Page 1
MASTERVOLT
Snijdersbergweg 93
1105 AN Amsterdam
The Netherlands
Tel.: +31-20-3422100
Fax: +31-20-6971006
www.mastervolt.com
INSTALLATION MANUAL U.S.A. EDITION
V1. April 2004
WHISPER 3,5
-3600 RPM-
Marine diesel generating set 120V-60Hz
Digital Diesel Control
Art.no. 50200314
Page 2
2 April 2004 / WHISPER 3,5 / USA
Page 3
CONTENTS
USA / WHISPER 3,5 / April 2004 3
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.1 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.2 Instructions for optimal sound and vibration insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.2.1 Steel base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.2.2 Further recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.3 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.4 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.4.1 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.4.2 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
1.4.3 Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
1.4.4 Digital Diesel Control system 12 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
1.4.5 AC power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
2 INSTALLATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.1 Whisper 3,5 installation table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
2.2 Commission table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
2.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2.4 Specification of the accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
2.5 Installation material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3 DIAGRAMS AND DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.1. DC wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
3.2. Codes and colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3.3 AC wiring diagram120V / 60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
3.4 Remote control panel drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
3.5 Whisper 3,5 dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Page 4
INSTALLATION
4 April 2004 / WHISPER 3,5 / USA
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.
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 car-
ry out any maintenance work. The unit must be easily ac-
cessible 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 pressu-
re sensor it is still essential that the oil level is checked
regularly.
1.2 INSTRUCTIONS FOR OPTIMAL SOUND
AND VIBRATION INSULATION
Position the generating set as low as possible in the
vessel. As the generating set is already secured to the
base frame by means of flexible engine mountings, the
frame can be mounted directly to the vessel’s main struc-
ture.
1.2.1 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. 1,18" (30 mm) thick weighing approx.
44 kg or 50% of the weight of the generating set. The en-
gine 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).
1.2.2 Further recommendations
Whisper generating sets are standardly equipped with a
"GRP" (Glass Reinforced Polyester) sound cover. The
canopy has been designed to give effective sound insula-
tion. For optimum sound and vibration dampening, the
following factors should be considered.
1Avoid 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 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 15 square
inches (100 cm
2
) is required.
A "sealed" engine compartment must have a good ex-
traction ventilator to maintain reasonable engine room
temperatures. High temperature of intake air reduces en-
gine performance and increases engine coolant tempe-
ratures. Air temperatures above 104 ° F (40°C) reduce
the engine power by 2% for each 9° F (5°C) of rise. To
minimise these effects the engine room temperature
must not be more than 27° F (15°C) above the outside
ambient air temperature.
Apply a combination of ventilators, blowers and air intake
ducting to meet the temperature limit. The air inlet ducts
should run to the bottom of the engine room to clear
fumes from the bilge and to circulate fresh air. Air outlets
should be at the top of the engine room to remove the
hottest air. An engine room blower should be used as an
extraction ventilator to remove air from the engine room.
In cases where it is impossible to meet the above mentio-
ned temperature limit by using machine room ventilation,
connections are to be made for an air inlet directly to the
enclosure. With these connections the generating set can
be directly connected to an air duct.
Page 5
INSTALLATION
USA / WHISPER 3,5 / April 2004 5
Air inlets should be louvered, where appropriate, to pro-
tect the engine room and to protect the generating set
from water spray. As an extra precaution, the fitting of a
cowl ventilator with a cover box located as high as possi-
ble, is recommended.
1.4 CONNECTIONS
The generating set comes supplied with all supply lines
and output cable (i.e. electric cables, cooling water con-
nections, exhaust, fuel lines etc.) already connected to
the engine and generator. The supply lines are fed
through the capsule’s front base. The connections are
marked as shown in fig. 1.
All electrical connections, cable types and sizes must
comply to the appropriate national regulations. Supplied
cables are rated for ambient temperatures up to 160° F
(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 in the
user manual.
1.4.1 Fuel supply
1 FUEL TANK
Fuel tanks should be made of appropriate material
such as (stainless) steel or plastic. Steel tanks should
not be galvanised or painted inside. Condensation
can occur in metal tanks when temperature changes.
Therefore, water accumulates at the bottom of the
tank and provisions should be made for the drainage
of this water.
The tank will need a filling connection, a return con-
nection and an air ventilation connection which will
require protection against water entry.
Some official regulations do not allow connection
points at the base of the fuel tank; in this instance
connections are to be made at the top of the tank with
internal tubing down to a few inches above the
bottom of the tank.
1 Battery +;
2 Fuel return;
3 Exhaust;
4Water out;
5 By-pass air vent;
6Water return;
7Water in;
8 Oil strainer;
9 Fuel in;
10 Remote cable;
11 Battery -;
12 AC cable;
13 Cable fuel lift pump.
Fig. 1.
Page 6
INSTALLATION
6 April 2004 / WHISPER 3,5 / USA
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 3 ft. (1 m).
If the pump has to lift the fuel higher than 3 ft. (1 m)
an external fuel lift pump must be installed. The con-
trol board is already prepared to connect an extra fuel
pump.
3 FUEL PIPES
When the tank is above the generating set we recom-
mend ending the return line on the top of the tank (fig.
2). 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.
1
2
3
5
6
7
Fig. 2.
1 Fuel return;
2 Fuel supply;
3 Prefilter / water separator (optional);
5 Fuel tank;
6 Standard fuel lift pump;
7 Standard fuel filter.
Page 7
INSTALLATION
USA / WHISPER 3,5 / April 2004 7
When the tank is below the generating set we recom-
mend ending the return line on the bottom of the tank
(fig. 3) 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.
Both supply and return fuel pipe lines should be
appropriate material and 5/16 inner diameter tubing.
The quality of the tubing of fuel pipes could be sub-
mitted to local regulations depending on the applica-
tion of the vessel.
The fuel pipes can be plumbed to the flexible hoses
which are on the generating set. This fuel lines fulfils
CE standards and are according to ISO 7840 A2.
It is important to avoid bends in the pipes, as they
could trap air bubbles. The return pipe should never
be connected to the suction pipe. Other consumers of
diesel fuel, such as the propulsion engine and hea-
ters, have to be connected to separate suction and
return pipes
4 FUEL FILTERS
A fine fuel filter is installed which requires maintenan-
ce. Mastervolt advises to install an extra fuel filter/
water fuel separator near the fuel tank.
Before starting your generating set for the first time
follow the fuel system bleeding procedure in the users
manual.
> 1m
1
2
3
4
5
6
7
Fig. 3.
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.
Page 8
INSTALLATION
8 April 2004 / WHISPER 3,5 / USA
1.4.2 Cooling
Intercooling is based on a raw water pump, heat exchan-
ger 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 accepta-
ble range. Ensure that the installation complies to the
following installation instructions.
1RAW WATER SUPPLY
For raw water supply the following installation mate-
rials are required: -a skin fitting - a sea cock - a water
strainer - hoses and clamps. In order to keep the suc-
tion resistance in the line at a minimum, the sea water
intake system (i.e. sea cock, tru-hull fitting, inlet filter,
etc.) must have an inner diameter of at least 1/2"
(12.5 mm) diameter. 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 ho-
ses, 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 2 to 3
gallons/min. ( 8 to 12 litres /min.)
min. !
24 inches
(60 cm)
max. !
48 inches
(120 cm)
Fig. 4.
1Water level;
2Water/exhaust separator;
3 Seacock;
4Waterlock;
5 Air vent;
6Water strainer;
7 Seacock.
Page 9
INSTALLATION
USA / WHISPER 3,5 / April 2004 9
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 propul-
sion engines in motorboats the water scoop is often
mounted against the sailing direction to induce more
water intake for cooling.
This should not be done in the case of a
generating set! When sailing at higher
speeds not using the generator, water will
be forced into the inlet and your generating
set will overflow!
On motorboats and on sailing boats the water scoop
for a generating set should be fitted with the opening
faced backwards to prevent water being forced in du-
ring sailing. Use a sealant when mounting the skin
fitting.
3WATER STRAINER
Use an appropriate water strainer with connections of
1/2" (12.5 mm). Install the water strainer in a well ac-
cessible position, (refer to fig. 4-6) with the top 2 - 4
inches (5-10 cm.) above the waterline.
4 SIPHON BREAKER (AIR VENT)
When the point of water injection is below the water-
line, then - when the engine is stopped - there is a
risk that the cooling water may enter the engine as a
result of siphoning. To avoid this happening, the ge-
nerating set is designed to accommodate a siphon
breaker (air vent). In the standard delivery the con-
nections are bypassed. Hose of 1/2" (12.5 mm) 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 2 ft. (60 cm)
above waterline and install an air vent (refer to fig.
15). Ideally, the air vent should be mounted above the
yacht keel center line (i.e. to minimize the influence of
swaying on the water intake). The hose of the drain
should go downwards. Water must flow out freely; air
must flow in freely as well.
Fast motorboats will lay deeper when sailing at large
speed and can cause pressure on the waterinlet. This
should be avoided to prevent fleeding the engine.
If the air vent is clogged the water hoses
will not be vented when the generating set
has stopped and water can be forced into
the engine. This leads to immediate engine
problems and eventually severe damage!
DAMAGE CAUSED BY THE INGRESS OF
WATER IN THE ENGINE IS NOT COVERED BY
WARRANTEE
On the valve is a little hose to drain a little water that
could be spilled from the valve. This hose should go
down and may not end under water, because it
should ventilate air into the valve to break the
siphoning.
Check the air vent at regular intervals. Open, clean
and lubricate the valve as required (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.
flow direction
sailing direction
WRONG!
thru-vessel inlet
Fig. 5.
Fig. 6.
Page 10
INSTALLATION
10 April 2004 / WHISPER 3,5 / USA
1STANDARD EXHAUST SYSTEM INSTALLATION
The generating set exhaust system must remain
completely independent and separate from the ex-
haust system of any other engine on board. A water
lock prevents the generating set from being flooded
by 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 ex-
haust hose must have an inner diameter of 1
5
/8” (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 24 inches (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 8 ft.(2,5 m). The exhaust
hose descends from the capsule to the water lock.
Then the hose rises maximum lift 4 ft. (120 cm) via
the "goose neck" to the through-hull exhaust outlet,
situated minimum 2 inches (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 gasflow 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 adviced 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
cause the system to fill up with water that
affects the outlet valve and valve seat.
min.
24 inches
60 cm
1
2
3
3
4
5
6
max.
lift
48 inches
(120 cm)
max. total length 8 ft. (2,5 m)
Fig. 7.
1 Exhaust water lock;
2 Exhaust outlet muffler;
3 Exhaust line 1
5
/8” Ø (40 mm);
4 Goose neck
5 Through-hull exhaust outlet 1
5
/8” Ø (40 mm);
6 Water level.
Page 11
INSTALLATION
USA / WHISPER 3,5 / April 2004 11
2 "SUPER SILENT" EXHAUST SYSTEM
In order to reduce the noise level of the generating
set to a minimum, an option to reduce the exhaust
noise further (especially exhaust water splashing) is
an exhaust/water separator. The exhaust/water sepa-
rator allows the cooling water to be drained through a
line (A) 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 2 ft. (60 cm) above the water
level.
If the through-hull exhaust outlet has to be mounted
far from the generating set, an exhaust/water separa-
tor must definitely be installed. (Total length of the
exhaust piping from generator to top of goose neck
(waterseparator) is more than 8 ft. (2,50 m.)) The sea
water from the separator must run down along the
shortest possible path to the through-hull outlet.
Under no circumstances the hose may go up again.
(Refer to fig. 8a)
Only when using an exhaust /water separator the
exhaust may have a length up to 25 ft (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. An additional outlet
exhaust muffler close to the hull outlet will help further
to reduce noise emission. (Refer to fig. 9)
Fig. 8.
Fig. 8a.
Page 12
INSTALLATION
12 April 2004 / WHISPER 3,5 / USA
Fig. 9.
Fig. 10.
If the generating set and the exhaust system have
been installed correctly, neighboring 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 (center
outlet on the unit) should run to the through-hull outlet
below the water level along the shortest possible path.
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.
Page 13
INSTALLATION
USA / WHISPER 3,5 / April 2004 13
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 genera-
ting 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 cross-wired 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.
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.
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.
Acoustic alarm or warning lamp
One can connect an external max.150 mAmp 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.
Fig. 11.
J3
MASTERVOLT
WRP/2
Whisper Remote Panel
TAILOR MADE ENERGY
+-
123456789101112
+-
SENSE BAT. 2
12
9
10
11
6
7
8
3
4
5
1
2
REMOTE CABLE
REMOTE CABLE
WARNING RELAY
MAX. 150 mA
BLACK
RED/BLUE
GREY
GREY/PINK
WHITE
BLUE
PURPLE
PINK
YELLOW
BROWN
GREEN
RED
WIRING COLOURS
Fig. 12.
Page 14
INSTALLATION
14 April 2004 / WHISPER 3,5 / USA
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.
2STARTER 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 connec-
ted 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 char-
ger will help to keep the battery in good condition
when the generating set is not used. A battery char-
ger in 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 condi-
tions 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 ca-
ble should be used and the vessel should not to be
used as a conductor.
In the negative battery cable a 250 Amp starter batte-
A
B
230V AC
IVO 12/10
12V
Fig. 11.
Page 15
INSTALLATION SPECIFICATIONS
USA / WHISPER 3,5 / April 2004 15
ry switch could be applied to switch off the battery.
The battery cables are supplied in a standard length
of 5 ft. (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
sever damage to the batteries within a short time.
Disconnect the battery leads if electrical welding is to
be carried out, otherwise damage could be caused to
the diodes of the alternator.
As explosive hydrogen gases are dischar-
ged 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 du-
ring or shortly after charging as sparking
can occur, which may ignite the hydrogen
gasses.
1.4.5 AC power system (120 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 brea-
king systems have to be installed onboard as the genera-
ting 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. For the
Whisper 3,5 the maximum single phase current is
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
In the U.S.A. models the neutral of the AC alternator
windings is grounded.
Measures against earth insulation failures have to be
taken. An earth insulation failure device has to be
installed. The housing of the alternator and all other
metal parts are grounded.
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.
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.
For safety reasons connect the main ships ground to
negative point of the generating set starter battery. When
a ungrounded DC system or positive grounded DC sys-
tem 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
oil resistant cable with a cross sectional area of 3x
AWG 12 (4 mm
2
) for 120V. 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
Page 16
INSTALLATION SPECIFICATIOINS
16 April 2004 / WHISPER 3,5 / USA
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 de-
signed 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.
Mastervolt advises the installation of a MASTER-
SWITCH 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 5 seconds delay time
over to the generating set position.
2 INSTALLATION
SPECIFICATIONS
2.1 WHISPER 3,5 INSTALLATION TABLE
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).
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.
2 Open the seawater inlet valve and check all water
connections. Check if the strainer is installed just
above the seawater level.
3 Check if the exhaust system is properly installed.
Also check the minimum required height of 2 ft. (60
cm above sea level of the exhaust loop (goose
neck).
Check maximum lentgh of exhausthose, diameter of
exhaust hose, position 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.
Fig. 12.
Page 17
INSTALLATION SPECIFICATIONS
USA / WHISPER 3,5 / April 2004 17
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.
(Refer to paragraph 4.2.2 of the users manual)
9 Check if the air intake in the canopy is not blocked.
10 Check the oil level and color of the oil.
11 Preheat the engine by pushing the glow button for
ten seconds. Start the engine by pushing the start
button until the set is running. Do not push the start
button longer than 3 seconds.
12 Check when the generating set is running, the delay
of 5 to 10 seconds in the power source selector
transfer.
13 Check voltage and frequency under ‘no load’ condi-
tions.
14 Check voltage and frequency under ‘full load’ condi-
tions.
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 om our website:
www.mastervolt.com
Commissioning form available on our website:
www.mastervolt.com
2.3 INSTALLATION SPECIFICATIONS WHISPER 3,5 RPM
TECHNICAL DATA
Article no 50900555
Dimensions wxdxh. 19,88” x 19,69” x 15,94” (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 0,18 - 0,37 gph (0,7-1,5 l/hr), load dependent
Lift fuel pump electric driven 12 V DC, max. lift 3 ft. (1 m)
Coolin indirect cooling
Cooling pump raw water Mastervolt self priming impeller pump, PTO driven, type K
Minimum water supply 2-3 gpmin. (8-12 l/min)
Crank case lube oil capacity, 1,3 US qts (1.3 litre) + 0.2 oil cooler, total 1,5 US qts (1.5 litre)
Alternator synchronous brushless, maintenance free water cooled
Voltage regulation capacitor
Output power 3,3 kW max, 120V/60 Hz at power factor cos phi =1
Battery charger extra 12V winding including regulator (6 Amps)
2.4 SPECIFICATION OF THE ACCESSORIES
Water scoop min. 1/2” (recommended 3/4”)
Inlet valve min. 1/2" in (recommended 3/4” in) 1/2" out
Water strainer 1/2" in, 1/2" out
Air vent 1/2"
Inlet suction hose 1/2"
Fuel filter/water separator minimum 30 micron
Fuel inlet and return 8 mm
Exhaust hose in/out Ø 1 5/8” (40 mm)
Water lock Ø 1 5/8“ (40 mm)
Water/gas separator Ø 1 5/8“ (40 mm)
Foundation plate min. 44 kg
Battery charger (optional) IVO smart 12/10; 12V / 10 Amps
Optional anti shock mounts art.no. 50230552
Page 18
2.5 INSTALLATION MATERIALS WHISPER 3,5
WATER INLET KIT 1/2” (13 mm)
no qtt article no description dimensions
11 50230052 intake strainer 3/4
21 50230042 lever operated ball valve FF 3/4
31 50221016 male hose connection 3/4x1/2
43 50221521 hose clamps 1/2 - 3/4
53 50220055 outboard cooling water hose 1/2
62 50221003 male hose connection 1/2
71 50230060 nickel plated brass intake strainer 1/2
81 50230067 mounting bracket waterstrainer
TOTAL 50230201 WATER INLET KIT 1/2
AIR VENT KIT 1/2” (13 mm)
no qtt article no description dimensions
11 2 50221260 hose connector 1/2
47 50221521 hose clamps 1/2 - 3/4
12 3 50220057 warm cooling water hose 1/2
13 2 50221082 elbow 90 gr m/f 1/2
62 50221003 male hose connection 1/2
14 1 50221042 TEE fittings 1/2
15 1 50230001 syphon breaker valve 1/2
16 1 50221001 male hose connection 3/8x1/2
TOTAL 50230202 AIR VENT KIT 1/2
EXHAUST KIT 1 5/8” (40 mm)
no qtt article no description dimensions
21 1 50221481 hose connector 1 5/8 (40 mm)
22 5 50221506 hose clamps 1,5-2,2 (44-56 mm)
23 3 50220033 marine exhaust hose 1 5/8 (40 mm)
24 1 50230071 waterlock 1 5/8 (40 mm)
25 1 50230038 brass through hull fitting hose connection 1 1/4x1 5/8
TOTAL 50230203 EXHAUST KIT 1 5/8 (40 mm)
OPTIONAL INSTALLATION MATERIALS
no qtt article no description dimensions
21A 1 50201830 elbow 90 ° adapter exhaust hose 1 5/8 (40 mm)
WATER SEPARATOR KIT 1 5/8 (40 mm)
no qtt article no description dimensions
22 4 50221506 hose clamps 1,5 - 2,2 inches (44-56 mm)
23 2.5 50220033 marine exhaust hose 1 5/8 (40 mm)
31 1 50221015 male hose connection 1 1/4 x 1 5/8
32 1 50230044 lever operated ball valve FF 1 1/4
33 1 50230033 brass through hull fitting 1 1/4x 2,0
34 1 50230080 water exhaust fumes separator 1 5/8 x 1 5/8 x 1 5/8 (40-40-40)
TOTAL 50230204 WATER SEPARATOR KIT 1 5/8 (40 mm)
INSTALLATION MATERIAL
18 April 2004 / WHISPER 3,5 / USA
Page 19
FUEL KIT U.S.A.
no qtt 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 50230206 FUEL KIT U.S.A.
OPTIONAL INSTALLATION MATERIALS
no qtt article no description dimensions
49 p/ft(m) 50220063 fuel hose 5/16” (8x16 mm)
BATTERY INSTALLATION KIT
no qtt 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 swich 250 Amp
58 4 6503001608 cable connectors M8x16
TOTAL 050230206 BATTERY INSTALLATION KIT
BASE PLATE KIT
no qtt 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
INSTALLATION MATERIAL
USA / WHISPER 3,5 / April 2004 19
Page 20
INSTALLATION MATERIAL
20 April 2004 / WHISPER 3,5 / USA
AC
- brandstoftoevoer kit
- accu-aansluit kit
- fundatieplaat kit
- fuel kit
- battery installation kit
- base plate kit
Fig. 14.
Page 21
INSTALLATION MATERIAL
USA / WHISPER 3,5 / April 2004 21
- water inlaat kit
- belucht kit
- uitlaat kit
- waterscheider kit
- water inlet kit
- air vent kit
- exhaust kit
- water separator kit
* Afvoerslang beluchter direct naar beneden voeren.
Water moet vrij weglopen. Verstoppingen en onjuiste
montage beluchter kan grote schade aan motor
veroorzaken. Raadpleeg installatiemanual.
* 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.
Fig. 15.
Page 22
DIAGRAMS
& DRAWINGS
22 April 2004 / WHISPER 3,5 / USA
3 DIAGRAMS & DRAWINGS
3.1 DC WIRING DIAGRAM
J20
PUMP
J21
ALT
J1
ALT
J2
REGULATOR
J18 J19 J22
START/STOP
J8 J9
J10
J11
J12
-
-
J13
-
-
J14
J16
-
J15
J17
-
WCH/0
--
TAILOR MADE ENERGY
ALT-L
J3
J4
J6
+
J5
J7
+
MASTERVO LT
+
+
10A 3A
F3
10A
ALT
hold
ct-2
ct-1
ct-1
ct-2
gnd
tem
str.
exh
oil
reg
alt.
fuel
heat start fuel fail
st
gl
+
pull
AC-1
AC-2
LOCA L CONTRO L PANEL
BATT ERY
RED 16
12VDC
BATT ERY
SWITCH
RED 2,5 (13)
RED 6 (1)
BLACK 16
GROUND TO
BLACK 2,5 (2)
TO GENERAT OR AC OUTPUT
OIL TEMP.
SWITCH
EXHAUST TEMP.
SWITCH
OIL PRESS.
SWITCH
FUEL
VALV E
SOLENOID
STOP
GLOW (PREHEAT)
PLUGS
FUEL LIFT
PUMP
MOTOR
START ER
CURRENT MEASURING
TRANSFORMER
BLUE 1 (7)
BLUE/GREEN 1 (8)
BLUE/BLACK 1 (7) J10
BLACK 1,5 (12) J8
BLUE/PINK 1 (8) J12
PURPLE 1 (6)
PURPLE/BLACK 1 (6) J14
BLACK 1.5 (15) J16
BROWN 1,5 (5)
GREY 1 ,5 (5)
BAT T ERY CHARGER
BLACK (11)
WINDING GENERATO R
RED (11)
YELLO W 2,5 (4)
GREEN 1,5 (9)
PINK 2,5 (20)
BROWN 4 (3)
ORANGE 1,5 (19)
RED/GREEN 1 (16)
RED 1,5 (14)
_
+
RED 1,5 (10)
RED 1,5 (10)
BROWN (33)
BLUE (33)
AC-1
TO REMOT E
CONTROL PANEL
SOLENOID
ENGINE BLOCK
(OPTIONAL)
(OPTIONAL)
GENERATING SET:
1 Fuse 1;
2 Fuse 2;
3 Contact relay;
4 Start relay;
5 Preheat relay;
6 Fuel shut off valve;
7Starter motor;
8 Fuel pump;
9Oil temperature switch;
10 Exhaust temperature switch;
11 Oil pressure switch;
12 Current transformer;
13 Glow plug;
14 Connector remote control.
Fig. 16.
Page 23
DIAGRAMS
& DRAWINGS
USA / WHISPER 3,5 / April 2004 23
Fig. 17.
3.2 CODES AND COLORS
AWG (American Wire Gauge)
Cable code number colour AWG cross section
battery > starter motor red 4 16 mm2
starter motor > DCC 1 red 10 6 mm2
starter motor > LCP 13 red 14 2,5 mm2
battery > ground black 4 16 mm2
ground > LCP ground (GND) 2 black 14 2,5 mm2
DDC > glow plug 3 brown 4 4 mm2
DDC > starter solenoid 4 yellow 14 2,5 mm2
LCP > fuel lift pump + 5 brown 16 1,5 mm2
LCP > fuel lift pump - 15 black 16 1,5 mm2
DDC > LCD 5 grey 16 1,5 mm2
DDC > oil pressure switch 6 purple 17 1 mm2
LCP > oil pressure switch 6 purple/black 17 1 mm2
DDC > oil temperature switch 7 blue 17 1 mm2
LCP > oil temperature switch 7 blue/black 17 1 mm2
DDC > exhaust temperature switch 8 blue/green 17 1 mm2
LCP > exhaust temperature switch 8 blue/rose 17 1 mm2
DCC > fuel valve solenoid 9 green 16 1,5 mm2
DCC > stop solenoid 20 pink 14 2,5 mm2
DCC > current measuring transformer 11 black 17 1 mm2
DCC > current measuring transformer 11 red 17 1 mm2
DCC > LCP 19 orange 16 1,5 mm2
DCC > LCP 12 black 16 1,5 mm2
DCC > LCP 14 red 16 1,5 mm2
DCC > LCP 16 red/green 16 1,5 mm2
DCC > generator AC output 33 brown 17 1 mm2
DCC > generator AC output 33 blue 17 1 mm2
LCP > battery charger winding generator 10 red 17 1 mm2
LCP > battery charger winding generator 10 red 17 1 mm2
DDC=Digital Diesel Control Unit
LCP=Local Control Panel
Page 24
3.3 AC WIRING DIAGRAM 120V / 60 HZ
STATOR
ROTOR
L1
N
PE
PE
N
L1
120V 60Hz
EARTH AND NEUTRAL CONNECTED
N
L2
120-240V 60Hz
PE
L1
EARTH AND NEUTRAL
CONNECTED
EARTH AND NEUTRAL NOT CONNECTED
L2
120-240V 60Hz
PE
N
L1
YELLOW/GREEN
CAPACITOR
MAIN WINDING
MAIN WINDING
(4)
(3)
(4)
CHARGER
WINDING
EXCITATION
BATTERY
(3)
(2)
(1)
(10)
(10)
BLUE
BROWN
ALT
YELLOW/GREEN
ALT
REGULATOR
WCH
J1
J2
DCC/AC-1
BROWN (33)
BLUE (33)
DCC/ct-1
(11)
RED
(11)
BLACK
CURRENT
TRANSFORMER
YELLOW/GREEN
YELLOW/GREEN
DCC/AC-1
BROWN (33)
BLUE (33)
(11)
RED
TRANSFORMER
CURRENT
DCC/ct-1
(11)
BLACK
BLUE
BROWN
BLUE
CURRENT
TRANSFORMER
DCC/AC-2
BLUE (33)
DCC/ct-2
DCC/AC-1
BROWN (33)
(22)
RED
(22)
BLACK
BROWN (44)
YELLOW/GREEN
BLUE (44)
BLACK
DCC/ct-1
RED
(11) (11)
BLACK
TRANSFORMER
CURRENT
BROWN
YELLOW/GREEN
TRANSFORMER
BLACK
BLACK
(22)
DCC/ct-2
DCC/AC-2
TRANSFORMER
CURRENT
BROWN (44)
BROWN (33)
BLUE (33)
DCC/AC-1
RED
(22)
RED
DCC/ct-1
(11) (11)
CURRENT
BLUE (44)
YELLOW/GREEN
BLACK
YELLOW/GREEN
BLUE
BROWN
Fig. 19.
DIAGRAMS
& DRAWINGS
24 April 2004 / WHISPER 3,5 / USA
Page 25
USA / WHISPER 3,5 / April 2004 25
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.
Page 26
26 April 2004 / WHISPER 3,5 / USA
DIAGRAMS
& DRAWINGS
Fig. 20.
CONNECTIONS:
• exhaust: 1 5/8” (40 mm)
• fuel hose: 5/16” (8 mm)
• sea water in: 1/2” (12,5 mm)
• air vent connection: 1/2” (12,5 mm)
• battery +: AWG 4 (16 mm
2
)
• battery -: AWG 4 (16 mm
2
)
• cables: 3x AWG 12 (3x 4mm
2
)
15 ft. (5 meter)
• remote control: 15 m. (45 ft.) 8 wire twisted
communication cable
(included)
3.5 WHISPER 3,5 DIMENSION
Page 27
USA / WHISPER 3,5 / April 2004 27
Page 28
28 April 2004 / WHISPER 3,5 / USA
MASTERVOLT
Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands
Tel.: +31-20-3422100 / Fax: +31-20-6971006
www.mastervolt.com / info@mastervolt.com
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