2.1 General ............................................................................................................................................................19

2.2 Commission table.............................................................................................................................................19

2.3 Installation specifications..................................................................................................................................20

2.4 Specification of the accessories....................................................................................................................... 20

2.5 Installation materials.........................................................................................................................................21

3 DIAGRAMS & DRAWINGS ........................................................................................................................................... 29

3.1 DC wiring Whisper 9.5 Ultra, 12.5 Ultra and 15 Ultra ....................................................................................... 29

3.2 DC wiring Whisper 20 Ultra.............................................................................................................................. 32

3.3 Wiring diagram electronic governor (Whisper 12.5 ultra only).......................................................................... 34

3.4 AC wiring diagram 120V - 240V / 60Hz............................................................................................................35

3.5 Remote control panel drawings........................................................................................................................36

3.6 Dimensions Whisper 9.5 and 12.5 ultra............................................................................................................37

3.7 Dimensions Whisper 15 Ultra........................................................................................................................... 38

3.8 Dimensions Whisper 20 Ultra........................................................................................................................... 39

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INSTALLATION

US / WHISPER 9.5/12.5/15/20 ULTRA / September 2006 3

1 INSTALLATION

1.1 GENERAL

This installation 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 51109055 Whisper 12.5 Ultra 120/240V 1800RPM 51109056 Whisper 12.5 Ultra 120/240V 1800RPM -

ungrounded 51107055 Whisper 15 Ultra 120/240V 1800rpm 51107056 Whisper 15 Ultra 120/240V 1800rpm

-ungrounded 51108055 Whisper 20 Ultra 120V-240V 1800rpm 51108056 Whisper 20 Ultra 120V-240V 1800rpm

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

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.

1.2 LOCATION

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

1.3 INSTRUCTIONS FOR OPTIMAL SOUND AND VIBRATION INSULATION

Position the generating set as low as possible in the vessel. As the generating set is already secured to the base frame by means of flexible engine mountings, the frame must be mounted directly, without additional vibration dampers, to the vessel’s main structure.

Whisper generating sets are standard equipped with a sound cover. The canopy 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 places to be stiff. Directly below the rubber mountings the structure should be supported vertically to the superstructure of the ship.

2 Avoid mo unting the generating set in close proximity

to thin walls or floors that may cause resonance.

3 Sound dampening is extremely poor if the generating

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

4 Never connect the base of the generating set directly

to bulkheads or tanks.

Figure 1: Mounting of the Whisper generating set. X = wrong, V = OK

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INSTALLATION

4 September 2006 / WHISPER 9.5/12.5/15/20 ULTRA / US

1.4 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 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.

1.5 CONNECTIONS

The generating set comes supplied with all supply lines and output cable (i.e. electric cables, cooling water connections, exhaust, fuel lines etc.) already connected to the engine and generator. The supply lines are fed through the capsule’s front base. The connections are marked as shown in figures 2 till 4 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

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INSTALLATION

US / WHISPER 9.5/12.5/15/20 ULTRA / September 2006 5

Fig. 2a Connections Whisper 9.5 / 12.5 Ultra

Fig. 2b Connections Whisper 9.5 / 12.5 Ultra

05 Battery - 25mm2 06 Battery + 25mm2 07 Raw water inlet Ø19mm 08 Fuel in Ø8mm 09 Fuel out Ø8mm

01 Bypass cooling water in

Ø19mm (3/4")

02 Bypass cooling water out

Ø19mm (3/4") 03 Expansion tank Ø8mm 04 Exhaust hose Ø51mm 10 Remote control 11 AC power output

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INSTALLATION

6 September 2006 / WHISPER 9.5/12.5/15/20 ULTRA / US

Fig. 3a Connections Whisper 15 Ultra

Fig. 3b Connections Whisper 15 Ultra

01 Expansion tank Ø8mm 02 Bypass cooling water out

Ø19mm (3/4")

03 Bypass cooling water in

Ø19mm (3/4") 04 Exhaust hose Ø51mm 05 Remote control 06 AC power output

07 Battery - 25mm2 08 Battery + 25mm2 09 Raw water inlet Ø19mm 10 Fuel in Ø8mm 11 Fuel out Ø8mm

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INSTALLATION

US / WHISPER 9.5/12.5/15/20 ULTRA / September 2006 7

Fig. 4a Connections Whisper 20 Ultra

Fig. 4b Connections Whisper 20 Ultra

01 Fuel in Ø8mm 02 Battery - 35mm2 03 Battery + 35mm2 04 Fuel out Ø8mm 05 Raw water inlet Ø25.4mm

06 Expansion tank Ø8mm 07 Bypass cooling water out

Ø25.4mm 08 Bypass cooling water in

Ø25.4mm 09 Exhaust hose Ø51mm 10 Remote control 11 AC power output

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INSTALLATION

8 September 2006 / WHISPER 9.5/12.5/15/20 ULTRA / US

1.5.1 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; 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.

Fig. 5 Fuel supply (fuel tank is above the generating set)

1 Fuel return 2 Fuel supply

3 Prefilter / Water separator (optional) 5 Fuel Tank

Fig. 6 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

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INSTALLATION

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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 control board is already prepared to connect an extra fuel pump.

3 FUEL PIPES When the tank is above the generating set 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 vessel. 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. Other consumers of diesel fuel, such as the propulsion engine and he aters, have to be connected to separate suction and return pipes

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.

1.5.2 Cooling

Intercooling is based on a raw water pump, heat exchanger 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 acceptable 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 too high the release valve in the filling cap on the manifold opens an d 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 under-pressure. Another 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 th e side of the filling cap. This hose is made of heat resistant plastic and is not sensitive for kinks.

MA X .

Fig.7: Expansion tank placement

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 manua l for these applications.

2 RAW WATER SUPPLY

For raw water supply the following installation materials 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 the following inner diameter at least:

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INSTALLATION

10 September 2006 / WHISPER 9.5/12.5/15/20 ULTRA / US

Model Minimum inner diameter

Whisper 9.5 Ultra Whisper 12.5 Ultra Whisper 15 Ultra

3/4" (19 mm)

Whisper 20 Ultra 1" (25.4 mm)

The suction hose should be kept as short as possible. Raw water plumbing should avoid bends as much as possible. 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 propulsion 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 sailing at higher speeds, water will be forced into the inlet and your generating set will overflow!

Fig. 9 Installing water intake

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.

24"

60cm

24"

60"

150cm

Max.

Min.

5cm

Fig. 8. Internal cooling system

1 Water level; 2 Water/exhaust separator; 3 Seacock; 4 Waterlock; 5 Air vent; 6 Water strainer; 7 Seacock.

SAILING DIRECTION

FLOW DIRECTION

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INSTALLATION

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4 WATER STRAINER

Use an appropriate water strainer with connections of the following dimensions:

Model Inner dimensions

Whisper 9.5 Ultra Whisper 12.5 Ultra Whisper 15 Ultra

3/4" (19 mm)

Whisper 20 Ultra 1" (25.4 mm)

Install the water strainer in a well accessible position, (refer to fig. 8, ref. 6) 5 cm above the waterline.

5 SIPHON BREAKER (AIR VENT)

When the point of water injection is below the waterline, 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 generating set is designed to accommodate a siphon breaker (air vent). In the standard delivery the connections are bypassed. See figure 10

Fig. 10: Bypassed siphon breaker connections

Hoses with the following inner diameter should be used:

Model Inner dimensions

Whisper 9.5 Ultra Whisper 12.5 Ultra Whisper 15 Ultra

3/4" (19 mm)

Whisper 20 Ultra 1" (25.4 mm)

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. See figure 11 Extend the water hose of the by-pass 60 cm 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).

Fast motorboats will lay deeper when sailing at large speed and can cause pressure on the waterinlet. This should be avoided to prevent flooding 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 IN THE ENGINE IS NOT COVERED BY GUARANTEE

Fig.11: Siphon breaker connected

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.

Siphon breaker

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INSTALLATION

12 September 2006 / WHISPER 9.5/12.5/15/20 ULTRA / US

OPEN

Fig 12: Wrong siphon breaker hose routing

Check the air vent at regular intervals. Open, clean and lubricate the valve as required.

OPEN

Fig. 13 Mastervolt siphon breaker

1.5.3 Exhaust system

Water is injected in the exhaust system of the generating set. In this way the cooling water that has passed the heat exchanger is mixed with the exhaust gases. Temperature and volume of the gases are thereby reduced considerably, so that a rubber exhaust hose can be used and the level of noise is reduced as well.

1 STANDARD EXHAUST SYSTEM INSTALLATION The generating set exhaust system must remain completely independent and separate from the exhaust system of any other engine on board. A water lock prevents the generating set from being flooded by cooling water and should be installed as close to the generating set as possible. The lock must be large enough to hold th e 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. 14, ref. 1). The exhaust hose must have an inner diameter of 2” (51 mm) no less, no more-. The exhaust system must be installed so that the back pressure inside the exhaust does not exceed 0.07 bar (1psi = 27 inches (70 cm) watercolumn) (2 inches mercury) and total length from the generator to the top of the goose neck or or water/separator does not exceed 10ft. (3m). (Refer to paragraph 5.4.3 of the users manual).

The exhaust hose descends from the capsule to the water lock. Then the hose rises via the "goose neck" to the through-hull exhaust outlet, situated minimum 2” (50 mm) above the water line (ref. to fig. 14, ref. 5.) The "goose neck" must be vertical and situated preferable along the ship’s keel center line. If the generating set is mounted less than 24" (60 cm) 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. .

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INSTALLATION

US / WHISPER 9.5/12.5/15/20 ULTRA / September 2006 13

Minima l 24" 60c m

Max ima l 60" 150cm

2" 5cm

H OS E R OU TE A- B MAX . 1 0 f t (3m)

Fig. 14: Standard exhaust system

1 Exhaust water lock; 2 Exhaust outlet muffler; 3 Exhaust line Ø 2” (51 mm);

4 Goose neck 5 Through-hull exhaust outlet Ø 2” (63 mm) 6 Water level.

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 separator allows the cooling water to be ejected through a line (A) separate from the exhaust fumes and also functions as a goose neck to prevent water from flooding the engine. If the exhaust/water separator is mounted more than 24” (60 cm) above the water level an additional goose neck is not required.

MIN. 3C M (1,2")

MA X. 150CM (60")

MIN. 60CM (24")

MAX . 10CM (4")

WATERLINE

Fig. 15 Super silent exhaust system

Fig.16: Water trap in exhaust system

If the through-hull exhaust outlet has to be mounted far from the generating set (total length of the exhaust piping from generator to top of goose neck (water separator) is more than 10 ft (3 m.)), an exhaust/water separator must definitely be installed. The sea water from the separator must then run down along the shortest possible path to the through-hull outlet.

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INSTALLATION

14 September 2006 / WHISPER 9.5/12.5/15/20 ULTRA / US

Only after the exhaust/water separator the exhaust hose may have a length of over 25 ft (7.5 m) if the exhaust hose diameter is also increased from 2” (51 mm) to 2½” (63 mm) in order to reduce the back pressure (ref. to fig. 17)

However watertraps should be avoided as the fumes still contains water and this should not accumulate in bents (refer to fig 16). An additional outlet exhaust muffler close to the hull outlet will help further to reduce noise emission

If the generating set and the exhaust system have been installed correctly, neighbouring boats will not be disturbe d by generating set noise. With the "super silent" exhaust system, generating set noises are almost inaudible. For optimal noise reduction, the sea water outlet from the exhaust/water separator (centre outlet on the unit) should be installed below the water level to eliminate noisy splashing of the effluent sea water.

The through-hull outlet for the exhaust fumes should not direct the fumes directly toward the water surface as this will cause excessive noise (ref. to fig. 18).

Do not direct the outlet directly toward the water surface.

Fig. 18. Outlet direction

Fig.17.

HOSE ROUTE A-B

Up to 10ft (3m) Ø 2” (51 mm)

10-30ft (3 - 10 m) Ø 2.5” (63 mm)

Ø 1 5/8” (40mm)

Ø 2” (51mm)

MAX. 10ft (3m)

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INSTALLATION

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1.5.4 Digital Diesel Control system (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 a n option for aluminium vessels to prevent corrosion.

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 45 feet (15 m) intermediate 8-pole communication cable is in the standard supply as well (refer to fig. 19). If necessary an optional longer (up to 100ft / 30m) intermediate cable can be connected if the standard length does not suit the required distance. When a longer distance than 100ft / 30m is required, consult the Mastervolt service department for advice.

Fig. 19 Remote control cable

One can mount the control panel after drilling a hole in the dashboard using the plastic cover. Refer to the dimensional drawing in paragraph 3.5. The panel without the plastic cover fits the Mastervision modular panel system.

More remote control panels (slave panels) can 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 fig. 20 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 fig. 20.

WIRING COLOURS

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

Fig. 20 Remote box terminals

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INSTALLATION

16 September 2006 / WHISPER 9.5/12.5/15/20 ULTRA / US

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 fig. 20.

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 fig. 21. 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. 21: Connection for emergency stop / fire alarm switch

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 blocking and setting up this options refer to the APPENDIX of the DDC users manual. One of these options is to monitor a second battery (not being the starter battery) to start the generator automatically when the voltage of this battery drops 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. 20. 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 9.5 Ultra Whisper 12.5 Ultra Whisper 15 Ultra

70Ah

Whisper 20 Ultra 120Ah

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 propulsion engine and the domestic DC supply system completely separate and individually connected to separate batteries.

230VAC

IVO 12/10

12V

Fig. 22 Starter battery

Remove bypass between J7 - J18

Normal operation

Alarm / emergency

local control panel (rear view)

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INSTALLATION

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However, the negative of all the batteries on the vessel should be interconnected (when on earth) to avoid difference in the voltage level of the earth on different places causing trouble to electronic devices which might be in the system. The above recommendation is not valid for ships having the starter battery of the propulsion engine or other auxiliary equipment positive grounded. When this is the case an expert should be consulted. 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 ship’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 OTHER RECOMMENDATIONS AND WARNINGS

The battery should be secured for seagoing 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 vessel should not to be used as a conductor. The battery cables are supplied in a standard length of 5 feet (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 V olt supply system, never take off 12 Volt (starting) power from one of these batteries. This will result in severe damage t o 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.

1.5.5 AC power system (120/240 Volt)

Before working (installation) on the system read the sections on safety in the users manual.

Be sure that all electrical installations (including all safety systems) comply with all required regulations of the local authorities. All electrical safety/shutdown and circuit breaking systems have to be installed onboard as the generating set itself cannot be equipped with such equipment for every possible variation. The vessel’s power supply system should be suitable and safe for the AC voltage which is applied and the power that will be generated. Special attention has to be paid on dividing the system in branches which are fused individually. It is absolutely essential that each and every circuit in the on-board electrical system is properly installed by a qualified electrician.

1 FUSE

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

Maximum single phase output current

Model

120V 240V

Whisper 9.5 Ultra 80 Amps 40 Amps Whisper 12.5 Ultra 100 Amps 50 Amps Whisper 15 Ultra 125 Amp 62 Amps Whisper 20 Ultra 166 Amps 83 Amps

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

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INSTALLATION

18 September 2006 / WHISPER 9.5/12.5/15/20 ULTRA / US

2 GROUNDING

With the U.S.A. models neutral of the AC alternator is grounded. The housing of the alternator and all other metal parts are grounded as well.

The connection between “neutral” and “ground” is necessary as part of a insulation failure protection system as commonly used in the U.S.A.

WARNING

In all situations the transfer switches between shore, inverter and generator should switch all connections, the phase line (L) as wel as neutral (N). Off course this is the case when using a Mastervolt Masterswitch

For safety reasons connect the main ships ground to negative point of the generating set start battery. When a ungrounded DC system or positive grounded DC system is applied the battery negative should not be connected to the main ships ground.

3 CABLE

For the power cable we recommend the use of 4 wire oil resistant cable with a sufficient cross sectional area. One wire for earth is included. For 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 ship’s electrical supply system. This switch must ensure that all AC consumers can be switched off at once. This switch should also be installed to keep the generating set and shore (grid) power systems separate. Transfer switches - to switch over from shore to ship or from generating set to inverter - should be well 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 Masterswitch 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 Masterswitch switches automatically after 10 seconds delay time over to the generating set position.

Page 19

INSTALLATION SPECIFICATIONS

US / WHISPER 9.5/12.5/15/20 ULTRA / September 2006 19

2 INSTALLATION SPECIFICATIONS

2.1 GENERAL

1 Mount the generating set directly, without additional

vibration dampers, on a solid surface. 2 Connect the (sea) water inlet to the strainer. 3 Connect exhaust system. 4 Connect a siphon breaker or ‘air vent’ into the cooling

circuit, if necessary. 5 Connect ‘fuel supply line’ to the water separator/ fuel

filter. 6 Connect ‘fuel return line’ to the fuel tank. 7 Connect remote panel (just plug in). 8 Connect the AC cable from the AC box to the power

source selector (or Masterswitch). 9 Connect plus and minus from the 12V starter battery

to the battery cables. 10 Install a Mastervolt battery charger. (optional)

2.2 COMMISSION TABLE

1 Check if a siphon breaker (air vent) is necessary and

has been installed

2 Open the seawater inlet valve and check all water

connections. Check if the strainer is installed on or just above the seawater level.

3 Check if the exhaust system is properly installed.

Check maximum length of exhaust hose, diameter of exhaust hose, position of the water lock, maximum lift. Also check the minimum required height of 24" (60 cm) above sea level of the exhaust loop (goose neck).

4 Open the seawater outlet valve and check all water

connections. 5 Check the AC cables and the grounding. 6 Check if an AC breaker is installed befor e or after the

power source selector. When there is only a circuit

breaker, use it to disconnect the generating set from

the grid. 7 Check all DC connectio ns, check if the battery switch/

circuit breaker is closed. 8 Open the fuel valve. Check 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. 9 Check if the air intake in the canopy is not blocked. 10 Check the oil level and colour of the oil. Check the

coolant level 11 Bleed the fuel system; see chapter 4.2.2 of the user’s

manual 12 Start the engine by pushing the start button 13 Check when t he generating set is running, the delay

of 5 to 10 seconds in the power source selector

transfer. 14 Check voltage and frequency under ‘no load’

conditions. 15 Check voltage and frequency under ‘full load’

conditions. 16 Check if the battery charger of the generating set is

working (max. 14.5 Volt). 17 Close the sound shield and check the noise level. 18 Stop the generating set and check th e engine again

for leakages of oil, fuel or water.

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

Page 20

INSTALLATION SPECIFICATIONS

20 September 2006 / WHISPER 9.5/12.5/15/20 ULTRA / US

2.3 INSTALLATION SPECIFICATIONS

TECHNICAL DATA Model Whisper 9.5 Ultra Whisper 12.5 Ultra Whisper 15 Ultra Whisper 20 Ultra

Dimensions lxwxh. 35.4 x 22.6 x 25.2” 35.4 x 22.6 x 25.2” 41.7 x 22.6 x 25.2” 45.7 x 26.8 x 27.6” 90 x 58 x 64 cm 90 x 58 x 64 cm 106 x 58 x 64 cm 116 x 68 x 70 cm Weight including sound shield 735 lbs (334 kg) 735 lbs (334 kg) 838 lbs (380 kg) 1000lbs (4 54kg) Max. operation angle 25° 25° 25° 25° Remote panel 15 m cable Digital Diesel Control System Battery capacity min. 12V / 70Ah 12V / 70Ah 12V / 70Ah 12V / 120Ah Fuel consumption (load dependent)

0.53 – 1.2 US gph 1,5 – 4 litre/hour

0.53 – 1.2 US gph 1,5 – 4 litre/hour)

0.53 – 1.4 US gph 2-5.5 litre/hour

0.53 – 2 US gph 2-7 litre/hour

Model fuel pump Electrical driven

12V

Electrical driven 12V

Mechanical driven

Manual priming Max lift fuel pump 3 ft / 1m 3 ft / 1m 3 ft / 1m 3 ft / 1m Cooling Indirect Indirect Indirect Indirect Cooling pump Mastervolt self priming raw water impeller pump, PTO driven Model cooling pump M12 M12 M12 M16 Minimum water supply 4.8 – 6 US gpmin

(18-22 l/min.)

4.8 – 6 US gpmin (18-22 l/min.)

5.3 – 6.6 US gpmin

(20-25 l/min.) Alternator synchronous brushless, maintenance free water cooled Voltage regulation capacitor (+ optional: AVR ) Output power at 60Hz power factor cos phi = 1

9.5 kW 12.5 kW 15 kW 20 kW

Battery charger alternator including regulator (50 Amps)

2.4 SPECIFICATION OF THE ACCESSORIES

Model: Whisper 9.5 Ultra

Whisper 12.5 Ultra Whisper 15 Ultra

Whisper 20 Ultra

Water scoop 3/4” = 19 mm 1” = 25.4 mm Inlet valve 3/4” in / 3/4” out (19 mm in / 19 mm out) 1” in / 1” out (25.4 mm in / 25.4 mm out) Water strainer 3/4” in / 3/4” out (19 mm in / 19 mm out) 1” in / 1” out (25.4 mm in / 25.4 mm out) Air vent 3/4” = 19 mm 1” = 25.4 mm Inlet suction hose 3/4” = 19 mm 1” = 25.4 mm Fuel filter/water separator 30 micron 30 micron Fuel inlet and return 5/16” = 8 mm 5/16” = 8 mm Exhaust hose Ø 2” = 51 mm inner Ø 2” = 51 mm inner Water lock Ø 2” = 51 mm Ø 2” = 51 mm Water/gas separator Ø 2” (51mm) – 1 5/8’ (40mm) – 2” (51mm) Ø 2” (51mm) – 1 5/8’ (40mm) – 2” (51mm) Anti shock mounts Included Included Battery charger (optional) IVO SMART 12/10; 12V / 10 Amps, 230V-50/60Hz

Page 21

INSTALLATION SPECIFICATIONS

US / WHISPER 9.5/12.5/15/20 ULTRA / September 2006 21

2.5 INSTALLATION MATERIALS

WATER INLET KIT 3/4” (20 mm) for Whisper 9.5 Ultra, 12.5 Ultra and 15 Ultra

no qty article no description dimensions 1 1 50230052 Intake strainer 3/4” 2 1 50230042 Lever operated ball valve FF 3/4” 3 1 50221004 Male hose connection 3/4” x 25mm 4 4 50221502 Hose clamps 19-29 mm 5 3 50220056 Outboard cooling water hose 20x28 mm 6 2 50221007 Male hose connection 1/2 x20 7 1 50230060 Nickel plated brass intake strainer 1/2 8 1 50230067 Mounting bracket waterstrainer

TOTAL 50230211 WATER INLET KIT 20 mm

WATER INLET KIT 1” (25.4 mm) for Whisper 20 Ultra

no qty article no description dimensions 1 1 50230053 Intake strainer 1” 2 1 50230043 Lever operated ball valve FF 1” 3 1 50221010 Male hose connection 1” x 25 mm 4 4 50221503 Hose clamps 26-38 mm 5 3 50220050 Outboard cooling water hose 25x33 mm 6 2 50221008 Male hose connection 3/4” x 25 mm 7 1 50230061 Nickel plated brass intake strainer 3/4”

TOTAL 50230221 WATER INLET KIT 25 mm

AIR VENT KIT 3/4” (20 mm) for Whisper 9.5 Ultra, 12.5 Ultra and 15 Ultra

no qty article no description dimensions 4 7 50221502 Hose clamps 19-29 mm 5 3 50220056 Outboard cooling water hose 20x28 mm 11 2 50221031 Bend male type with hose connection 1/2x1/2 12 1 50221042 TEE fittings 1/2 13 1 50230001 Syphon breaker valve 1/2 14 1 50221001 Male hose connection 3/8x1/2 15 1 50221521 Hose clamps 12-20 mm 16 1,5 50220055 Outboard cooling water hose 12x18.2 mm

TOTAL 50230212 AIR VENT KIT 20 mm

AIR VENT KIT 1” (25 mm) for Whisper 20 Ultra

no qty article no description dimensions 4 7 50221503 Hose clamps 26 - 38 mm 5 3 50220050 Outboard cooling water hose 25 x 33 mm 11 2 50221083 Bend male type with hose connection 3/4 12 1 50221043 TEE fittings 3/4 12 1 50221102 Straight reducer 3/4 x 1/2 13 1 50230001 Syphon breaker valve 1/2 11 2 50221008 Male hose connection 3/4 x 25 14 1 50221001 Male hose connection 3/8x13 15 1 50221521 Hose clamps 12-20 mm 16 1,5 50220055 Outboard cooling water hose 12x18.2 mm

TOTAL 50230222 SYPHON BREAKER KIT 25 mm

Page 22

INSTALLATION SPECIFICATIONS

22 September 2006 / WHISPER 9.5/12.5/15/20 ULTRA / US

WHISPE R 12ULTRA

WHISPER 16ULTRA

Fig. 23: Installation materials water inlet and air vent

* Hose drain should go downwards. Water must flow out freely. Refer to installatio n manual for proper installation air-vent kit. Faulty installation can cause serious problems

Whisper 9.5 Ultra

Whisper 12.5 Ultra

Whisper 15 Ultra

Whisper 20 Ultra

Page 23

INSTALLATION SPECIFICATIONS

US / WHISPER 9.5/12.5/15/20 ULTRA / September 2006 23

EXHAUST KIT 2” (51 mm)

no qty article no description dimensions 22 5 50221541 Hose clamps 55-62 mm 23 3 50220035 Marine exhaust hose 2” (51 mm) inner 24 1 50230072 Waterlock 2” (51 mm) 25 1 50230034 Brass through hull fitting 1 ½ x 70 26 1 50221024 Female hose connector 1 ½ x 2”

TOTAL 50230213 EXHAUST KIT 2” (51 mm)

OPTIONAL INSTALLATION MATERIALS

no qty article no description dimensions 21A 1 50230077 Elbow 90° adapter exhaust hose 2” (51 mm) 22 2 50221541 Hose clamps HD 55-62 mm

WATER SEPARATOR KIT 51 mm

no qty article no description dimensions 21 2 50221506 Hose clamps 44-56 mm 22 2 50221541 Hose clamps HD 55-62 mm 23 2.5 50220035 Marine exhaust hose 2” (51 mm) inner 40 1.5 50220033 Marine exhaust hose 1 5/8” (40 mm) inner 31 1 50221015 Male hose connection 1 1/4 x 40 32 1 50230044 Lever operated ball valve FF 1 1/4 33 1 50230033 Brass through hull fitting 1/1/4x70 34 1 50230081 Water exhaust fumes separator 2”-1 5/8”-2” (51-40-51 mm) 35 4 50201121 Vibration mounting 25x30 mm M8 36 4 50211152 Bolt M8x16 37 4 50211465 Nut M8 38 8 50211405 Washer M8 39 8 50211445 Lock washer M8

TOTAL 50230214 W ATER SEPARATOR KIT 51 mm

Page 24

INSTALLATION SPECIFICATIONS

24 September 2006 / WHISPER 9.5/12.5/15/20 ULTRA / US

WHISPER 12ULTRA

Fig. 24: Installation materials exhaust Whisper 9.5 Ultra, 12.5 Ultra and 15 Ultra.

Whisper 9.5 Ultra Whisper 12.5 Ultra Whisper 15 Ultra

Page 25

INSTALLATION SPECIFICATIONS

US / WHISPER 9.5/12.5/15/20 ULTRA / September 2006 25

WHISPE R 16ULTRA

Fig. 25: Installation materials exhaust Whisper 20 Ultra.

Whisper 20 Ultra

Page 26

INSTALLATION SPECIFICATIONS

26 September 2006 / WHISPER 9.5/12.5/15/20 ULTRA / US

FUEL KIT USA

no qty article no description dimensions 42 1 50230090 Fuel strainer/water separator M14x1.5 mm 44 2 50221644 Reducing male nipple M14-M16 60 gr. 45 2 50221615 Hose connection 5/16” (8 mm) 46 2 50221616 Nut coupling M16x1.5 mm 48 4 50221522 Hose clamps 10-16 mm

TOTAL 50230205 FUEL KIT

OPTIONAL INSTALLATION MATERIALS

no qty article no description dimensions 51 1 50220063 fuel hose 8x16 mm

BATTERY INSTALLATION KIT 70 Ah for Whisper 9.5 Ultra, 12.5 Ultra and 15 Ultra

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

BATTERY INSTALLATION KIT 160 Ah for Whisper 20 Ultra

no qty article no description dimensions 51 1 62001600 Mastervolt AGM Battery 12V/160Ah 160Ah 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 6503003508 cable connectors M8x35

TOTAL 50230220 BATTERY INSTALLATION KIT 160 Ah

Page 27

INSTALLATION SPECIFICATIONS

US / WHISPER 9.5/12.5/15/20 ULTRA / September 2006 27

WHISPER 12ULTRA

Fig. 26: Installation materials battery and fuel Whisper 9.5 Ultra, 12.5 Ultra and 15 Ultra

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

Whisper 9.5 Ultra Whisper 12.5 Ultra Whisper 15 Ultra

Page 28

INSTALLATION SPECIFICATIONS

28 September 2006 / WHISPER 9.5/12.5/15/20 ULTRA / US

WHISPER 16ULTRA

Fig. 27: Installation materials battery and fuel Whisper 20Ultra

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

Whisper 20 Ultra

Page 29

DIAGRAMS & DRAWINGS

US / WHISPER 9.5/12.5/15/20 ULTRA / September 2006 29

3 DIAGRAMS & DRAWINGS

3.1 DC WIRING WHISPER 9.5 ULTRA, 12.5 ULTRA AND 15 ULTRA

Fig. 28a: DC wiring diagram Whisper 9.5 Ultra and 15 Ultra

Page 30

DIAGRAMS & DRAWINGS

30 September 2006 / WHISPER 9.5/12.5/15/20 ULTRA / US

Fig 28b: Electrical Diagram control wiring Whisper 12.5 Ultra