Mastervolt whisper 9, 5 ultra, whisper 12, whisper 15 ultra, whisper 20 ultra Installation Manual

MASTERVOLT

Snijdersbergweg 93

1105 AN Amsterdam

The Netherlands

Tel.: +31-20-3422100

Fax: +31-20-6971006

http://www.mastervolt.com

INSTALLATION MANUAL

V1. September 2004

WHISPER 9,5 / 12,5 / 15 / 20

ULTRA

-1800 RPM-

Diesel generating set 120/240V-60Hz

Art.nr. 50200404

2 Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA

CONTENTS

1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

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

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

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

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

1.3 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1.4 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

1.4.1 Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

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

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

1.4.4 DC control system 12 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

1.4.5 AC power system 230 Volt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

2 INSTALLATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

2.1 Installation table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

2.2 Commission table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

2.3 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

2.4 Specification of the accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

2.5 Installation materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

3 DIAGRAMS AND DRAWINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

3.1. DC wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

3.2. Codes and colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

3.3 Wiring diagram electronic governor Whisper 12,5 ULTRA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

3.4 AC wiring diagram Whisper 120/240V 60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

3.5 Whisper remote control panel drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

3.6 Whisper 9,5/12,5/15/20 ULTRA dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

CONTENTS

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 3

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. Plea-

se consider that even almost maintenance-free machi-

nery must still remain accessible.

When selecting the location area 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 ac-

cess to the V-belt.

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 already has 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

possible to mount the generating set on a solid steel base

plate, weighing 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.

1.2.2 Further recommendations

Whisper generating sets are standard equipped with a

"GRP" (Glass Reinforced Plastic) sound cover. The ca-

nopy has been designed to give an effective sound insu-

lation. 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 as that may resonate.

2 Sound dampening is extremely poor if the generating

set is mounted on alight 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 drilled or cut

through the surface to help reduce the resonance.

Covering the surrounding walls and floors with a

heavy coating plus foam will certainly improve the

situation.

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

extraction ventilator to maintain reasonable engine room

temperatures. High temperature of intake air reduces

engine performance and increases engine coolant tem-

peratures. Air temperatures above 104°F (40°C) reduce

the engine power by 2% for each 90°F (5°C) of rise. To

minimise these effects the engine room temperature

must not be more than 30°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 connection the generating set can

be directly connected to an air duct.

INSTALLATION

4 Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA

Water in (8) 25,4 mm

Battery + (5) 35 mm2

Battery - (7) 35 mm2

Fuel return (6) 8 mm

Fuel in (4) 8 mm

Power cable (3) Remote cable (2)

Airvent out (9) 25,4 mm

Airvent in (10) 25,4 mm

Exhaust (1) 51 mm

INSTALLATION

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 dorade 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 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 158°F (70°C). If the

cables are required to meet higher temperature require-

ments, 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 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 cm above the bottom of

the tank.

AWG 2 (25 mm2)

2" (51 mm)

EXHAUST (1)

REMOTE CABLE (2)

AC CABLE (3)

12xAW 22 (0,3 mm

2

)

FUEL RETURN (6)

WATER IN (8) 3/4" (19 mm)

BATTERY + (5)

AWG 2 (25 mm

2

)

5/16" (8 mm)

FUEL IN (4)

AIRVENT OUT (9) 3/4" (19 mm)

BATTERY - (7)

3/4" (19 mm)

AIRVENT IN (10)

5/16" (8 mm)

Fig. 1.

WHISPER 9,5 / 12,5 / 15 ULTRA

WHISPER 20 ULTRA

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 5

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 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 to end the return line on the top of the tank.

When the return is on the top - in case of a leakage -

the return line cannot overflow because of siphoning.

One will only need a fuel cock in the fuel supply line.

Fig. 2.

1 Fuel return;

2 Fuel supply;

3 Prefilter / water separator (optional);

5 Fuel tank;

INSTALLATION

6 Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA

INSTALLATION

When the tank is below the generating set we recom-

mend to end 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 need only a fuel cock

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 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 and have a connec-

tion 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 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.

Fig. 3.

1 Fuel return;

2 Fuel supply;

3 Prefilter / water separator (optional);

4 Extra fuel lift pump (optional);

5 Fuel tank;

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 7

1.4.2 Cooling

Intercooling is based on a raw water pump, heat exchan-

ger and water-injected exhaust. Cooling liquid in the

internal cooling system is cooled in a heatexchanger by

outboard water (raw water or seawater). After the raw

water is warmed up in the heatexchanger it is dumped

overboard by injecting it in the exhaust.

The generating set should have its own sea water

(coolant water) inlet and should not be connected to any

other engine systems. A properly installed cooling system

is critical to keep engine temperatures within an accepta-

ble range. Ensure that the installation complies to the

following installation instructions.

1 THE INTERNAL COOLING SYSTEM

The internal cooling system should be filled with

cooling liquid. (Refer to the users manual 2.5.12)

When the engine becomes hot the liquid expands and

the system is pressurised. After the pressure becomes

to high the release valve in the filling cap on the

manifold opens and the expanding liquid is pressed

into the expansion tank that is in the delivery. Also the

air in the system that is collected at the top of the

manifold is released in this way. When the liquid cools

down there will be underpressure. An other valve

opens and the liquid is sucked into the manifold again.

This system works only when there is enough liquid

initially. This has to be checked when commissioning

the generator set. By filling up the expansion tank

when necessary there will always be enough liquid in

the system. The hose that is in the delivery has to be

connected to the connection on the side of the filling

cap. This hose is made of heat resistant plastic and is

not sensitive for kinks.

The hose goes through a hole that has to be drilled in

the lower part of the canopy close to the place where

the tank is mounted.

The tank has to be placed close to the generator.

When it is mounted above the top of the manifold the

liquid in the tank will be drained when the cap on the

manifold is taken off.

When keel cooling or radiator cooling is applied the

system will not be pressurised. A cap without release

valve should be applied. Refer to the special manual

for these applications.

2RAW 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 19 mm

diameter (3/4") Whisper 15 and 25,4 mm (1”) Whisper

20. The suction hose should be kept as short as pos-

sible. Raw water plumbing should avoid bends as

much as possible.

1

2

3

4

5

7

6

Min.

24"

60 cm

2"

5 cm

Max.

60"

150 cm

Min.

24"

60 cm

Fig. 4b.

1Water level; 2Water/exhaust separator; 3 Seacock; 4Waterlock;

5 Air vent; 6Water strainer; 7 Seacock.

Afb. 4a.

INSTALLATION

8 Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA

INSTALLATION

Restriction of raw water flow, caused by kinked hoses,

undersized pipes or connections, will reduce the

engine cooling capability. This is the main cause for

overheating of an engine.

After running the generating set for the first time, check

the coolant flow rate using a stopwatch and by holding

a pail of a known volume under the wet exhaust outlet.

The flow rate should be according to the data in the

users manual.

3 INSTALLATION OF THROUGH HULL FITTING

It is good practice for yachts to use a hull inlet fitting

with an integrated strainer (water scoop). For 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 ailing at higher

speeds, 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

during sailing.

4WATER STRAINER

Use an appropriate water strainer with connections of

3/4" (19mm) Whisper 15 ULTRA and 1" (25,4mm)

Whisper 20 ULTRA. Install the water strainer in a well ac-

cessible position, (ref. to fig. 4 - 6) 15 cm above the

waterline.

5 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 3/4" (19 mm)

Whisper 9,5/ 12,5/ 15 ULTRA and 1" (25,4 mm)

Whisper 20 ULTRA 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).

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.

flow direction

sailing direction

WRONG!

thru-vessel inlet

Fig. 5.

Fig. 6.

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 9

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.

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 outside sea 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 2” (51

mm). The exhaust system must be installed so that

the back pressure inside the exhaust does not

exceed 0.7 bar (1 psi = 27 inches (70 cm)

watercolumn)(2 inches mercury) and total length

from generator to the top of the goose neck or

water/gasseparator does not exceed 10 ft. (3m).

(Refer to paragraph 5.4.3 of the users manual.

The exhaust hose descends from the capsule to the

water lock. Then the hose rises via the "goose neck"

to the through-hull exhaust outlet, situated minimum

2” (50 mm) above the water line (ref. to fig. 7-5. The

"goose neck" must be vertical and situated preferable

along the ship’s keel center line. If the generating set

is mounted less than 24” (600 mm) above the

waterline, a "goose neck" must be installed to prevent

the engine from overflowing. It is recommended to

install an extra muffler close to the through-hull fitting.

A

B

Minimal

24"

60 cm.

Maximal

60"

150 cm.

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

2"

5 cm.

Fig. 7.

1 Exhaust water lock;

2 Exhaust outlet muffler;

3 Exhaust line Ø 2” (51 mm);

4 Goose neck

5 Through-hull exhaust outlet Ø 2” (51 mm);

6 Water level.

INSTALLATION

10 Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA

INSTALLATION

2 "SUPER SILENT" EXHAUST SYSTEM

In order to reduce the noise level of the generating

set to a minimum, an option to reduce the exhaust

noise further (especially exhaust water splashing) is

an exhaust/water separator. The exhaust/water sepa-

rator allows the cooling water to be ejected through a

line (A) separate from the exhaust fumes and also

functions as a goose neck to prevent water from

flooding the engine. If the exhaust/water separator is

mounted more than 24 inches (600 mm) above the

water level an additional goose neck is not required.

If the through-hull exhaust outlet has to be mounted

far (total length exhaust piping from generator to top

of goose neck (waterseparator) is more than 10 ft.

(3 m)) from the generating set, an exhaust/water se-

parator must definitely be installed. The sea water

from the separator must then run down along the

shortest possible path to the through-hull outlet. Only

after the exhaust/water separator the exhaust hose

may have alength of over 25 ft. (7,5 m) if the exhaust

hose diameter is also increased from 2” (51 mm) to 2

1/2” (63 mm) in order to reduce the back pressure

(ref. to fig. 9).

However watertraps should be avoided as the fumes

still contains water and this shouldnot accumulate in

bents. (Referto fig 8a) An additional outlet exhaust

muffler close to the hull outlet will help further to

reduce noise emission.

2" (51 mm)

24 inch

1 5/8" (40 mm)

WATERLEVEL

2" (51 mm)

MAX. 4 inches (10 cm)

Fig. 8.

Fig. 8a.

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 11

ø 2" (51 mm)

up to 10 ft. (3 m) ø 2" (51 mm) 10-30 ft. (3-10 m) ø 2,5" (63 mm)

ø 1 5/8" (40 mm)

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

A

B

Wrong

Good

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 be installed below the water

level to eliminate noisy splashing of the effluent sea

water.

The through-hull outlet for the exhaust fumes should

not direct the fumes directly toward the water surface

as this will cause excessive noise (ref. to fig. 10).

Do not direct the outlet directly toward the

water surface.

INSTALLATION

12 Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA

INSTALLATION

1.4.4 DC control system (12 Volt)

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 genera-

ting set and control panel prior to despatch from the

factory. The engine is controlled by a very advanced

microprocessor based system: Digital Diesel Control.

The “black box” containing the microprocessor is

located on top of the alternator.

A local control panel is on the generating set.

Remote control

A remote control panel also containing a

microprocessor is in the delivery. A 45 feet (15 m)

intermediate 8-pole cross-wired communication cable

is in the standard supply too. If necessary an optional

longer max. 90 feet (30 m) intermediate cable can be

connected if the standard length does not suit the

required distance. When a longer distance than 90

feet (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.

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

WARNING RELAY MAX. 150 mA

BLACK

RED/BLUE

GREY

GREY/PINK

WHITE

BLUE

PURPLE

PINK

YELLOW

BROWN

GREEN

RED

WIRING COLOURS

Fig. 12.

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 13

In the delivery are warning stickers to stick

on several parts of the electric installation

(transfer switch, distribution box, etc.) to

warn for automatic start.

The Mastervolt Digital Diesel Control system offers

several options for automatic starting and stopping.

Access to this menu and other menus could be

blocked. For blocking and setting up this options refer

to the APPENDIX of the DDC users manual.

One of these options is to monitor a second battery

(Not being the starter battery) to start the generator

automatically when the voltage of this battery drops

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 9,5 / 12,5 / 15 requires a

battery with a capacity of at least 85 Ah. The Whisper

16 ULTRA reguires 120 Ah. The generating set can

be connected with the main engine battery or with its

own battery. We strongly recommend to use a

separate battery for the generating set and to keep

the wiring system for the propulsion engine and the

domestic DC supply system completely separate and

individually connected to separate batteries.

However the negative of all the batteries on the

vessel should be interconnected (when on earth) to

avoid difference in the voltage level of the earth on

different places causing trouble to electronic devices

which might be in the system. The above

recommendation is not valid for ships having the

starter battery of the propulsion engine or other

auxiliary equipment positive grounded. When this is

the case an expert should be consulted.

A battery switch may be used to interrupt the positive

connection. The starter battery is charged by the

alternator on the engine. An additional battery char-

ger will help to keep the battery in good condition

when the generating set in not used.

A battery charger 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 for the stater battery only,

such as 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.

INSTALLATION

12V

IVO 12/10

A

B

230VAC

Fig. 13.

14 Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA

INSTALLATION SPECIFICATIOINS

The battery cables are supplied in a standard length

of 1.5 m, if longer cables are required a larger cross

sectional area should be considered to compensate

for voltage reduction.

When two batteries are used in series to provide a 24

Volt supply system, never take off 12 Volt (starting)

power from one of these batteries. This will result in

sever damage to the batteries within short time.

Disconnect the battery leads if electrical welding is to

be carried out, otherwise damage will be caused to

the diodes of the alternator.

As explosive hydrogen gases are discharged

during charging, the battery should be

located in a well ventilated room. Ensure that

the supplied battery cable connectors are

properly fitted and never remove during or

shortly after charging as sparking can occur,

which may ignite the hydrogen gasses.

1.4.5 AC power system (120/240 Volt)

Before working (installation) on the system

read the sections on safety in the users

manual.

Be sure that all electrical installations (including all safety

systems) comply with all required regulations of the local

authorities. All electrical safety/shutdown and circuit

breaking system have to be installed onboard as the

generating set itself cannot be equipped with such equip-

ment 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.

For the Whispers the maximum single phase current

at 240V is 62A (15), 83A (20). At 120V the maximum

single phase current is: 125A (15) 166A (20). 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 neutral of the AC

alternator windings is grounded.

The housing of the alternator and all other

metal parts are grounded as well.

The connection between “neutral” and “ground” is

necessary as part of a insulation failure protection

system as commonly used in the U.S.A.

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. For safety

reasons connect the main ships ground to

negative point of the generating set start

battery. When an ungrounded DC system

or positive grounded DC system is applied

the battery negative should not be

connected to the main ships ground.

3 CABLE

For the power cable we recommend the use of 4 wire

oil resistant cable with a sufficient cross sectional

area. One wire for earth is included. For very long ca-

bles it is recommended to apply cables with a larger

cross section than the above mentioned. (refer to ISO

13297 anex A)

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 de-

signed to switch over all wires including neutral (and

not only phases or line) and there should be provi-

sions with the aid of timers to prevent relays from

clattering.

Mastervolt advises to install a MASTERSWITCH as a

power source selector. This works automatically when

the generating set is not running the input remains in

the shore position and as soon as the generating set

is running the masterswitch switches automatically

after 10 seconds delay time over to the generating

set position.

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 15

2 INSTALLATION

SPECIFICATIONS

2.1 WHISPER 15/20 ULTRA INSTALLATION TABLE

1 Install the generating set, direct or with 4 shock

mounts (ref. to fig. 12)

2 Connect the (sea) water inlet to the strainer.

3 Connect exhaust system.

4 Connect a siphon breaker or ‘air vent’ into cooling cir-

cuit, if necessary.

5 Connect ‘fuel supply line’ to the water separator/ fuel

filter.

6 Connect ‘fuel return line’ to the fuel tank.

7 Connect remote panel (just plug in).

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

source selector or masterswitch.

9 Connect plus and minus from the 12V starter battery

to the battery cables.

10 Install a Mastervolt battery charger. (optional)

2.2 COMMISSION TABLE

1Check 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 above

the seawater level.

3 Check if the exhaust system is properly installed.

Check maximum lentgh of exhaust hose, diameter of

exhaust hose, position of waterlock, maximum lift.

Also check the minimum required height of 600 mm

above sea level of the exhaust loop (goose neck).

4 Open the seawater outlet valve and check all water

connections.

5 Check the AC cables and the grounding.

6 Check if an AC breaker is installed before or after the

power source selector. When there is only a circuit

breaker, use it to disconnect the generating set from

the grid.

7 Check all DC connections, check if the battery switch/

circuit breaker is closed.

8Check 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. Check the

coolant level.

11 Bleed the fuel system (refer to the users manual

§4.2.2)

12 The starting procedure is initialized by pushing the

START button.

13 Check when the generating set is running, the delay

of 5 to 10 seconds in the power source selector trans-

fer.

14 Check voltage and frequency under ‘no load’ condi-

tions.

15 Check voltage and frequency under ‘full load’ condi-

tions.

16 Check if the battery charger of the generating set is

working (max. 14.2 Volt).

17 Close the sound shield and check the noise level.

18 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

INSTALLATION SPECIFICATIONS

Fig. 14.

16 Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA

2.3 INSTALLATION SPECIFICATIONS WHISPER 9,5 / 12,5 / 15 / 20 ULTRA

TECHNICAL DATA

9,5 / 12,5 ULTRA: 35,4 x 24,21 x 27,17 inches (900 x 615 x 690 mm)

Dimensions wxdxh. 15 ULTRA:41,73 x 24,21 x 27,17 inches (1060 x 615 x 690 mm)

20 ULTRA: 45,27 x 26,77 x 29,52 inches (1150 x 680 x 750 mm)

Weight 9,5 / 12,5 ULTRA: 640 lbs (290 kg)

15 705: lbs (320 kg) 20 ULTRA: 926 lbs (420 kg)

Max. operation angle 25°

Remote panel 45 ft.15 m cable, indicating: run, load, overload, failure, hour counter, glow-, start-, stop button.

Battery capacity min. 9,5 / 12,5 / 15 ULTRA: 12V, 85 Ah

20 ULTRA: 12V, 120 Ah

Fuel consumption 0,25-1,2 gl/hr (1-4,5 l/hr), load dependent

Fuel lift pump 9,5 / 12,5 / 15 ULTRA electric driven 12 V DC, max. lift 3 ft. (1 m)

Fuel lift pump 20 ULTRA mechanical driven; manually priming; lift 3 ft. (1 m).

Cooling indirect cooling

Cooling pump 9,5 / 12,5 / 15 ULTRA raw water Mastervolt self priming impeller pump,

PTO driven, type M12

20 ULTRA raw water Mastervolt self priming impeller pump,

PTO driven, type M16

Minimum water supply 9,5 / 12,5 / 15 ULTRA: 4,8 - 6,9 gl/min (18-22 l/min)

20 ULTRA: 5,3 - 6,6 gl/min (20-25 l/min)

Alternator synchronous brushless, maintenance free water cooled

Voltage regulation capacitor + AVR (optional)

Output power at 9,5 ULTRA: 9,5 kW 120/240V 60 Hz power factor cos phi =1

12,5 ULTRA: 12,5 kW 120/240V 60 Hz

15 ULTRA: 15 kW, 120/240V 60 Hz 20 ULTRA: 20 kW, 120/240V 60Hz

Battery charger alternator including regulator (50 Amps)

2.4 SPECIFICATION OF THE ACCESSORIES

Whisper 9,5 / 12,5 / 15 ULTRA Whisper 20 ULTRA

Water scoop 3/4” 1”

Inlet valve 3/4" 1”

Water strainer 3/4" 1”

Air vent 3/4" 1”

Inlet suction hose 3/4" 1”

Fuel filter/water separator 30 micron 30 micron

Fuel inlet and return 5/16” (8 mm) 5/16” (8 mm)

Exhaust hose Ø 2” (51 mm) Ø 2” (51 mm)

Water lock Ø 2” (51 mm) Ø 2” (51 mm)

Water/gas separator Ø 2” (51) -1 5/8” (40) -2” (51 mm) Ø 2” (51) -1 5/8” (40) -2” (51 mm)

Anti shock mounts 50230550 50230550

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

INSTALLATION SPECIFICATIONS

INSTALLATION MATERIALS

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 17

2.5 INSTALLATION MATERIALS WHISPER 9,5/12,5/15/20 ULTRA

WATER INLET KIT 3/4”(20mm) 9,5/12,5/15 ULTRA

no qtt article no description dimensions 11 50230052 Intake strainer 3/4 21 50230042 Lever operated ball valve FF 3/4 31 50221004 Male hose connection 3/4 34 50221502 Hose clamps 19-29 mm 53 50220056 Outboard cooling water hose 20x28 mm 62 50221007 Male hose connection 1/2x20 71 50230060 Nickel plated brass intake strainer3/4 81 50230067 Mounting bracket waterstrainer

TOTAL 50230211 WATER INLET KIT 3/4” (20 mm)

WATER INLET KIT 1”(25,4 mm) 20 ULTRA

no qtt article no description dimensions 11 50230053 Intake strainer 1” 21 50230043 Lever operated ball valve FF 1” 31 50221010 Male hose connection 1”x25 34 50221503 Hose clamps 26-38 mm 53 50220050 Outboard cooling water hose 25x33 mm 62 50221008 Male hose connection 3/4x25 71 50230061 Nickel plated brass intake strainer 3/4

TOTAL 50230221 WATER INLET KIT 25 mm

AIR VENT KIT 3/4” (20mm) 9,5/12,5/15 ULTRA

no qtt article no description dimensions 44 50221502 Hose clamps 19-29 mm 53 50220056 Outboard cooling water hose 20x28 mm 11 2 50221031 Bend male type with hose connection 1/2x1/2 12 1 50221042 TEE fittings 1/2 13 1 50230001 Syphon breaker valve 1/2 14 1 50221001 Male hose connection 3/8x1/2 15 1 50221521 Hose clamps 12-20 mm 16 1,5 50220055 Outboard cooling water hose 12x18,2 mm

TOTAL 50230212 AIR VENT KIT 3/4” (20 mm)

AIR VENT KIT 1” (25,4 mm) 20 ULTRA

no qtt article no description dimensions 44 50221503 Hose clamps 26 - 38 mm 53 50220050 Outboard cooling water hose 25 x 33 mm 11 2 50221083 Bend male type with hose connection 3/4 12 1 50221043 TEE fittings 3/4 12 1 50221102 Straight reducer 3/4 x 1/2 13 1 50230001 Syphon breaker valve 1/2 11 2 50221008 Male hose connection 3/4 x 25 14 1 50221001 Male hose connection 3/8x13 15 1 50221521 Hose clamps 12-20 mm 16 1,5 50220055 Water hose 12x18,2 mm

TOTAL 50230222 AIR VENT KIT 25 mm

INSTALLATION MATERIALS

18 June 2002 / WHISPER 15/20 ULTRA / USA

EXHAUST KIT 2” (51 mm)

no qtt article no description dimensions 22 5 50221541 Hose clamps HD. 55-62 mm 23 3 50220035 Marine exhaust hose 2” 24 1 50230081 Waterlock 2” 25 1 50230034 Brass through hull fitting 1 1/2 x 70 26 1 50221024 Female hose connector 1 1/2 x 2”

TOTAL 50230213 EXHAUST KIT 2” (51 mm)

OPTIONAL INSTALLATION MATERIALS

no qtt article no description dimensions 21A 1 50230077 Elbow 90 degr adapter exhaust hose 2” 22 2 50221541 Hose clamps H.D. 55-62 mm

WATER SEPERATOR KIT 1 5/8” (40 mm)

no qtt article no description dimensions 21 2 50221506 Hose clamps 44-56 mm 22 2 50221541 Hose clamps H.D. 55-62 mm 23 2,5 50220035 Marine exhaust hose 2” 40 1,5 50220033 Marine exhaust hose 1 5/8” 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 1/1/4 34 1 50230080 Water exhaust fumes seperator 2” - 1 5/8” - 2” (51-40-51) 35 4 50201121 Vibration mounting 25x30 mm M8 36 4 50211152 Bolt M8x16 37 4 50211465 Nut M8 38 8 50211405 Washer M8 39 8 50211445 Lock washer M8

TOTAL 50230204 WATER SEPERATOR KIT

FUEL KIT U.S.A.

no qtt articleno description dimensions 42 1 50230090 Fuel strainer/water seperator 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 articleno description dimensions 51 1 50220063 Fuel hose 5/16” (8x16 mm)

BATTERY INSTALLATION KIT 85 Ah 9,5/12,5/15 ULTRA

no qtt articleno description dimensions 51 1 64000850 Battery 85Ah 52 1 43011030 Battery charger 53 1 68060100 Battery terminal + M8 54 1 68060200 Battery terminal - M8 55 1 68456902 Isolation cap 56 1 68456914 Isolation cap 57 1 79009005 Battery switch 250 Amp 58 4 6503001608 Cable connectors M8x16 58 4 6503002508 Cable connectors M8x25

TOTAL 50230216 BATTERY INSTALLATION KIT 85 Ah

BATTERY INSTALLATION KIT 120 Ah 20 ULTRA

no qtt articleno description dimensions 51 1 64001200 Battery 85Ah 52 1 43011000 Battery charger IVO SMART 12/10 53 1 68060100 Battery terminal + M8 54 1 68060200 Battery terminal - M8 55 1 68456902 Isolation cap 56 1 68456914 Isolation cap 57 1 79009005 Battery swich 250 Amp 58 4 6503003508 Cable connectors M8x35

TOTAL 50230226 BATTERY INSTALLATION KIT 120 Ah

RUBBER MOUNTING KIT 420 kg. 9,5/12,5/15 ULTRA

no qtt articleno description dimensions 64 1 50230015 Fastener kit rubber mountings 61 4 50230551 Rubber mountings M12

TOTAL 50230231 RUBBER MOUNTING KIT 420 kg.

RUBBER MOUNTING KIT 520 kg. 20 ULTRA

no qtt articleno description dimensions 64 1 50230015 Fastener kit rubber mountings 61 4 50230550 Rubber mountings M12

TOTAL 50230232 RUBBER MOUNTING KIT 520 kg.

INSTALLATION MATERIALS

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 19

INSTALLATIOJ MATERIALS

20 Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA

- Fuel kit

- Battery installation kit

- Mounting kit

included are all fittings to fit rubber fuel hoses.

Fig. 15.

INSTALLATION MATERIALS

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 21

- Water inlet kit

- Air vent kit

- Exhaust kit

- Water separator kit

* Hose drain should go downwards. Water must flow out

freely. Refer to installation manual for proper installation air-vent kit. Faulty installation can cause serious problems.

Fig. 16.

22 Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA

3 DIAGRAMS & DRAWINGS

3.1.1 DC WIRING DIAGRAM 9,5 / 12,5 ULTRA

DIAGRAMS

& DRAWINGS

Fig. 17.

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 23

hold

ct-2

ct-1

ct-2

gnd

tem

str.

exh

oil

reg

alt.

fuel

heat start fuel fail

st

gl

+

pull

AC-1

AC-2

8586

30

87

LOCAL CONTROL PANEL

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

+

MASTERVOLT

+

10A 3A

F3

10A

ALT

CURRENT MEASURING

TRANSFORMER

BLACK (11)

RED (11)

TO GENERATOR AC OUTPUT

AC-1

BROWN (33)

BLUE (33)

AC-1

BROWN (44)

BLUE (44)

RED (22)

BLACK (22)

CURRENT MEASURING

TRANSFORMER

CONTROL PANEL

TO REMOTE

SWITCH

EXHAUST TEMP.

WATER TEMP. OIL PRESS.

SWITCH

SOLENOID

FUEL

WHITE (HOLD)

BLUE (COM.)

RED (PULL)

PINK 1,5 (20)

GREEN 1,5 (9)

RED/GREEN 1 (16)

BLUE/GREEN 1 (8)

BLUE 1 (7)

PURPLE 1 (6)

ORANGE 1,5 (19)

RED 25

BLACK 25

GROUND TO

ENGINE BLOCK

GLOW (PREHEAT)

PLUGS

BATTERY

SWITCH

(OPTIONAL)

PURPLE/BLACK 1 (6) J14

GLOW (PREHEAT)

SOLENOID

BROWN 4 (3)

BROWN 1.5 (24)

+-

BLACK 4 (2) J17

BATTERY

12VDC

(OPTIONAL)

FUEL LIFT

PUMP

BLACK 1,5 (25) J13

RED 4 (3)

BLACK 1,5 (23) J15

BLACK 1,5 (17) J16

BLUE/PINK 1 (8) J12

WHITE 1,5 (18)

R

B

L

P

ALTERNATOR

STARTER

MOTOR

RED 6 (21)

RED 2,5 (1)

GREY 1,5 (5)

BLACK 1,5 (12) J8

BLUE/BLACK 1 (7) J10

RED 1,5 (14)

YELLOW 2,5 (4)

RED 2,5 (13)

SWITCH

3.1.2 DC WIRING DIAGRAM 15 ULTRA

Fig. 18.

24 Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA

CONTROL PANEL

TO REMOTE

hold

ct-2

ct-1

ct-2

gnd

tem

str.

exh

oil

reg

alt.

fuel

heat start fuel fail

st

gl

+

pull

AC-1

AC-2

8586

30

87

LOCAL CONTROL PANEL

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

+

MASTERVOLT

+

10A 3A

F3

10A

ALT

CURRENT MESURING

TRANSFORMER

BLACK (11)

RED (11)

AC-2

AC-1

TO GENERATOR AC OUTPUT

BLUE (44)

BROWN (44)

BLUE (33)

BROWN (33)

TRANSFORMER

CURRENT MEASURING

BLACK (22)

RED (22)

SWITCH

EXHAUST TEMP.

WATER TE MP. OIL PRESS.

SWITCH

SOLENOID

FUEL

WHITE (PULL)

BLACK (COMM.)

RED (HOLD)

GREY 2,5 (20)

GREEN 1,5 (9)

RED/GREEN 1 (16)

PURPLE 1 (6)

BLUE/GREEN 1 (8)

BLUE 1 (7)

ORANGE 1,5 (19)

RED 35

ENGINE BLOCK

GROUND TO

GLOW (PREHEAT)

PLUGS

SWITCH

BATTERY

(OPTIONAL)

PURPLE/BLACK 1 (6) J14

BLACK 35

SOLENOID

BROWN 6 (3)

GLOW (PREHEAT)

BROWN 1.5 (24)

BLACK 4 (2)J17

(OPIONAL)

12VDC

BATTERY

RED 6 (3)

BLACK 1,5 (25) J15

BLACK 2,5 (17) J16

BLUE/PINK 1 (8) J12

BLUE/BLACK 1 (7) J10

WHITE 1,5 (18)

R

B

L

P

ALTERNATOR

STARTER

MOTOR

RED 6 (21)

RED 2,5 (1)

GREY 1,5 (5)

BLACK 1,5 (12) J8

RED 1,5 (14)

YELLOW 2,5 (4)

RED 2,5 (13)

SWITCH

Fig. 19. 20 ULTRA Lay out

3.1.3. DC WIRING DIAGRAM WHISPER 20 ULTRA

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 25

3.2 CODES AND COLORS 9,5 / 12,5 / 15 ULTRA

15 ULTRA

AWG (American Wiring Gauge) cable code no colour AWG cross section

battery > starter motor red 2 25 mm2

starter motor > DCC 1 red 10 6 mm2

starter motor > LCP 13 red 14 2,5 mm2

battery > ground black 2 25 mm2

ground > LCP ground (GND) 2 black 12 4 mm2

DDC > glow plugs 3 brown 12 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 > water temperature switch 7 blue 17 1 mm2

LCP > water temperature switch 7 blue/black 17 1 mm2

DDC > exhaust temperature switch 8 blue/green 17 1 mm2

DCC > fuel solenoid (hold) 9 green 16 1,5 mm2

DCC > fuel solenoid (pull) 20 pink 16 1,5 mm2

DCC > fuel solenoid (com.) 17 black 16 1,5 mm2

B+ terminal alternator > starter motor 21 red 10 6 mm2

DCC >R terminal alternator 18 wit 16 1,5 mm2

DCC > L terminal alternator 19 orange 16 1,5 mm2

DCC > current measuring transformer 11 black 17 1 mm2

DCC >current measuring transformer 11 red 17 1 mm2

DCC > current measuring transformer 22 black 17 1 mm2

DCC >current measuring transformer 22 red 17 1 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

DCC > generator AC output 44 brown 17 1 mm2

DCC > generator AC output 44 blue 17 1 mm2

DDC=Digital Diesel Control Unit

LCP=Local Control Panel

DIAGRAMS & DRAWINGS

26 Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA

DIAGRAMS & DRAWINGS

20 ULTRA

AWG (American Wiring Gauge) cable code no colour AWG cross section

battery > starter motor red 2 35 mm2

starter motor > DCC 1 red 10 6 mm2

starter motor > LCP 13 red 14 2,5 mm2

battery > ground black 2 35 mm2

ground > LCP ground (GND) 2 black 12 4 mm2

DDC > glow plugs 3 brown 12 4 mm2

DDC > starter solenoid 4 yellow 14 2,5 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 > water temperature switch 7 blue 17 1 mm2

LCP > water 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 solenoid (hold) 9 green 16 1,5 mm2

DCC > fuel solenoid (pull) 20 grey 14 2,5 mm2

DCC > fuel solenoid (com.) 17 black 14 2,5 mm2

B+ terminal alternator > starter motor 21 red 10 6 mm2

DCC > R terminal alternator 18 wit 16 1,5 mm2

DCC > L terminal alternator 19 orange 16 1,5 mm2

DCC > current measuring transformer 11 black 17 1 mm2

DCC > current measuring transformer 11 red 17 1 mm2

DCC > current measuring transformer 22 black 17 1 mm2

DCC > current measuring transformer 22 red 17 1 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

DCC > generator AC output 44 brown 17 1 mm2

DCC > generator AC output 44 blue 17 1 mm2

DDC=Digital Diesel Control Unit

LCP=Local Control Panel

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 27

DIAGRAMS & DRAWINGS

3.3 ELECTRONIC GOVERNOR WHISPER 12,5 ULTRA

APECS

RPM+

EPSW

PTO

SW1

AUX

VBAT

TAC+

GND

VBAT

GND

2

13

4

9

101112

131415

16 8

76543

2

1 TAC-

SRTN

RPS

APP

VREF

IVS

SW2

RPM-

MAGNETIC PICKUP

POWER SUPPLY 12VDC

PROPORTIONAL ACTUATOR

TO LOCAL CONTROL PANEL

VBAT(11)

GND(9)

PUMP OUTPUT (J24)

GND(16)

RPM+(16)

RPM-(8)

WHITE BLACK

WHITE WHITE

TAC+ (10)

TAC- ( 1)

MODEL 4100

TWISTED PAIR WIRE

TWISTED PAIR SHIELDED WIRE

Fig. 20.

The Whisper 12,5 ULTRA is equipped with an electronic

governor in addition to the mechanical governor that is on all

Whisper models. A governor keeps the speed

(RPM=Rotations Per Minute) of the engine at a fixed value.

The RPM of the engine correlates with the frequency of the

electrical output (1800 RPM=60Hz) of the alternator.

Under full load the RPM of the Whisper 8 ULTRA that has

only a mechanical governor can drop 75 RPM (=2.5 Hz) at

9,5 kW and will go further down or collapse when further

loaded. However the electronic governor of the Whisper

12,5 will keeep the RPM and frequency at the set value. As

the RPM represents power and the alternator performs

better as well on a higher speed, the Whisper 12,5 ULTRA

will brng 3 kW more than the Whisper 9,5 ULTRA.

28 Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA

STATOR

N

120-240V 60Hz

PE

L1

ROTOR

L2

EARTH AND NEUTRAL CONNECTED

EARTH AND NEUTRAL NOT CONNECTED

EARTH AND NEUTRAL CONNECTED

DCC/AC-1

BROWN (33)

YELLOW/GREEN

BLUE (33)

120V 60Hz

BROWN

L1

BLUE

N

YELLOW/GREEN

BROWN

120V 60Hz

PE

L1

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

L2

BLUE (44)

YELLOW/GREEN

BLACK

YELLOW/GREEN

120-240V 60Hz

BLUE

PE

N

BROWN

L1

DCC/ct-1

(11)(11)

CURRENT TRANSFORMER

BLACKRED

(22) (22)

DCC/ct-2

BLACKRED

CURRENT TRANSFORMER

TRANSFORMER

CURRENT

DCC/AC-1

BROWN (33)

YELLOW/GREEN

BLUE (33)

DCC/ct-1

BLUE

N

YELLOW/GREEN

PE

RED

DCC/ct-2

(22)

BLACK (22)

RED (11)

BLACK (11)

TRANSFORMER

CURRENT

MAIN WINDING

(4)

MAIN WINDING

(4)

(3)

EXCITATION WINDING

(2)

(1)

YELLOW/GREEN

DCC/AC-1

BROWN (33)

BLUE (33)

BLUE

YELLOW/GREEN

TRANSFORMER

RED (11)

DCC/ct-1

BLACK (11)

CURRENT

CAPACITOR

BROWN

DCC/ct-2

(22)

RED

(22)

BLACK

DCC/AC-2

BROWN (44)

BLUE (44)

CURRENT TRANSFORMER

BLACK

3.4 AC WIRING DIAGRAM WHISPER 120-240V 60HZ

DIAGRAMS & DRAWINGS

Fig. 21.

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 29

DIAGRAMS & DRAWINGS

3.5 WHISPER REMOTE CONTROL PANEL DRAWINGS

Fig. 22.

30 Septemberl 2004 / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / USA

WHISPER 9,5 / 12,5 / 15 ULTRA

WHISPER 20 ULTRA

topview

service side

afb 18a.

afb 18b.

596 646

Whisper 9,5 / 12,5

530

Whisper 20

560

CONNECTIONS WHISPER 9,5 / 12,5 / 15 ULTRA

• exhaust: 2” (51 mm)

• fuel hose: 5/16” (8 mm)

• sea water in: 3/4” (19 mm)

• air vent connection: 3/4” (19 mm)

• battery +: AWG 2 (25 mm

2

)

• battery -: AWG 2 (25 mm

2

)

POWER CABLES ISO 13297 anex A (70˚C)

• 9,5 / 12,5 / 15 ULTRA 120/240V 4xAWG4 (25mm2)( not incl.)

• 9,5 / 12,5 / 15 ULTRA 120V 3xAWG0 (70mm2)( not incl.)

BOX DIMENSIONS WHISPER 9,5 / 12,5 / 15 ULTRA:

• length 35,4 inch 900 mm

• width 24,21 inch 615 mm

• height 27,17 inch 690 mm

• weight Whisper 9,5 / 12,5 ULTRA 640 lbs 290 kg

BOX DIMENSIONS WHISPER 15 ULTRA:

• length 41,73 inch 1060 mm

• width 24,21 inch 615 mm

• height 27,17 inch 690 mm

• weight Whisper 15 ULTRA 705 lbs 320 kg

3.6 WHISPER 9,5/12,5/15/20 ULTRA DIMENSIONS

CONNECTIONS WHISPER 20 ULTRA

• exhaust: 2” (51 mm)

• fuel hose: 5/16” (8 mm)

• sea water in: 1” (25,4 mm)

• air vent connection: 1” (25,4 mm)

• battery +: AWG 2 (35 mm

2

)

• battery -: AWG 2 (35 mm

2

)

POWER CABLES

• 20 ULTRA 120/240V 4xAWG2 (35mm2)( not incl.)

• 20 ULTRA 120V 3xAWG000 (95mm2)( not incl.)

REMOTE CABLE (ALL MODELS):

8-pole communication cable standard: 45 ft. (15 m) max. 90 ft.(30 m) For longer distances refer to Mastervolt service department.

BOX DIMENSIONS WHISPER 20 ULTRA

• length 45,27 inch 1150 mm

• width 26,77 inch 680 mm

• height 29,52 inch 750 mm

• weight Whisper 20 ULTRA 926 lbs 420 kg

Fig. 22.

Fig. 23.

Fig. 24.

USA / WHISPER 9,5 / 12,5 / 15 / 20 ULTRA / September 2004 31

NOTES

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 June 2002 / WHISPER 15/20 ULTRA / USA

MASTERVOLT

Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands

Tel.: +31-20-3422100 / Fax: +31-20-6971006

www.mastervolt.com / info@mastervolt.com