Mastervolt whisper 3.5m Installation Manual

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INSTALLATION MANUAL

WHISPER 3.5M

- 3000 RPM -

Marine diesel generating set 230V / 50Hz

MasterBus controlled

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

V5 October 2009

Art.nr. 50261141

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CONTENTS

This manual applies to the Mastervolt Whisper 3.5 Marine Diesel Generating set controlled by MasterBus first launched in April 2008. For earlier models refer to other manuals available on our website: www. mastervolt.com

Copyright © 2009 Mastervolt. All rights reserved. Reproduction, transfer, distribution or storage of part or all of the contents in this document in any form without the prior written permission of Mastervolt is prohibited.

CONTENTS:

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

1.1 Location.............................................................................................................................................................. 3

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

1.2.1 Steel base plate................................................................................................................................. 3

1.2.2 Further recommendations ................................................................................................................. 3

1.3 Ventilation........................................................................................................................................................... 4

1.4 Connections ....................................................................................................................................................... 5

1.4.1 Fuel supply ........................................................................................................................................ 5

1.4.2 Cooling .............................................................................................................................................. 7

1.4.3 Exhaust system ................................................................................................................................. 9

1.4.4 Control system ................................................................................................................................ 12

1.4.5 AC power system (230 Volt)............................................................................................................ 15

2 INSTALLATION SPECIFICATIONS.............................................................................................................................. 17

2.1 Whisper 3.5 installation table............................................................................................................................ 17

2.2 Commissioning table ........................................................................................................................................ 17

2.3 Installation specifications Whisper 3.5.............................................................................................................. 18

2.4 Specification of the accessories ....................................................................................................................... 18

2.5 Installation materials Whisper 3.5..................................................................................................................... 19

3 DIAGRAMS & DRAWINGS ...........................................................................................................................................24

3.1 DC wiring diagram............................................................................................................................................ 24

3.2 Wiring names and colours ................................................................................................................................ 26

3.3 AC wiring diagram 230V / 50Hz ....................................................................................................................... 27

3.4 Dimensions MasterView Easy Panel................................................................................................................ 28

3.5 Dimensions Whisper 3.5 .................................................................................................................................. 28

4 MASTERBUS................................................................................................................................................................. 29

4.1 What is MasterBus? ......................................................................................................................................... 29

4.2 Event-based commands................................................................................................................................... 29

4.3 How to set up a MasterBus network................................................................................................................. 30

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INSTALLATION

1 INSTALLATION

This installation manual is valid for the following models:

Part number

Description

51200500 Whisper 3.5 / 230V 3000rpm wet exhaust

MasterBus controlled

51200506 Whisper 3.5 / 230V 3000rpm wet exhaust

MasterBus controlled - ungrounded

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

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. 23, page 21).

1.2.2 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.

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

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INSTALLATION

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.

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 Battery POS 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 NEG 4 Water out 8 Oil strainer 12 AC cable

Figure. 2:

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INSTALLATION

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 figure 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

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.

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.

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

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.

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INSTALLATION

Figure 3: Fuel supply (fuel tank is above the generating set)

Figure. 4: Fuel supply (fuel tank is above the generating set)

> 1m

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.

1 Fuel return; 2 Fuel supply; 3 Prefilter / water separator (optional); 5 Fuel tank; 6 Standard fuel lift pump; 7 Standard fuel filter.

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INSTALLATION

Figure 5: Internal cooling system

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.

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 wet-exhaust outlet. The flow rate should be 8 to 12 litres /min.

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!

Figure 6 Installing water intake

MIN. 60CM (24")

MAX. 150CM (60")

MAX. 10CM (4")

MIN. 3CM (1,2")

5CM (2")

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

SAILING DIRECTION

FLOW DIRECTION

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INSTALLATION

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 figure. 5, ref 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 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 figure 7).

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 (figure 7).

OPEN

Figure 7: Wrong siphon breaker hose routing

Check the air vent at regular intervals. Open, clean and lubricate the valve as required (figure 8).

Figure 8

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INSTALLATION

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.

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 figure 9, ref. 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 figure 9, ref. 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 (see figure 9, ref.

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.

Figure 9: Standard exhaust system

Minimum 60cm (24")

Maximum 120cm (48")

5 cm (2")

Max. length A - B = 2.5m (8 ft.)

1 Exhaust water lock; 4 Goose neck; 2 Exhaust outlet muffler; 5 Through-hull exhaust outlet Ø 40 mm;

3 Exhaust line Ø 40 mm; 6 Water level.

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INSTALLATION

Figure 10: Super silent exhaust system

Figure 11: Only after the exhaust / water separator the exhaust hose may have a length up to 7,5m

MAX. 10CM (4")

MIN. 60CM (24")

MAX. 120CM (48")

MIN. 3CM (1,2")

Ø 40 mm

1 Water level 3 Seacock

2 Water/exhaust separator 4 Waterlock

Max. length A - B = 2.5 m. (8 ft)

Ø 40 mm

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INSTALLATION

2 "SUPER SILENT" EXHAUST SYSTEM

See figure 10. 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.

See figure 11. 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 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/gasseparator. However watertraps should be avoided as the fumes still contains water and this should not accumulate in bents (refer to figures 12 and 13). An additional outlet exhaust muffler close to the hull outlet will help further to reduce noise emission

Fig.12: Water trap in exhaust system

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

OK!

WRONG

OK!

WRONG

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INSTALLATION

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 (center outlet on the unit) should be installed below the water level to eliminate noisy splashing of the effluent sea water. The through-hull outlet for the exhaust fumes should not direct the fumes directly toward the water surface as this will cause excessive noise (refer to figure 14).

Do not direct the outlet directly toward the water surface.

Figure 14

1.4.4 Control system

1 DC 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 prior to despatch from the factory. Operation of the engine is controlled by a microprocessor based control system called “Digital Diesel Control”. The Digital Diesel Control Panel is integrated in the generating set.

MasterBus

The generating set is compatible with MasterBus: a fully decentralized data network for communication between the different Mastervolt system devices such as the inverter, battery charger, generator, batteries and many more. See chapter 4 for details

The generating set as well as the rest of the electrical system can be monitored and controlled by any MasterBus compatible remote control panel. The MasterView Easy is a MasterBus compatible monitoring and control panel that is standard included in the delivery of the generating set.

Important to know:

This generating set is only feasible for the connection of MasterBus compatible remote control panels. Connection

of other remote control panels such as the Digital Di esel Control panel, the System Manager AC + Whisper pane l and the Power System Control Panel is not possible.

The Masterview Easy must be mounted on an easy accessible location, protected against rain, moist, dust and condensation. For good visibility avoid installing the panel in direct sunlight

Installation of the MasterView Easy

Below mentioned steps describe a basic installation of the MasterView Easy in combination with the generating set. Refer to the separate user’s manual of the Masterview Easy if you want to add any other Mastervolt system devices to the MasterBus network (see www.mastervolt.com)

Figure 15

DIGITAL DIESEL CONTROL PANEL

MasterBus terminating device

MasterBus communication cable

OK!

WRONG!

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INSTALLATION

1 See figure 15 Insert a MasterBus terminating device

into one of both communication ports (it doesn’t matter which one) of the Digital Diesel Control Panel on the generating set. Insert the communication cable in the other communication port

Figure 16

2 See figure 16. Connect the other end of the

communication cable to one of both communication ports of the MasterView Easy. Insert a MasterBus terminating device into the other communication port.

3 The Masterview Easy can be flush mounted or panel

mounted on a wall or board:

Figure 17

o Flush mounting (see figure 17):

• Remove the outer housing and remove the front from the panel.

• Make a cut out in the mounting wall and drill the holes using the saw template in the box or using the dimensions at the back of the front plate.

• Mount the MasterView Easy onto the panel (1) and then reattach the front (2).

Figure 18

o Panel mounting (see figure 18):

• Remove the outer housing and remove the front.

• Drill the holes using the dimensions at the back of

the front plate and fasten the outer housing (1).

• Click the panel into the outer housing (2).

• Reattach the front (3)

During first commissioning the generator set will be recognized by the MasterBus network automatically. This may take a few seconds. Then the Masterview Easy will show the initial screen

Refer to the operation manual of the MasterView Easy for initial settings and operating instructions

Event based commands One of the main features of MasterBus is the possibility of programming for interactive operation of the connected devices, including automatic starting and stopping of the generator set. This is done by means of event based commands. Refer to the operation manual of the MasterView Easy for details about programming these event based commands.

Mastervolt cannot be held responsible for damage caused by unattended running of the generator due to the use of event

based commands

Using event based commands the generator can start unexpectedly. When working on the electrical system, the 30 Amp fuse must be removed from the Local Control Panel and the battery plus cable must be removed from the battery.

MasterBus terminating device

MasterBus communication cable

Rear side MasterView Easy

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INSTALLATION

Connection of an 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 wires 13 and 14 that come from the The Digital Diesel Control Panel. See fig. 19. To do so, remove the top cover plate of the connection box to get access to the wiring loom.

Figure 19: Location of the connection box

Disconnect the bypass between wires 13 and 14 and then replace it by an emergency switch or a potential free fire alarm switch with normally closed contacts (figure 20).

Fig. 20: Connection for emergency stop / fire alarm switch

2 STARTER BATTERY

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

Model Minimum capacity

Whisper 3.5 55Ah

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.

Figure 21: Installation of a 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. 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.

Normal operation

Alarm / emergency

230VAC

IVO 12/10

12V

Top cover plate of the connection box

Digital Diesel Control Panel

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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 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 (figure 22). This will result in severe damage to the batteries within a short time.

Figure 22

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 output 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%. The maximum single phase output current is as listed below

Model Maximum output current

Whisper 3.5 – 3000 rpm 13 Amp

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

12V12V

24V

12V

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INSTALLATION

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.

WARNING

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

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 oil resistant cable with the following cross sectional area:

Model cross sectional area

Whisper 3.5 – 3000 rpm 3x2.5 mm² (5m. 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. Mastervolt advises the installation of a Mass Systemswitch as the power source selector. This works automatically when the generating set is not running the input remains in the shore position and as soon as the generating set is running the Mass Systemswitch switches automatically after 10 seconds delay time over to the generating set position.

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INSTALLATION SPECIFICATIONS

2 INSTALLATION SPECIFICATIONS

2.1 WHISPER 3.5 INSTALLATION TABLE

Figure 23

1 Install a steel foundation plate between ship’s hull and

generating set, with 4 shock mounts (ref. to figure.

23).

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 the MasterView Easy remote panel

9 Connect the AC cable from the AC box to the power

source selector or Mass SystemSwitch.

10 Connect plus and minus from the 12V starter battery

to the battery cables.

11 Install a Mastervolt battery charger. (optional)

2.2 COMMISSIONING 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 60 cm 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 Whisper 3.5 is 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 to bleed, push “start” and hold on the local control panel (so not on the MasterView Easy 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.

Foundation plate

Shock mounts

Generating set

Page 18

INSTALLATION SPECIFICATIONS

12 Check when the generating set is running, the delay

of 3 – 10 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. 14.5 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 51200500

Dimensions WxDxH 505 x 400 x 500 mm

Weight 104 kg including sound shield

Max. operation angle 25°

Remote control: MasterView Easy (MasterBus)

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 - 3kWatt @ cos phi = 1

Battery charger additional 12V winding including regulator (4 Amps)

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 (1 5/8”)

Water lock Ø 40 mm (1 5/8”)

Water/gas separator Ø 40 mm (1 5/8”)

Anti shock mounts art. nr. 50230552

Foundation plate min. 44 kg (97 Lbs)

Battery charger (optional) IVO SMART 12/10; 12V / 10 Amps

Page 19

INSTALLATION SPECIFICATIONS

2.5 INSTALLATION MATERIALS WHISPER 3.5

Figure 24: Installation materials battery installation kit

BATTERY INSTALLATION KIT 55 Ah

pos. qty article no description

51 1 62000550 MV 12/55 Ah AGM Battery

52 1 43011000 IVO Smart 12/10 230V/50-60Hz IP65 battery charger

55 1 68230302 Terminal Cover RED 230N3V02

56 1 68230314 Terminal Cover BLACK 230N3V14

57 1 79006005 Battery switch ON/OFF with key 250A

58 2 6503001606 Cable lug 16mm² / M6

59 2 6503001610 Cable lug 16mm² / M10

TOTAL 50230208 BATTERY INSTALLATION KIT 55Ah

OPTIONAL INSTALLATION MATERIALS

• Additional installation parts

pos. qty article no description

60 6501208010 Cable 16mm² red per 100 meter

61 6501208020 Cable 16mm² black per 100 meter

Generator

battery positive (+)

Generator

battery negative (–)

Page 20

INSTALLATION SPECIFICATIONS

Figure 25: 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

Page 21

INSTALLATION SPECIFICATIONS

Figure 26: Installation materials Water inlet kit and Syphon breaker kit

WATER INLET KIT 12.5 mm

pos. qty article no description

1 1 50230052 Intake strainer 3/4"

2 1 50230042 Lever operated ball valve FF 3/4"

3 3 50221016 Male hose connection 3/4"x13

4 3 50221521 Hose clamp stainless 12-20

5 3m 50220055 Cool. water hose transp.spiral 13x19mm

6 1 50230062 Nickel plated brass intake strainer 3/4"

7 1 50230067 Mouting bracket small waterstrainer 1158

TOTAL 50230201 WATER INLET KIT 12.5 mm

SYPHON BREAKER KIT 12.5 mm

pos. qty article no description

1 1 50230017 Syphon breaker valve 12.5mm (1/2”), complete (including valve assembly)

2 6 50221521 Hose clamp stainless 12-20

3 3m 50220057 Cooling water hose warm water 13x21mm

4 2 50221260 Hose connector 12.5mm (1/2”)

TOTAL 50230272 SYPHON BREAKER KIT 12.5 MM (1/2")

Generator

cooling water inlet

Bypass

cooling

water out

Bypass cooling

water in

WATER INLET KIT 1/2” (12.5 mm) SYPHON BREAKER KIT 1/2” (12.5 mm)

Page 22

INSTALLATION SPECIFICATIONS

Figure 27: Installation materials “Delta” exhaust kit ø 40 mm (1 5/8”) and water separator kit 40 mm (1 5/8”)

“DELTA” EXHAUST KIT Ø 40 mm (1 5/8”)

pos. qty article no description

22 8 50221504 Hose clamp stainless 32-44 mm

23 3m 50220033 Marine exhaust hose 40 mm (1⅝”)

24 1 50230093 Waterlock 40 mm Delta

25 1 50230038 Brass hull fitting hose connection 1¼"x40

TOTAL 50230251 DELTA EXHAUST KIT 40 mm

“DELTA” WATER SEPARATOR KIT 40 mm (1 5/8”)

pos. qty article no description

22 8 50221504 Hose clamp stainless 32-44 mm

23 2.5m 50220033 Marine exhaust hose 40 mm (1⅝”")

31 1 50221015 Male hose connection 1¼” x 40mm

32 1 50230044 Lever operated ball valve FF 1¼”

33 1 50230033 Brass through hull fitting 1¼” x 70

34 1 50230097 Water / gas separator Delta 40/40/40mm (1⅝")

TOTAL 50230261 Delta water/gas separator kit 40mm

OPTIONAL INSTALLATION MATERIALS

pos. qty article no description

21 1 50201830 Elbow 90° adapter exhaust hose

22 4 50221504 Hose clamp stainless 32-44 mm

27 1 50230113 Straight coupling Delta 40mm

28 1 50230112 Elbow (45º) Delta 40mm

Generator

exhaust

According to ABYC recommendations all hose connections must

be fitted with two hose clamps

Maximum torque hose clamps: 12Nm / 105 InLbs

Page 23

INSTALLATION SPECIFICATIONS

Figure 28: installation materials base plate kit

BASE PLATE KIT for Whisper 3.5 (3000 rpm)

pos. qty article no description

61 4 50230552 Rubber mounting up to 70 kg RAB3

62 1 50230012 HD base plate 3500 yellow zinc plated

63 4 50211449 Washer spring SP M12

64 4 50211251 Bolt hexagonal socket ZP M12x40

65 4 50211438 Washer SP M10x30x1,5

66 4 50211447 Washer spring SP M10

67 4 50211241 Bolt hexagonal socket ZP M10x25

TOTAL 50230207 BASE PLATE KIT WHISPER 3.5

Page 24

DIAGRAMS & DRAWINGS

3 DIAGRAMS & DRAWINGS

3.1 DC WIRING DIAGRAM

14 (1mm2)

13 (1mm2)

31 (1mm2)

30 (1mm2)

12 (1mm2)

11 (1mm2)

BATTERY CHARGER

WINDING GENERATOR

ALARM CONTACT

(OPTIONAL)

TO GENERATOR

AC OUTPUT

DIGITAL DIESEL CONTROL PANEL

30 (1mm2)

31 (1mm2)

MASTERBUS

TERMINATOR

TO REMOTE PANEL

(MASTERBUS NETWORK)

CURRENT MEA

SURING

TRANSFORMER

STOP

SOLENOID

EXHAUST

TEMPERATURE

SWITCH

OIL PRESSURE

SWITCH

FUEL LIFT

PUMP

FUEL

VALVE

SOLENOID

GLOW (PREHEAT)

PLUGS

OIL TEMP.

SWITCH

GROUND TO

ENGINE BLOCK

(OPTIONAL)

BATTERY

SWITCH

STARTER

MOTOR

(OPTIONAL)

BATTERY

12v

26 (1mm2)

(1mm2)

7 (1.5mm2)

6 (1.5mm2)

22 (1mm2)

9 (1.5mm2)

10 (1.5mm2)

25 (1mm2)

24 (1mm2)

3 (2.5mm2)

2 (2.5mm2)

1 (2.5mm2)

4 (2.5mm2)

(16mm2)

Figure 29a: DC wiring Whisper 3.5 grounded (part. Nr. 51200500)

Page 25

DIAGRAMS & DRAWINGS

14 (1mm2)

13 (1mm2)

31 (1mm2)

30 (1mm2)

12 (1mm2)

11 (1mm2)

BATTERY CHARGER

WINDING GENERATOR

ALARM CONTACT

(OPTIONAL)

TO GENERATOR

AC OUTPUT

DIGITAL DIESEL CONTROL PANEL

30 (1mm2)

31 (1mm2)

MASTERBUS

TERMINATOR

TO REMOTE PANEL

(MASTERBUS NETWORK)

CURRENT MEASURING

TRANSFORMER

STOP

SOLENOID

EXHAUST

TEMPERATURE

SWITCH

FUEL LIFT

PUMP

FUEL

VALVE

SOLENOID

GLOW (PREHEAT)

PLUGS

OIL TEMP.

SWITCH

GROUND TO

ENGINE BLOCK

(OPTIONAL)

BATTERY

SWITCH

STARTER

MOTOR

(OPTIONAL)

BATTERY

12v

26 (1mm2)

27 (1mm2)

7 (1.5mm2)

6 (1.5mm2)

22 (1mm2)

9 (1.5mm2)

10 (1.5mm2)

25 (1mm2)

24 (1mm2)

3 (2.5mm2)

2 (2.5mm2)

1 (2.5mm2)

4 (2.5mm2)

(16mm2)

5 (1.5mm2)

8 (1.5mm2)

OIL PRESSURE

SWITCH

23 (1mm2)

19 (1mm2)

15 (2.5mm2)

4 (2.5mm2)

17 (1mm2)

16 (2.5mm2)

3 (2.5mm2)

49 (1mm2)

18 (1mm2)

19 (1mm2)

49 (1mm2)

48 (2.5mm2)

(16mm2)

15 (1mm2)

16 (1mm2)

19 (1mm2)

18 (1mm2)

17 (1mm2)

Figure 29b: DC wiring Whisper 3.5 ungrounded (part. Nr. 51200506)

Page 26

DIAGRAMS & DRAWINGS

3.2 WIRING NAMES AND COLOURS

Wire number Wire name Colour Cross section

1 Battery + White 2.5 mm²

2 Battery – White 2.5 mm²

3 Glow + White 2.5 mm²

4 Start solenoid + White 2.5 mm²

5* Stop solenoid – White 2.5 mm²

6 Stop solenoid + White 1.5 mm²

7 Fuel valve + White 1.5 mm²

8* Fuel valve – White 1.5 mm²

9 Fuel pump + Brown 1.5 mm²

10 Fuel pump – Black 1.5 mm²

11 Charger a White 1 mm²

12 Charger b White 1 mm²

13 Safety switch + White 1 mm²

14 Safety switch – White 1 mm²

15* Battery + White 2.5 mm²

16* Battery + White 2.5 mm²

17* Start relay + White 1 mm²

18* Glow relay + White 1 mm²

19* Battery – White 1 mm²

22 Oil pressure + White 1 mm²

23* Oil pressure – White 1 mm²

24 Exhaust temp. + White 1 mm²

25 Exhaust temp. – White 1 mm²

26 Engine temp. + White 1 mm²

27 Engine temp. – White 1 mm²

30 Iac1-L White 1 mm²

31 Iac1-N White 1 mm²

40 Uac1-L White 1 mm²

41 Uac1-N White 1 mm²

49* Ground relay + White 1 mm²

Battery + Red 16 mm²

Battery – Black 16 mm²

Earth wire Green/yellow 6 mm²

* Ungrounded versions only (part nr. 51200506)

Page 27

DIAGRAMS & DRAWINGS

3.3 AC WIRING DIAGRAM 230V / 50HZ

Figure 30 AC wiring diagram

230V 50Hz

DDC/ct-1

(11)

RED

TRANSFORMER

(11)

BLACK

CURRENT

DDC/AC-1

YELLOW/GREEN

BLUE

YELLOW/GREEN

BROWN

BROWN (33)

BLUE (33)

EARTH AND NEUTRAL CONNECTED

STATOR

ROTOR

BLACK

TRANSFORMER

YELLOW/GREEN

CAPACITOR

MAIN WINDING

(4)

(3)

(4)

CURRENT

CHARGER

WINDING

EXCITATION

BATTERY

(3)

(2)

(1)

RED

(10)

BLUE

BROWN

ALT

YELLOW/GREEN

ALT

REGULATOR

WCH

(11) (11)

DCC/ct-1

DCC/AC-1

BROWN (33)

BLUE (33)

EARTH AND NEUTRAL NOT CONNECTED

230V 50Hz

Page 28

DIAGRAMS & DRAWINGS

3.4 DIMENSIONS MASTERVIEW EASY PANEL

Figure 31: Dimensions of the panel without and with outer casing. All dimensions are in mm (inch)

3.5 DIMENSIONS WHISPER 3.5

Figure 32: Dimensions in mm [inch]

CONNECTIONS

• exhaust: 40 mm • battery +: 16 mm² red (included)

• fuel hose: 8 mm • battery -: 16 mm² black (included)

• sea water in: 13 mm • cables: 3x 2.5 mm2 (5 meter included)

• air vent connection: 13 mm • remote control: MasterBus communication cable (15 meter included)

10 (0.39)

37 (1.46)

113 (4.45)

90 (3.54)

37 (1.46)

27 (1.06)

113 (4.45)

90 (3.54)

305 [12.0]

M12

410 [16.1]

430 [16.9]

Box dimensions:

• width: 505 mm [19.9 inch]

• depth: 400 mm [15.7 inch]

• height: 500 mm [19.7 inch]

• weight: 104 kg [229 Lbs]

Top view

Service side

Page 29

MASTERBUS

4 MASTERBUS

4.1 WHAT IS MASTERBUS?

All devices that are suitable for MasterBus are marked by the MasterBus symbol.

MasterBus is a fully decentralized data network for communication between the different Mastervolt system devices. It is a CAN-bus based communication network which has proven itself as a reliable bus-system in automotive applications. MasterBus is used as power management system for all connected devices, such as the inverter, battery charger, generator and many more. This gives the possibility for communication between the connected devices, for instance to start the generator when the batteries are low.

MasterBus reduces complexity of electrical systems by using UTP patch cables. All system components are simply chained together. Therefore each device is equipped with two MasterBus data ports. When two or more devices are connected to each other through these data ports, they form a local data network, called the MasterBus. The results are a reduction of material costs as only a few electrical cables are needed and less installation time.

For central monitoring and control of the connected devices Mastervolt offers a wide range of panels which show full status information of your electrical system at a glance and a push of a button. Four different panels are available, from the small Mastervision compatible 120 x 65mm LCD screen up to the full colour MasterView System panel. All monitoring panels can be used for

monitoring, control and configuration of all connected MasterBus equipment.

New devices can be added to the existing network in a very easy way by just extending the network. This gives the MasterBus network a high degree of flexibility for extended system configuration, not only today, but in the future as well! Mastervolt also offers several interfaces, making even non-MasterBus devices suitable to operate in the MasterBus network

4.2 EVENT-BASED COMMANDS

With MasterBus each device can be programmed to initiate an action at an other connected device. This is

done by means of event based commands.

Example: if the state of charge of the service batteries is at 40%, the generator must be started. In this example, the MasterBus network should at least

exist of the following devices: a MasterView Easy panel for programming of event based commands, a MasterShunt

to measure the state of charge of the service batteries and

a Whisper generator set as power supply for the battery

charger As the state of charge of the service batteries is measured

by the MasterShunt, this device is considered as the Event source. The Whisper generator set is the device that

should initiate an action (starting the generator to charge the service batteries), and is therefore considered to be

the target. This means that you should use the MasterView Easy panel to program the MasterShunt as

follows:

Event source: Battery pre low Select from list of events sources

(see manual of the MasterShunt) Event target: GEN Whisper 3.5 Select from the device list (devices connected to the MasterBus) Event command: Auto start Select event command from the list of event commands of the target

(see manual of the of the Generator) Event data: Copy Select event action from the list of event commands of the target

(see manual of the of the Generator)

Page 30

MASTERBUS

4.3 HOW TO SET UP A MASTERBUS

NETWORK

Each device that is suitable for the MasterBus network is equipped with two data ports. When two or more devices are connected to each other through these ports, they form a local data network, called the MasterBus.

Keep the following rules in mind:

Do not make T-connections in the network

Do not make ring networks

The electric power for the network comes from the connected devices. At least one device in the network should have powering capabilities (see specifications). One powering device can power up to three nonpowering devices. As all powering devices are galvanically isolated, multiple powering devices are allowed

As with all high speed data networks, MasterBus needs a terminating device on both ends of the network

Terminating

device

Terminating

device

Connections between the devices are made by standard straight UTP patch cables. Mastervolt can supply these cables. These cables are also commonly available at computer supply stores.

1 2 3 4 5 6 7 8

Page 31

NOTES

Page 32

MASTERVOLT

Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands

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

www.mastervolt.com / info@mastervolt.com