Page 1
INSTALLATION MANUAL
WHISPER 3,5
- 3000 RPM -
Marine diesel generating set 230V / 50Hz
Digital Diesel Control
Art.nr. 50200311
MASTERVOLT
Snijdersbergweg 93,
1105 AN Amsterdam
The Netherlands
Tel.: +31-20-3422100
Fax.: +31-20-6971006
www.mastervolt.com
V2. October 2004
Page 2
CONTENTS
This manual applies to the Mastervolt Whisper 3,5 Marine Diesel Generating
set controlled by Digital Diesel Control first launched in April 2004. For earlier
models refer to other manuals available on our website: www. mastervolt.com
CONTENTS:
1
INSTALLATION....................................................................................................................................................................3
1.1 Location ..................................................................................................................................................................3
1.2 Instructions for optimal sound and vibration insulation ..........................................................................................3
1.2.1 Steel base plate.....................................................................................................................................3
1.3 Ventilation ...............................................................................................................................................................3
1.4 Connections............................................................................................................................................................4
1.4.1 Fuel supply............................................................................................................................................4
1.4.2 Cooling ..................................................................................................................................................7
1.4.3 Exhaust system.....................................................................................................................................8
1.4.4 Digital Diesel Control system (12 Volt) .............................................................................................. 12
1.4.5 AC power system (230 Volt) .............................................................................................................. 14
2 INSTALLATION SPECIFICATIONS ................................................................................................................................. 15
2.1 Whisper 3,5 installation table .............................................................................................................................. 15
2.2 Commission table ................................................................................................................................................ 15
2.3 Installation specifications Whisper 3,5 ................................................................................................................ 16
2.4 Specification of the accessories.......................................................................................................................... 17
2.5 Installation materials Whisper 3,5 ....................................................................................................................... 17
3 DIAGRAMS & DRAWINGS............................................................................................................................................... 21
3.1 DC wiring diagram............................................................................................................................................... 21
3.2 Wiring codes and colours .................................................................................................................................... 22
3.3 AC wiring diagram 230V / 50Hz .......................................................................................................................... 23
3.4 Remote control panel drawings........................................................................................................................... 24
3.5 Whisper 3,5 dimensions ...................................................................................................................................... 25
2 October 2004 / WHISPER 3,5 / EN
Page 3
INSTALLATION
1 INSTALLATION
To ensure reliability and durability of the equipment, it is
very important that the installation is carried out with the
utmost care and attention. To avoid problems, such as
temperature problems, noise levels, vibration, etc. the
instructions set out in this manual must be followed and all
installation work must be carried out professionally.
1.1 LOCATION
Since Whisper generating sets have extremely compact
dimensions, they can be installed in tight locations. 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 side
to have access to the raw water pump and oil strainer.
Please also note that in spite of the automatic oil pressure
sensor it is still essential that the oil level is checked
regularly.
1.2 INSTRUCTIONS FOR OPTIMAL SOUND
AND VIBRATION INSULATION
Position the generating set as low as possible in the
vessel. As the generating set is already secured to the
base frame by means of flexible engine mountings, the
frame can be mounted directly to the vessel’s main
structure.
1.2.1 Steel base plate
However to keep resonant vibrations at a minimum, it is
recommended to mount the generating set on a solid steel
base plate, approx. 30 mm weighing approx. 44 kg or 50%
of the weight of the generating set. The engine draws its
inlet combustion air through several holes in the capsule
base. Therefore the capsule must be fitted with sufficient
clearance between the capsule underside and the base
plate. A steel base plate is available from Mastervolt as an
optional accessory (ref. fig. 12, page 15).
Further recommendations
Whisper generating sets are standard equipped with a
"GRP" (Glass Reinforced Plastic) 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 Avoid mounting the generating set in close proximity
to thin walls or floors that may cause resonance.
2 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 at least be reinforced with stiffening struts or
ribbing. If possible, holes should be bored or cut
through the surface to help reduce the resonance.
Covering the surrounding walls and floors with a
heavy coating plus foam will certainly improve the
situation.
3 Never connect the base of the generating set directly
to bulkheads or tanks.
1.3 VENTILATION
The generating set normally draws air from the engine
room. Engine rooms with natural ventilation must have
vent openings of adequate size and location to enable the
generating set to operate without overheating. To allow an
ample supply of air within the temperature limits of the
generating set an opening of at least 100 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.
EN / WHISPER 3,5 / October 2004 3
Page 4
INSTALLATION
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.
1.4 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 fig. 1.
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
1.4.1 Fuel supply
1 FUEL TANK
Fuel tanks should be made of appropriate material
such as (stainless) steel or plastic. Steel tanks should
not be galvanised or painted inside. Condensation
can occur in metal tanks when temperature changes.
Therefore, water accumulates at the bottom of the
tank and provisions should be made for the drainage
of this water.
The tank will need a filling connection, a return
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.
1 Battery + 5 By-pass air vent 9 Fuel in 13 Cable fuel lift pump.
2 Fuel return 6 Water return 10 Remote cable
3 Exhaust 7 Water in 11 Battery -
4 Water out 8 Oil strainer 12 AC cable
Fig. 1
4 October 2004 / WHISPER 3,5 / EN
Page 5
Fig. 2.
INSTALLATION
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 (A).
When the return is on the top - in case of a leakage
the return line cannot overflow because of siphoning.
One will only need a fuel cock in the fuel supply line.
Fig. 2
1
5
3
2
7
6
1 Fuel return;
2 Fuel supply;
3 Prefilter / water separator (optional);
5 Fuel tank;
6 Standard fuel lift pump;
7 Standard fuel filter.
EN / WHISPER 3,5 / October 2004 5
Page 6
> 1m
1
2
3
4
5
6
7
INSTALLATION
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 to
discharge under the lowest fuel level. This prevents
air getting into the fuel line. Here also one needs a
fuel cock only in the supply line.
Fig. 3
Both supply and return fuel pipe lines should be
appropriate material and 8 mm outer diameter tubing.
The quality of the tubing of fuel pipes could be
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
connection 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
heaters, 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 Fuel return;
2 Fuel supply;
3 Prefilter / water separator (optional);
4 Extra fuel lift pump (optional);
5 Fuel tank;
6 Standard fuel lift pump;
7 Standard fuel filter.
6 October 2004 / WHISPER 3,5 / EN
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INSTALLATION
1.4.2 Cooling
Intercooling is based on a raw water pump, heat
exchanger and water-injected 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.
Fig. 4.
1 Water level 5 Air vent;
2 Water/exhaust separator 6 Water strainer;
3 Seacock 7 Seacock.
4 Waterlock
1 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 suction resistance in the line at a minimum, the
sea water intake system (i.e. sea cock, tru-hull fitting,
inlet filter, etc.) must have an inner diameter of at
least 12.5 mm diameter ( 1/2"). 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 wetexhaust outlet. The flow rate should be 8 to 12 litres
/min.
max.
120 cm
min.
60 cm
EN / WHISPER 3,5 / October 2004 7
Page 8
INSTALLATION
2 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!
Fahrtrichtung
sailing direction
Einlass durch den Schiffsrumpf
thru-vessel inlet
flow direction
Flie§richtung
FALSCH!
WRONG!
waterline, an air vent must be installed. Extend the
water hose of the by-pass 600 mm above waterline
and install an air vent. Ideally, the air vent should be
mounted above the yacht keel center line (i.e. to
minimize the influence of swaying on the water
intake). The hose of the drain should go downwards.
Water must flow out freely and air has to flow in freely
as well. (refer to fig. 15).
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
WARRANTEE
Check the air vent at regular intervals. Open, clean
and lubricate the valve as required (fig. 6).
Fig 5.
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. Use a sealant when mounting the skin
fitting.
3 WATER STRAINER
Use an appropriate water strainer with connections of
12.5 mm (1/2"). Install the water strainer in a well
accessible position, (refer to fig. 4-6) 5 cm above the
waterline.
4 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. Hose of 12.5 mm (1/2")
inner diameter should be used.
If the generating set cannot be mounted such that the
bottom of the generating set is placed above the
Fig 6.
1.4.3 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.
8 October 2004 / WHISPER 3,5 / EN
Page 9
INSTALLATION
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 the entire water volume held in the
hose from the top of the goose neck to the water lock.
The water lock must be installed at the lowest point of
the exhaust system (ref. to fig. 7-1). The exhaust hose
must have an inner diameter of 40 mm no less, no
more-. The exhaust system must be installed so that
the back pressure inside the exhaust does not exceed
0,8 psi 60 cm. waterpressure (refer to paragraph 5.4.3
of the users manual) and total length up to the outlet
or water separator does not exceed 2,5 m. The
exhaust hose descends from the capsule to the water
lock. Then the hose rises maximum lift 120 cm via the
"goose neck" to the through-hull exhaust outlet,
situated minimum 50 mm above the water line (refer
to fig. 7-5. The "goose neck" must be vertical and
situated preferable along the ship’s keel center line. It
is recommended to install an extra muffler fig.7 (2)
close to the through-hull fitting.
Because of the small gas flow of the small
engine it is very important to keep strictly to
the instructions above. Some mufflers and
water locks cause too high back pressure.
You are advised to use a Mastervolt
installation kit or check the back pressure
(refer to paragraph 5.4.3 of the users manual).
Too high back pressure causes the system to
fill up with water that affects the outlet valve
and valve seat.
3
6
Fig 7
1 Exhaust water lock;
2 Exhaust outlet muffler;
3 Exhaust line Ø 40 mm;
4 Goose neck;
5 Through-hull exhaust outlet Ø 40 mm;
6 Water level.
Max. total length 2,5 m
max. total length 2,5 m
1
4
max.
Max.
lift
lift
120 cm
120 cm
min.
2
Min
60 cm
60 cm
3
5
EN / WHISPER 3,5 / October 2004 9
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INSTALLATION
2 "SUPER SILENT" EXHAUST SYSTEM
In order to reduce the noise level of the generating set
to a minimum, an option to reduce the exhaust noise
further (especially exhaust water splashing) is an
exhaust/water separator. The exhaust/water
separator allows the cooling water to be ejected
through a line separate from the exhaust fumes and
also functions as a goose neck to prevent water from
flooding the engine. The exhaust/water separator is
mounted more than 60 cm above the water level.
shortest possible path to the through-hull outlet.
Only when using an exhaust /water separator the
exhaust may have a length up to 7,5m after the
water/gas-separator. However water traps should be
avoided as the fumes still contain water and this
should not accumulate in bents. Under no
circumstances the hose may go up again. (Refer to
fig. 8a) An additional outlet exhaust muffler close to
the hull outlet will help further to reduce noise
emission. (Refer to fig. 9)
A
Fig. 8.
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 2,50 m.) The sea
water from the separator must run down along the
Fig. 8a.
10 October 2004 / WHISPER 3,5 / EN
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INSTALLATION
Fig. 9.
If the generating set and the exhaust system have
been installed correctly, neighbouring boats will not
be disturbed 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 run to the through-hull outlet
along the shortest possible path. The sea water outlet
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. 10).
Do not direct the outlet directly toward the
water surface.
Fig 10
EN / WHISPER 3,5 / October 2004 11
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INSTALLATION
1.4.4 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
an 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 communication cable is in the standard supply
too. If necessary an optional longer (max 30 m)
intermediate cable can be connected if the standard
length does not suit the required distance. When a
longer distance than 30 m is required, consult the
Mastervolt service department for advice. Refer to fig.
11.
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.
12 when fitting cable to the green connector. Some
software versions in old system panels (supplied
before may 2004) could conflict with the software in
the DDC and an up-date 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. 12.
WIRING COLOURS
1 RED
2 GREEN
3 BROWN
4 YELLOW
5 PINK
6 PURPLE
7 BLUE
8 WHITE
9 RED/BLUE
10 GREY/PINK
11 GREY
12 BLACK
Fig. 11
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 be 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.
Fig. 12
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. 12.
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.
The Mastervolt Digital Diesel Control system offers
several options for automatic starting and stopping.
12 October 2004 / WHISPER 3,5 / EN
Page 13
INSTALLATION
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
below 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. 12. 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 3,5 requires a battery with a
capacity of at least 55 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.
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.
The starter battery is charged by the standard internal
charger in the alternator. 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.
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 used and the vessel should not to be
used as a conductor.
In the negative battery cable a 250 Amp starter
battery switch could be applied to switch off the
battery. 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
230V AC
IVO 12/10
A
EN / WHISPER 3,5 / October 2004 13
B
12V
Page 14
INSTALLATION
severe damage to the 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.
1.4.5 AC power system (230 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 input fuse (from the generating set to the system)
should be installed to protect the installed electrical
system. The fuse should be sized such that the rated
generating set current is not exceeded by more than
15%.
For the Whisper 3,5 the maximum single phase
current is 13A fro 230V or 25A for 120V. 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.
Measures against earth insulation failures are often
subject to local regulations. The housing of the
alternator and all other metal parts are grounded. For
safety reasons connect the main ships ground to
negative point of the generating set start battery.
When an ungrounded return DC system or positive
grounded DC system is applied the battery negative
should not be connected to the main ships ground.
To make a connection between “neutral” and “ground”
could be necessary as part of a specific insulation
failure protection system.
Small pleasure craft in Europe 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. (Refer to page 53)
Warnings:
In all situations the transfer switches between
shore, inverter and generator should switch
both neutral and L1. Of course this is the case
when using a Mastervolt Masterswitch.
Be aware that insulation protection systems can be
different for different applications and even within the ship
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.
3 CABLE
For the power cable we recommend the use of 3 wire
oil resistant cable with a cross sectional area of 2.5
mm2 for 230V. One wire for earth is included. For
very long cables it is recommended to apply cables
with a larger cross section than the mentioned above.
4 TRANSFER SWITCH
A power source selector switch much be installed
between 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
chattering.
14 October 2004 / WHISPER 3,5 / EN
Page 15
INSTALLATION
Mastervolt advises 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
2 INSTALLATION SPECIFICATIONS
2.1 WHISPER 3,5 INSTALLATION TABLE
Fig. 12
1 install a steel foundation plate between ship’s hull and
generating set, with 4 shock mounts (ref. to fig. 12)
‘foundation plate’.
2 Mount the generating set directly to the foundation
plate.
3 Connect the (sea) water inlet to the strainer.
4 Connect exhaust system.
5 Connect a siphon breaker or ‘air vent’ into the cooling
circuit, if necessary.
6 Connect ‘fuel supply line’ to the water separator/ fuel
filter.
7 Connect ‘fuel return line’ to the fuel tank.
8 Connect remote panel (just plug in).
MASTERSWITCH switches automatically after 10
seconds delay time over to the generating set
position.
9 Connect the AC cable from the AC box to the power
source selector or MASTERSWITCH.
10 Connect plus and minus from the 12V starter battery
to the battery cables.
11 Install a Mastervolt battery charger. (optional)
2.2 COMMISSION TABLE
1 Check if a siphon breaker (air vent) is necessary and
has been installed and that the drain is without bents
and air can flow in freely.
2 Open the seawater inlet valve and check all water
connections. Check if the strainer is installed above
the seawater level.
3 Check if the exhaust system is properly installed. Also
check the minimum required height of 600 mm above
sea level of the exhaust loop (goose neck). Check
length of exhaust hose, diameter of exhaust hose,
position of the waterlock, maximum lift.
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 and bleed the fuel system.
Ensure there is sufficient fuel. The Whispers are self
bleeding. To check the well functioning release the
bleed screw on the high pressure fuel pump. Push the
start button activating the electric system and
activating the fuel pump. When more time is needed
EN / WHISPER 3,5 / October 2004 15
Page 16
INSTALLATION SPECIFICATIONS
to bleed, push “start” and hold on the local control
panel (so not on the remote panel). Hold as long as
necessary to bleed the system. Retighten the bleed
screw when no further air bubbles are expelled.
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 color of the oil.
11 Start the engine by pushing the start button.
12 Check when the generating set is running, the delay
of 3 seconds in the power source selector transfer.
13 Check voltage and frequency under ‘no load’
conditions.
14 Check voltage and frequency under ‘full load’
conditions.
15 Check if the battery charger of the generating set is
working (max. 14.2 Volt).
16 Close the sound shield and check the noise level.
17 Stop the generating set and check the 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.
2.3 INSTALLATION SPECIFICATIONS WHISPER 3,5
TECHNICAL DATA
Article no 50900500
Dimensions wxdxh. 505x400x500 mm
Weight 97 kg including sound shield
Max. operation angle 25°
Remote panel 15 m cable Digital Diesel Control System
Battery capacity min. 12V, 55 Ah
Fuel consumption 0,7-1,5 l/hr, load dependent
Lift fuel pump electric driven 12 V DC, max. lift 1 m
Cooling indirect cooling
Cooling pump raw water Mastervolt self priming impeller pump, PTO driven, type K
Minimum water supply 8-10 l/min
Crank case lube oil capacity 1.3 litre + 0.2 oil cooler, total 1.5 litre
Alternator synchronous brushless, maintenance free water cooled
Voltage regulation capacitor
Output power 230V 50 Hz 3,6 KVA cos phi = 0,8; 3 KVA = 3 kWatt cos phi = 1
Battery charger additional 12V winding including regulator (6 Amps)
16 October 2004 / WHISPER 3,5 / EN
Page 17
INSTALLATION SPECIFICATIONS
2.4 SPECIFICATION OF THE ACCESSORIES
Water scoop min. 1/2” (recommended 3/4”)
Inlet valve min. 1/2" in 12.5 mm out (recommended 3/4” in 12.5 mm out)
Water strainer 12.5 mm in, 12.5 mm out
Air vent 12.5 mm
Inlet suction hose 12.5 mm
Fuel filter/water separator 30 micron
Fuel inlet and return 8 mm
Exhaust hose in/out Ø 40 mm
Water lock Ø 40 mm
Water/gas separator Ø 40 mm
Anti shock mounts art. nr. 50230552
Foundation plate min. 44 kg
Battery charger (optional) IVO SMART 12/10; 12V / 10 Amps
2.5 INSTALLATION MATERIALS WHISPER 3,5
WATER INLET KIT 13 mm
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 50221016 male hose connection 3/4x13
4 3 50221521 hose clamps 12-20 mm
5 3 50220055 outboard cooling water hose 12x18,2 mm
6 2 50221003 male hose connection 1/2x13
7 1 50230060 nickel plated brass intake strainer 1/2
8 1 50230067 mounting bracket waters trainer
TOTAL 50230201 WATER INLET KIT 13 mm
AIR VENT KIT 13 mm
no qty article no description dimensions
11 2 50221260 hose connector 13 mm
4 7 50221521 hose clamps 12-20 mm
12 3 50220057 warm cooling water hose 13x20 mm
13 2 50221082 elbow 90 º m/f 1/2
6 2 50221003 male hose connection 1/2x13
14 1 50221042 TEE fittings 1/2
15 1 50230001 siphon breaker valve 1/2
16 1 50221001 male hose connection 3/8x13
TOTAL 50230202 AIR VENT KIT 13 mm
EXHAUST KIT 40 mm
no qty article no description dimensions
21 1 50221481 hose connector 40 mm
22 5 50221506 hose clamps 44-56 mm
23 3 50220033 marine exhaust hose 40 mm
24 1 50230071 waterlock 40 mm
25 1 50230038 brass through hull fitting hose connection 1 1/4x40
TOTAL 50230203 EXHAUST KIT 40 mm
EN / WHISPER 3,5 / October 2004 17
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INSTALLATION SPECIFICATIONS
OPTIONAL INSTALLATION MATERIALS
no qty article no description dimensions
21A 50201830 elbow 90° adapter exhaust hose 40 mm
WATER SEPERATOR KIT 40 mm
no qty article no description dimensions
22 4 50221506 hose clamps 44-56 mm
23 2.5 50220033 marine exhaust hose 40 mm
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 50230080 water exhaust fumes separator 40-40-40
TOTAL 50230204 WATER SEPERATOR KIT 40 mm
FUEL KIT
no qty article no description dimensions
41 2 50221203 straight coupling 8 mm
42 1 50230090 fuel strainer/water separator M14x1,5 mm
43 2 50221618 parallel male stud coupling M14 - 8 mm
44 2 50221644 reducing male nipple M14-M16 60 gr.
45 2 50221615 hose connection 8 mm
46 2 50221616 nut coupling M16x1,5 mm
47 1 50221352 nipple hose pipe 8 mm
TOTAL 50230205 FUEL KIT
OPTIONAL INSTALLATION MATERIALS
no qty article no description dimensions
48 1 50222020 copper fuel pipe 6x8 mm
49 1 50220063 fuel hose 8x16 mm
BATTERY INSTALLATION KIT 55 Ah
no qty article no description dimensions
51 1 64000550 battery 55Ah
52 1 43011030 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 6503001608 cable connectors M8x16
TOTAL 50230206 BATTERY INSTALLATION KIT 55 Ah
BASE PLATE KIT
no qty article no description dimensions
61 4 50230052 rubber mountings M12
62 1 50230012 base plate Whisper 3,5
63 1 50230011 fastener kit base plate
TOTAL 50230207 BASE PLATE KIT
18 October 2004 / WHISPER 3,5 / EN
Page 19
INSTALLATION SPECIFICATIONS
fuel kit
battery installation kit
base plate kit
Fig. 14
EN / WHISPER 3,5 / October 2004 19
Page 20
INSTALLATION SPECIFICATIONS
- water inlet kit
- air vent kit
- exhaust kit
- water seperator kit
Fig. 15
20 October 2004 / WHISPER 3,5 / EN
* Hose drain should go downwards. Water must flow
out freely. Refer to installation manual for proper
installation of the air vent kit.
Faulty installation can cause serious damage.
Page 21
DIAGRAMS & DRAW INGS
3 DIAGRAMS & DRAWINGS
3.1 DC WIRING DIAGRAM
3A
Fig. 16
EN / WHISPER 3,5 / October 2004 21
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DIAGRAMS & DRAWINGS
3.2 WIRING CODES AND COLOURS
battery > starter motor red 16 mm2
starter motor > DCC 1 red 6 mm2
starter motor > LCP 13 red 2,5 mm2
battery > ground black 16 mm2
ground > LCP ground (GND) 2 black 2,5 mm2
DDC > glow plug 3 brown 4 mm2
DDC > starter solenoid 4 yellow 2,5 mm2
LCP > fuel lift pump + 5 brown 1,5 mm2
LCP > fuel lift pump – 15 black 1,5 mm2
DDC > LCD 5 grey 1,5 mm2
DDC > oil pressure switch 6 purple 1 mm2
LCP > oil pressure switch 6 purple/black 1 mm2
DDC > oil temperature switch 7 blue 1 mm2
LCP > oil temperature switch 7 blue/black 1 mm2
DDC > exhaust temperature switch 8 blue/green 1 mm2
LCP > exhaust temperature switch 8 blue/rose 1 mm2
DDC > fuel valve solenoid 9 green 1,5 mm2
DDC > stop solenoid 20 pink 2,5 mm2
DDC > current measuring transformer 11 black 1 mm2
DDC > current measuring transformer 11 red 1 mm2
DDC > LCP 19 orange 1,5 mm2
DDC > LCP 12 black 1,5 mm2
DDC > LCP 14 red 1,5 mm2
DDC > LCP 16 red/green 1,5 mm2
DDC > generator AC output 33 brown 1 mm2
DDC > generator AC output 33 blue 1 mm2
LCP > battery charger winding generator 10 red 1 mm2
LCP > battery charger winding generator 10 red 1 mm2
DDC=Digital Diesel Control Unit
LCP=Local Control Panel
Cable code number colour cross section
22 October 2004 / WHISPER 3,5 / EN
Page 23
DIAGRAMS & DRAW INGS
3.3 AC WIRING DIAGRAM 230V / 50HZ
Fig. 17
EN / WHISPER 3,5 / October 2004 23
EARTH AND NEUTRAL CONNECTED
Page 24
DIAGRAMS & DRAWINGS
3.4 REMOTE CONTROL PANEL DRAWINGS
The remote panel comes in a carton that can be used as
a template to drill the mounting hole.
Fig. 18
24 October 2004 / WHISPER 3,5 / EN
Page 25
DIAGRAMS & DRAW INGS
3.5 WHISPER 3,5 DIMENSIONS
Top view
Aufsicht
Box dimensions:
Kastenabmessungen:
• width: 505 mm
L nge : 505 mm
• depth: 400 mm
Breite : 400 mm
• height: 500 mm
H he : 500 mm
Gewicht : 86 kg
• weight: 97 kg
Service side
Service seite
Fig. 19
CONNECTIONS
• exhaust: 40 mm
• fuel hose: 8 mm
• sea water in: 13 mm
• air vent connection: 13 mm
• battery +: 16 mm2 red (included)
• battery -: 16 mm2 red (included)
• cables: 50 Hz : 3x 2.5 mm2 /
5 meter (included)
• remote control: 15 meter 8 wire twisted
communication cable (included)
EN / WHISPER 3,5 / October 2004 25
Page 26
26 October 2004 / WHISPER 3,5 / EN
Page 27
EN / WHISPER 3,5 / October 2004 27
Page 28
Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands
Tel : + 31-20-3422100 / F ax : + 31-20-6971006
MASTERVOLT
www.mastervolt.com / info@mastervolt.com
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