Mastervolt whisper 25 ultra Installation Manual

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Page 1

INSTALLATION MANUAL

WHISPER 25 ULTRA

- 1500 RPM -

Marine diesel generating set 230/400V / 50Hz

Digital Diesel Control

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

V3. November 2008

Art.nr. 50200451

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TABLE OF CONTENTS

Copyright © 2008 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.

TABLE OF CONTENTS:

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

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

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

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

1.3.1 Further recommendations ................................................................................................................. 3

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

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

1.5.1 Fuel supply........................................................................................................................................5

1.5.2 Cooling.............................................................................................................................................. 7

1.5.3 Exhaust system...............................................................................................................................10

1.5.4 Digital Diesel Control system (12 Volt)............................................................................................ 13

1.5.5 AC power system (230 / 400 Volt)...................................................................................................16

2 INSTALLATION SPECIFICATIONS..............................................................................................................................18

2.1 General ............................................................................................................................................................18

2.2 Commission table.............................................................................................................................................18

2.3 Installation specifications Whisper 25 ULTRA.................................................................................................. 19

2.4 Specifications of the accessories ..................................................................................................................... 19

2.5 Installation materials Whisper 25 ULTRA......................................................................................................... 20

3 DIAGRAMS & DRAWINGS ........................................................................................................................................... 25

3.1 DC wiring diagram............................................................................................................................................25

3.2 Terminal modes Whisper 25 ultra 115V / 400V 50Hz....................................................................................... 26

3.3 AC wiring diagram Tri-Phase with AVR 230V / 400V 50Hz (Star)....................................................................27

3.4 AC wiring diagram Single Phase with AVR (Double Delta) .............................................................................. 28

3.5 Whisper remote panel ...................................................................................................................................... 29

3.6 Whisper 25 ULTRA dimensions and footprint................................................................................................... 30

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INSTALLATION

1 INSTALLATION

1.1 General

This manual applies to the Mastervolt Whisper 25 ULTRA Marine Diesel Generating set controlled by Digital Diesel Control first launched in September 2005. This manual is valid for the following models:

Part number Description

51101005 Whisper 25 Ultra 230 Volt Single phase

– 1500rpm / Marine

51101006 Whisper 25 Ultra 230 Volt Single phase

– 1500rpm / Marine -ungrounded

51101305 Whisper 25 Ultra 230 / 400 Volt 3 phase

– 1500rpm / Marine

51101306 Whisper 25 Ultra 230 / 400 Volt 3 phase

– 1500rpm / Marine -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. The generating set is already secured to the base frame by means of flexible engine mountings. The base frame can be mounted to the vessel’s main structure on a second set of rubber mountings that is included in the delivery. Use the included mounting template to determine the mounting spots.

1.3.1 Further recommendations

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. See figure 1. Directly below the rubber mountings the structure should be supported vertically to the superstructure of the ship.

2 Avoid mounting the generating set in close proximity

to thin walls or floors that may cause resonance.

3 Sound dampenin g 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 generati ng set directly

to bulkheads or tanks.

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

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INSTALLATION

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 a half square meter (0,5 m

) 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 base. The connections are marked as shown in fig. 2. 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

01 Remote control 05 Bypass cooling water out Ø25.4mm 09 Fuel out Ø8mm 02 AC power output 06 Bypass cooling water in Ø25.4mm 10 Fuel in Ø8mm 03 Exhaust connection Ø63mm 07 Battery positive + 35mm2 11 Raw water inlet 04 Expansion tank 08 Battery negative - 35mm2 12 Rubber engine mounting

Fig. 2 Connections

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INSTALLATION

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.

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 electrical 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 (see figure 3). 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 (see figure 4)

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

Fig. 3 Fuel supply

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INSTALLATION

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

Fig. 4 Fuel supply

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 or to other consumers of diesel fuel, such as the propulsion engine and heaters 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.

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INSTALLATION

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 heat exchanger by outboard water (raw water or seawater). After the raw water is warmed up in the heat exchanger 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 with 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.

The hose goes through a hole in the canopy

MA X .

Fig. 5: 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.

Fig. 6. Internal cooling system

1 Water level; 2 Water/exhaust separator; 3 Seacock;

4 Waterlock; 5 Air vent; 6 Water strainer; 7 Seacock.

MIN. 60CM (24")

MAX. 150CM (60")

5 CM (2”)

MIN. 60CM (24")

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INSTALLATION

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, trough-hull fitting, inlet filter, etc.) must have an inner diameter of at least 25.4 mm diameter (1"). 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! (see figure

7).

Fig. 7 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.

SAILING DIRECTION

FLOW DIRECTION

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INSTALLATION

4 WATER STRAINER

Use an appropriate water strainer with connections of 25.4 mm (1"). Install the water strainer in a well accessible position, 5 cm above the waterline (see fig. 6, ref. 6).

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). See figure 2. In the standard delivery the connections are bypassed. Hose of 25.4 mm (1") inner diameter should be used.

If the generating set cannot be mounted such that the bottom of the generating set is placed above the waterline, an air vent must be installed. Extend the water hose of the by-pass 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). See figure 6, ref. 5.

Fast motorboats will lay deeper when sailing at large speed and can cause pressure on the waterinlet. This should be avoided to prevent fleeding the engine.

If the air vent is clogged the water hoses will not be vented when the generating set has stopped and water can be forced into the engine. This leads to immediate engine problems and eventually severe damage!

DAMAGE CAUSED BY THE INGRESS OF WATER IN THE ENGINE IS NOT COVERED BY GUARANTEE

OPEN

Fig 8: Wrong siphon breaker hose routing

On the valve is a little hose to drain a little water that could be spilled from the valve. See figure 8. This hose s hould go down and may not end under water, because it should ventilate air into the valve to break the siphoning.

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

OPEN

Fig. 9 Mastervolt siphon breaker

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INSTALLATION

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. 10, ref. 1). The exhaust hose must have an inner diameter of 63 mm (2½”). The exhaust system must be installed so that the back pressure inside the exhaust does not exceed 0.07 bar (1psi – 70 cm watercolumn) and total length from the genearot to the top of the goose neck or or water/separator does not exceed 3m (10 ft.). (Refer to paragraph 5.4.3 of the users manual).

The exhaust hose descends from the capsule to the water lock. Then the hose rises via the "goose neck" to the through-hull exhaust outlet, situated minimum 50 mm above the water line (see fig. 10, 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 60 cm (24") above the waterline, a "goose neck" must be installed to prevent the engine from overflowing. It is recommended to install an extra muffler close to the through-hull fitting.

1 Exhaust water lock; 2 Exhaust outlet muffler; 3 Exhaust line Ø 63 mm (2½”); 4 Goose neck 5 Through-hull exhaust outlet Ø 63 mm (2½”); 6 Water level.

Fig. 10. Exhaust system

Minimum 60cm (24")

Maximum 150cm (60")

5 cm (2")

Maximum length A-B =

3 meter (10 feet)

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INSTALLATION

1 Water level 3 Seacock

2 Water/exhaust separator 4 Waterlock

Figure 11: Super silent exhaust system

Figure 12: Only after the exhaust / water separator the exhaust hose may have a length of over 7.5 meter

MAX. 10CM (4")

MIN. 60CM (24")

MAX. 150CM (60")

MIN. 3CM (1,2")

Ø 51 mm (2”)

Ø 63 mm (2½”)

WRONG!

OK!

Max. length A - B = 3 m (10 ft.)

Maximum length: 10 m (30ft)

Ø 2½” (63 mm)

Ø 2” (51 mm)

Ø 2½” (63 mm)

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INSTALLATION

2 "SUPER SILENT" EXHAUST SYSTEM

See figure 11. 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 throug h a line (figure 11, ref. 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 60 cm above the water level an additional goose neck is not required.

If the through-hull exhaust outlet has to be mounted far from the generating set an exhaust/water separator must definitely be installed (Total length of the exhaust piping from generator to top of goose neck (water separator) is more than 3 m.) (ref. to fig. 12). The sea water from the separator must then run down along the shortest possible path to the through-hull outlet. Only after the exhaust/water separator the exhaust hose may have a length of over 7,5 m (ref. to fig. 12)

However water traps should be avoided as the fumes still contains water and this should not accumulate in bents (see figures 13a and 13b). An additional outlet exhaust muffler close to the hull outlet will help further to reduce noise emission (figure 10, ref. 2)

Figure 13a: Water trap in exhaust system

Figure 13b: Water will collect in the hanging bend of the exhaust gas hose and will cause back pressure

OK!

WRONG!

OK!

WRONG

Page 13

INSTALLATION

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, see figure 11) 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 (see fig. 14).

Do not direct the outlet directly toward the water surface.

Figure 14: Outlet direction

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 15 m intermediate 8-pole communic ation cable is in the standard supply too (refer to fig. 15). 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.

Fig. 15 Remote control cable

OK!

WRONG!

Page 14

INSTALLATION

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. 16 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. 16.

WIRING C OLOURS

RED GREEN BROWN YELLOW PINK PURPLE BLUE WHITE

GREY/ PI NK GREY

RED/BLUE

BLACK

MAX. 150 mA

WARNING RELAY

REMOTE CABLE

SENSE BAT. 2

121110987654321

Whisper Re mote Panel

WRP/2

Fig. 16 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 fig. 16.

Connection for emergency stop / fire alarm switch

Fig. 17 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. 17. 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

Remove bypass between J7 - J18

Normal operation

Alarm / emergency

local control panel (rear view)

Page 15

INSTALLATION

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. 16. 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 battery with a capacity of at least 120 Ah. 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. 18 Starter battery

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 kit, art. no. 50230220 (160Ah)

Page 16

INSTALLATION

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 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 are discharged during charging, the battery should be located in a well ventilated room. Ensure that the supplied battery cable connectors are properly fitted and never remove during or shortly after charging as sparking can occur, which may ignite the hydrogen gasses.

1.5.5 AC power system (230 / 400 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.

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.

The Whisper 25 ULTRA can be connected as a single phase 230 Volt generator by an arrangem ent of the wiring in double DELTA. When the wires are arranged in STAR the output will be 230/400Volt. Connected as a three phase 230/400 Volt generator, 3x 400 Volt is available between the phases. At the same time 230 Volt is available between every phase and neutral.

When applying 3 phases the installation should be laid out in such a way that there is a reasonable balance of lo ad between the three phases.

To avoid problems with unbalanced loads one co uld apply a 400V 3 phase to 230 Volt single phase transformer.

Page 17

INSTALLATION

1 FUSE

An input fuse (from the generating set to the system) should be installed to protect the installed electrical system. For the Whispers the maximum single phase current at 230V is 108 Amps. Using three phases the fuses shoul d be three times 36 Amps and mechanically connected. 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. Small pleasure craft in Europe (length up to 24 meter) is submitted to The Recreational Craft Directive 94/25/EC. The guidelines of this directive refer to (ISO 13297). When the installation comply to this standard the “neutral” and “ground” should be connected on the generating set by connecting the blue (neutral) wire with the terminal on which the yellow/green wire is connected. A Ground Fault Circuit Interrupter (GFCI) or similar device must be applied Be aware that insulation protection systems can be different for different applications and even within the shi p there could be different standards for different spaces. We did refer to the Recreational Craft Directive that applies to pleasure craft up to 24 m of length. Sometimes one has to comply with other standards such as the rules of certification societies like Lloyds Register of Shipping or Veritas, regulations for the protection of personal, building legislation, etc. It is of the greatest importance to have expert advice on this issue. 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 3 wire single phase or 5 wire tri-phase oil res istant 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.

WARNING

In all situations the transfer switches between shore, inverter and generator should switch all connections, the line(s) as wel as neutral.

Page 18

INSTALLATION SPECIFICATIONS

2 INSTALLATION SPECIFICATIONS

2.1 General

1 Install the generating set on the 4 anti vibration

mounts. Use the template included in the shipment to drill the 8 mounting holes.

MOUNTS

ANTIVIBRATI ON

Fig. 19 Antivibration mounts

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 t he power

source selector or MASTERSWITCH. 9 Connect plus and minus from the 12V starter batter y

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

2.2 Commission table

1 Check if a si phon 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 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 before 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 connections, 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 To bleed the fuel system use the manual pump by

turning the cap loose and pumping as long as

necessary to bleed the system 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 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 19

INSTALLATION SPECIFICATIONS

2.3 Installation specifications Whisper 25 ULTRA

TECHNICAL DATA

Dimensions incl. sound shield. 126 x 68 x 80 cm (L x W x H) Dimensions w/o. sound shield. 115 x 60 x 75 cm (L x W x H) Weight incl. sound shield 580 kg Weight w/o. sound shield 480 kg Max. operation angle 25° Remote panel 15 m cable Digital Diesel Control System Battery capacity min. 120 Ah Fuel consumption 1 – 6 l/hr, load dependent Lift fuel pump Mechanical driven; manually priming; lift 1m Cooling Indirect cooling Cooling pump Mastervolt self priming impeller pump, PTO driven, type M16 Minimum water supply 20-25 l/min Alternator synchronous brushless, maintenance free water cooled Voltage regulation AVR Output power at power factor cos phi = 1 25kW, 230V or 230/400V 50Hz Battery charger alternator including regulator (50 Amps)

2.4 Specifications of the accessories

Water scoop 1” = 25,4 mm Inlet valve 1” in / 25,4 mm out Water strainer 25,4 mm in, 25,4 mm out Air vent 25,4 mm Inlet suction hose 25,4 mm Fuel filter/water separator 30 micron Fuel inlet and return 8 mm Exhaust hose Ø 63 mm inner Water lock Ø 63 mm Water/gas separator Ø 63 - 51 - 63 mm Anti vibration mounts Included, art. nr. 50230552

Page 20

INSTALLATION SPECIFICATIONS

2.5 Installation materials Whisper 25 ULTRA

Figure 20: Installation materials Water inlet kit and Syphon breaker kit

WATER INLET KIT 1” (25 mm)

pos qty article no description 1 1 50230053 Intake strainer 1" 2 1 50230043 Lever operated ball valve FF 1" 3 2 50221008 Male hose connection 3/4x25 4 4 50221503 Hose clamp stainless 25-35 mm 5 3m 50220050 Cooling water hose transp.spiral 25x33mm 6 1 50230061 Nickel plated brass intake strainer 3/4" 7 1 50221010 Male hose connection 1"x25

TOTAL 50230221 WATER INLET KIT 25 mm

SYPHON BREAKER KIT 1” (25 mm)

pos qty article no description 1 1 50230001 Syphon breaker valve 2 1 50221043 TEE fittings 3/4" 3 2 50221083 Elbow 90 degr male/female 3/4" 4 4 50221503 Hose clamp stainless 25-45 mm 5 1 50221522 Hose clamp stainless 10-16 6 50221008 Male hose connection 3/4x25 7 1 50230002 TEE fitting syphon breaker valve 8 1 50221102 Straight reducer male/female 3/4-1/2 9 3m 50220050 Cooling water hose transp.spiral 25x33mm 10 1.5m 50220054 Cooling water hose transparant spiral 20x28 mm

TOTAL 50230222 SYPHON BREAKER KIT 25 MM (1")

Generator

cooling water inlet

WATER INLET KIT 1” (25 mm)

Generator

Bypass

cooling water out

Generator

Bypass

cooling water in

SYPHON BREAKER KIT 1” (25 mm)

Page 21

INSTALLATION SPECIFICATIONS

Figure 21: Delta L - exhaust kit and DeltaLl water/gas separator kit 63mm

DELTA L - EXHAUST KIT 63 mm

pos. qty article no description 22 8 50221542 Hose clamp heavy duty exhaust hose 63 mm 23 3m 50220036 Marine exhaust hose 63mm (2 1/2") 24 1 50230191 Waterlock 63 mm Delta L - 16 ltr 25 1 50230036 Brass through hull fitting 2 1/2"x122 26 1 50221012 Brass male hose connector 2 1/2"x63 29 1 50221098 Brass straight coupling 2 1/2" 30 1 50221078 Brass elbow female/female 2 1/2"

TOTAL 50230254 DELTA-L EXHAUST KIT 63 MM (16 LITER)

DELTA L WATER/GAS SEPARATOR KIT 63MM

pos. qty article no description 22 4 502 21542 Hose clamp heavy duty exhaust hose 63mm 35 4 502 21541 Hose clamp heavy duty exhaust hose 51mm 23 2.5m 50220036 Marine exhaust hose 63mm (2 1/2") 40 1.5m 50220035 Marine exhaust hose 51mm (2") 31 1 50221020 Male hose connectio n 11/2"x50 32 1 50230045 Lever operated ball valve FF 11/2" 33 1 50230034 Brass through hull fitting 11/2"x70 34 1 50230194 Water/gas separator 63/51/63mm Delta-L

TOTAL 50230264 DELTA L WATER/GAS SEPARATOR KIT 63MM

ADDITIONAL INSTALLATION MATERIALS

pos. qty article no description 21 1 50230087 Stainless bent 45 degr 63mm 2-1/2" 22 4 50221542 Hose clamp heavy duty exhaust hose 63mm 27 1 50230153 Straight coupling Delta L 63 mm 28 1 50230152 Elbow coupling (45º) Delta L 63 mm

Maximum torque hose clamps:

12Nm / 105 InLbs

Generator

exhaust

According to ABYC recommendations all hose connections

must be fitted with two hose clamps

Page 22

INSTALLATION SPECIFICATIONS

Figure 22 Installation materials fuel supply kit

FUEL SUPPLY KIT

pos. qty article no description 41 2 50221203 Straight coupling 8 mm 42 1 50230091 Filter head strainer fuel/water separator 43 2 50221618 Parallel male coupling M14- 8 mm 44 2 50221619 Parallel male coupling M14- 10 mm 45 2 50221620 Hose connection 8 mm outer cone 46 1 50230092 Filter for strainer fuel/water separator 47 2 50221252 Nipple hose pipe 8-8 48 4 50221522 Hose clamp stainless 10-16 49 2 50221632 Copper gasket ring 18x14x1,5 mm

TOTAL 50230205 FUEL SUPPLY KIT

Note: fuel pipes / fuel hoses are not included in the delivery of the fuel supply kit.

OPTIONAL INSTALLATION MATERIALS

• Additional installation parts pos. qty article no description 48 50221522 Hose clamp stainless 10-16 50 50222020 Copper fuel pipe per meter 51 50220063 Fuel hose per meter

• Spare parts pos. qty article no description 46 50230092 Filter for strainer fuel/water separator

Generator

fuel out

Generator

fuel in

Whisper 3.5

Page 23

INSTALLATION SPECIFICATIONS

Figure 23: Installation materials battery installation kit

BATTERY INSTALLATION KIT 160 Ah

pos. qty article no description 51 1 62001600 MV 12/160 Ah AGM Battery 52 1 43011000 IVO Smart 12/10 230V/50-60Hz IP65 charger 53 1 68060100 Battery terminal with nut M8 PLUS 54 1 68060200 Battery terminal with nut M8 MINUS 55 1 68456902 Terminal Cover RED 456N9V02 56 1 68456914 Terminal Cover BLACK 456N9V14 57 1 79006005 Batteryswitch ON/OFF with key 250A 58 2 6503003508 Cable lug 35mm² / M8 59 2 6503003510 Cable lug 35mm² / M10

TOTAL 50230220 BATTERY INSTALLATION KIT 160Ah

Generator

battery positive (+)

Generator

battery negative (–)

Page 24

INSTALLATION SPECIFICATIONS

Figure 24 Installation materials rubber mounting kit (standard included in the delivery of the Whisper 25 Ultra)

Page 25

DIAGRAMS & DRAWINGS

3 DIAGRAMS & DRAWINGS

3.1 DC wiring diagram

Figure 25 DC wiring diagram Whisper 25 Ultra

Page 26

DIAGRAMS & DRAWINGS

3.2 Terminal modes Whisper 25 ultra 115V / 400V 50Hz

Figure 26 Terminal modes 25U 115V-400V 50Hz

Page 27

DIAGRAMS & DRAWINGS

3.3 AC wiring diagram Tri-Phase with AVR 230V / 400V 50Hz (Star)

R EF ER TO 2.1.3 USER M ANUAL WHIS PE R 25U

* TO CONNECT NE UTR A L TO GROUND

Figure 27: AC wiring diagram Tri-Phase with AVR 230V / 400V 50Hz (Star)

Page 28

DIAGRAMS & DRAWINGS

3.4 AC wiring diagram Single Phase with AVR (Double Delta)

* TO CONNE CT NEUTRAL TO GROUND

REFER TO 2.1.3 USER MANUAL WHISPER 25U

Figure 28: AC wiring diagram Single Phase with AVR (Double Delta)

Page 29

DIAGRAMS & DRAWINGS

3.5 Whisper remote panel

Figure 29: Whisper remote panel

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

Page 30

DIAGRAMS & DRAWINGS

3.6 Whisper 25 ULTRA dimensions and footprint

Figure 30 Whisper 25 Ultra dimensions and footprint

CONNECTIONS WHISPER 25 ULTRA: POWERCABLES

• exhaust: 63 mm 2 1/2”

• fuel hose: 8 mm

• Whisper 25 ULTRA 230V single phase (108 Amps)

3x25 mm2 (not included)

• water inlet: 25 mm (1”)

• battery +: 35 mm2

• Whisper 25 ULTRA 230/400V 3 phases (3x 36Amps)

5x6 mm2 (not included)

• battery -: 35 mm2

REMOTE CABLE (ALL MODELS)

• 8 wire communication cable, 15 meter (included).

For longer lengths (max. 30 m), refer to Mastervolt service department

DIMENSIONS WHISPER 25 ULTRA

Incl. sound canopy Without sound canopy

• length 126 cm 115 cm

• width 68 cm 60 cm

• height 80 cm 75 cm

• weight 580 kg 480 kg

Page 31

NOTES

NOTES:

Page 32

Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands

Tel : + 31-20-3422100 / F ax : + 31-20-6971006

www.mastervolt.com / info@mastervolt.com