Mastervolt whisper 9.5 ultra, whisper 11 ultra User Manual

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USERS MANUAL U.S.A EDITION

WHISPER 9.5/11 ULTRA

- 1800 RPM -

Marine diesel generating set 120/240V / 60Hz

Digital Diesel Control

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

V3. August 2009

Art.nr. 50200227

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TABLE OF CONTENTS

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.

TABLE OF CONTENTS:

1 INTRODUCTION..............................................................................................................................................................4

1.1 General .............................................................................................................................................................. 4

1.2 Service and maintenance................................................................................................................................... 4

1.3 Guarantee .......................................................................................................................................................... 4

1.4 Liability ............................................................................................................................................................... 5

1.5 Identification ....................................................................................................................................................... 6

1.5.1 General.............................................................................................................................................. 6

1.5.2 Identification plate ............................................................................................................................. 6

2 INFORMATION................................................................................................................................................................ 7

2.1 Safety ................................................................................................................................................................. 7

2.1.1 General.............................................................................................................................................. 7

2.1.2 Electrical safety ................................................................................................................................. 7

2.1.3 Earth insulation failures ..................................................................................................................... 7

2.1.4 Installation ......................................................................................................................................... 7

2.1.5 Operation........................................................................................................................................... 8

2.1.6 Fire and explosion ............................................................................................................................. 8

2.1.7 Chemicals.......................................................................................................................................... 8

2.2 Transport, lifting and storage.............................................................................................................................. 9

2.3 The Whisper 9.5 / 11 ULTRA ............................................................................................................................. 9

2.3.1 Features ............................................................................................................................................ 9

2.3.2 Remote control .................................................................................................................................. 9

2.3.3 Documentation .................................................................................................................................. 9

2.3.4 Accessories included in the standard delivery...................................................................................9

2.4 Components ..................................................................................................................................................... 10

2.4.1 Main components to identify............................................................................................................ 10

2.4.2 Generator control panel................................................................................................................... 12

2.4.3 Remote control panel ...................................................................................................................... 12

2.5 Technical Information ....................................................................................................................................... 12

2.5.1 AC alternator ................................................................................................................................... 12

2.5.2 Engine ............................................................................................................................................. 12

2.5.3 Digital Diesel Control system........................................................................................................... 12

2.5.4 Battery charger................................................................................................................................ 12

2.5.5 Alarms and shut down..................................................................................................................... 13

2.5.6 Control............................................................................................................................................. 13

2.5.7 Remote control ................................................................................................................................ 13

2.5.8 Hour counter.................................................................................................................................... 13

2.5.9 Load indicator.................................................................................................................................. 13

2.5.10 Fuel specification............................................................................................................................. 13

2.5.11 Oil information ................................................................................................................................. 13

2.5.12 Cooling liquid................................................................................................................................... 13

2.5.13 Technical data ................................................................................................................................. 14

2.5.14 Wiring codes and colours ................................................................................................................ 15

2.5.15 Lay out control wiring....................................................................................................................... 16

2.5.16 Electrical diagram 120V – 240 V AC / 60 Hz ................................................................................... 18

2.5.17 Diagram electronic governor Whisper 11 ULTRA............................................................................ 19

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TABLE OF CONTENTS

3 OPERATION.................................................................................................................................................................. 20

3.1 General ............................................................................................................................................................ 20

3.2 Operating Instructions ...................................................................................................................................... 20

3.2.1 Summarised operating instructions (daily use)................................................................................ 20

3.2.2 Extended operating instructions ...................................................................................................... 20

4 MAINTENANCE............................................................................................................................................................. 23

4.1 Alternator.......................................................................................................................................................... 23

4.2 Engine .............................................................................................................................................................. 23

4.2.1 Preliminary instructions ................................................................................................................... 23

4.2.2 Bleeding fuel lines ........................................................................................................................... 23

4.2.3 Valve clearance............................................................................................................................... 23

4.2.4 Replacing fuel filter .......................................................................................................................... 23

4.2.5 Replacing oil filter ............................................................................................................................ 23

4.2.6 Readjustment V-beltplacing oil filter ................................................................................................ 24

4.3 Regular maintenance ....................................................................................................................................... 24

4.3.1 Maintenance schedule..................................................................................................................... 25

4.3.2 Putting out of service ....................................................................................................................... 26

5 TROUBLE SHOOTING.................................................................................................................................................. 27

5.1 Alternator/ electrical faults ................................................................................................................................ 27

5.1.1 General............................................................................................................................................ 27

5.1.2 Trouble shooting table ..................................................................................................................... 27

5.2 Engine faults..................................................................................................................................................... 28

5.2.1 General............................................................................................................................................ 28

5.2.2 Trouble shooting table ..................................................................................................................... 29

5.2.3 Warnings ......................................................................................................................................... 31

5.2.4 Service address............................................................................................................................... 32

5.3 Special procedures alternator........................................................................................................................... 32

5.3.1 Residual voltage check / excitation procedure (Whisper 9.5 Ultra only).......................................... 32

5.3.2 Testing rotary rectifier diodes .......................................................................................................... 32

5.3.3 Winding resistant values.................................................................................................................. 32

5.3.4 Meggering ....................................................................................................................................... 32

5.4 Special procedures engine ............................................................................................................................... 33

5.4.1 Setting the RPM .............................................................................................................................. 33

5.4.2 Adjusting valve clearance and retightening the cylinder head bolts. ............................................... 33

5.4.3 Measuring exhaust backpressure.................................................................................................... 34

5.4.4 Disassembling instructions .............................................................................................................. 35

6 SPARE PARTS LIST..................................................................................................................................................... 36

MAINTENANCE LOG ............................................................................................................................................................... 38

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INTRODUCTION

1 INTRODUCTION

1.1 GENERAL

The Whisper 9.5/11 ULTRA Marine Diesel Generating set is manufactured and marketed by Mastervolt. It is important to read this manual before installing and operating the generating set. Both safety and durability rely very much on the correct identification, installation and a good understanding of ratings, features, design, maintenance and operation procedures. The information, specifications, illustrations and statements contained within this publication are given with our best intentions and are believed to be correct at the time of going to press.

All of the specifications, provisions and instructions contained in this manual apply solely to standard versions of the Mastervolt Whisper 9.5/11 ULTRA generating set. This manual is valid for the following models:

Part number

Description

51106055 Whisper 9.5 Ultra 120/240V 1800RPM

51106056 Whisper 9.5 Ultra 120/240V 1800RPM -

ungrounded

51189055 Whisper 11 Ultra 120/240V 1800RPM

51189056 Whisper 11 Ultra 120/240V 1800RPM -

ungrounded

For other models see other manuals available on our website: www.mastervolt.com

Our policy is one of continued development and we reserve the right to amend any technical information without prior notice. Whilst every effort is made to ensure the accuracy of the particulars contained within this publication neither the manufacturer, distributor, or dealer in any circumstances shall be held liable for any inaccuracy or the consequences thereof. Keep this manual at a secure place!

WARNING

A warning symbol draws attention to special warnings, instructions or procedures which, if not strictly observed, may result in damage or destruction of equipment, severe personal injury or loss of life.

DANGER

This danger symbol refers to electric danger and draws attention to special warnings, instructions or procedures which, if not strictly observed, may result in electrical shock which will result in severe personal injury or loss of life.

1.2 SERVICE AND MAINTENANCE

Regular service and maintenance should be carried out according to the directions in this manual. For service and maintenance one can appeal to the manufacturer or the dealers.

1.3 GUARANTEE

Mastervolt guarantees that this generating set has been built according to good workmanship, according to the specifications in this manual and according to European Community safety regulations. During production and prior to delivery, all of our generating sets are tested and inspected.

The well functioning of this generating set is subject to guarantee. The period and conditions of this guarantee are laid down in the general conditions of delivery as registered with the Chamber of Commerce and Industries in Amsterdam number 33279951 and are available on request. The guarantee period is two years, limited to 1000 running hours. For USA deliveries there are additional conditions. These are available at Mastervolt USA. Some aspects of our guarantee scheme are given here in more detail:

Guarantee does not cover failures that are caused by misuse, neglect or a faulty installation.

Example 1. Faulty installation: Seawater entering the engine is the most common cause of damage to combustion engines in boats (both to propulsion and generator engines). The entry of water must be avoided under all conditions. Be aware that the conditions in blue water sailing can be extreme. Refer to the installation manual for instructions but remember these are for guidance only as many factors influence the installation of a generator. The ultimate responsibility will always be with the owner to ensure a safe and compliant installation. If in doubt ask!

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INTRODUCTION

DAMAGE CAUSED BY THE INGRESS OF WATER IS NEVER COVERED BY GUARANTEE

Example 2: Misuse: Long term running with no load or too little load can cause the exhaust to get choked with soot or carbon. Cleaning the exhaust is not covered by guarantee.

Example 3: Neglect Sometimes the seal of the raw water pump starts leaking. Mostly this begins with a little drip and slowly gets worse. Regular visual inspection of the generator is necessary to prevent damage to occur from a leaking water pump. When one find serious damage after weeks of neglect guarantee claims will not be honoured.

Example 4: Neglect Whisper generators have an option for an auto start/stop mode or interval mode. Mastervolt cannot be held responsible for damage caused by the unattended running generator.

Guarantee means that faulty parts are repaired or replaced free of charge. If necessary the whole generator unit will be exchanged. Labour necessary to complete repairs on board a vessel executed by an authorized service engineer is covered, but is limited to a reasonable number of hours and reasonable rates in relation to the actual repair work that has to be done. Travel expenses and travel hours are not covered. Also not covered is the labour required to take a generator out of a boat or for reinstallation. There is no cover for labour needed to get access to the generator, for example to remove equipment or bulkheads etc. For details refer to Mastervolt U.S.A.

Goods to be delivered under guarantee will be invoiced. Only after the faulty goods are returned will the invoice be credited. Payment in advance may be required or guaranteed by credit card. If after the faulty goods are returned, it is indicated that the failure was not covered by guarantee a credit will not be issued. For example if a Printed Circuit Board is returned with clear damage caused by seawater, guarantee will be refused.

Freight costs to deliver spares by normal mail or carriers is covered under guarantee. Special services like express mail, overnight delivery etc. are not covered. Taxes and duties are not covered. For shipments to remote off shore areas any additional costs incurred over normal carriage will be invoiced to the customer. The cost for returning faulty goods is not covered under guarantee.

Additional agreements could be part of the contract of delivery.

If any problem arises which could be subject of guarantee, procedures should be followed as described in the guarantee conditions, unauthorised repairs could lead to further damage and violate the guarantee conditions.

Should work take place, which is not in accordance with the guidelines, instructions and specifications contained in this user’s manual and the supplementary installation manual, then damage may occur and the generating set may not fulfil its specifications. In all these cases the guarantee may become invalid. Use original spareparts only!

1.4 LIABILITY

Mastervolt does not accept responsibility for damage, injuries or casualties which are the result of operation of the generating set in specific conditions which brings dangers which could not be foreseen, or could be avoided by additional measures. Mastervolt does not accept liability for damage due to use of the generator, possible errors in the manuals and the results thereof.

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.

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INTRODUCTION

1.5 IDENTIFICATION

1.5.1 General

Before using this generating set it is very important to identify the set correctly. To communicate for service or ordering parts it is also essential to correctly identify the generating set. Also for the daily operation of the generating set it is necessary that the operator knows the correct specifications.

1.5.2 Identification plate

All required identification data are on the identification plate. For location of the identification plate see figure 1

Fig. 1: Location identification plate.

1 The identity of the generating set is given by the

SERIAL NUMBER.

Example:

When this number is available the manufacturer can trace the specifications of the generating set. On the identification plate are also some basic features of the set:

2 POWER

The identification plate gives the nominal maximum continues load in kVA (= kW) calculated with power factor one. When calculating a load one should always take into account the power factor or cos phi of this load. The power should never exceed the nominal power as shown on the identification plate. Power is rated at an ambient temperature of 104°F (40°C) and a seawater temperature of 77°F (25ºC). For higher temperatures the generating set has to be derated.

3 VOLTAGE shows the nominal voltage.

This voltage should be within the specified tolerance at the nominal frequency.

4 FREQUENCY is shown in Hz and is determined by

the speed of the engine (RPM). 60 Hz correlates with 1800 RPM.

5 CURRENT shows the maximum current that is

acceptable at the specified frequency, voltage and power factor.

6 WEIGHT shows the net dry weight (approximately) in

kg. This is without fuel, oil, packing and external installation equipment

7 CE-marking: the “CE” symbol shows that the

generating set is build according to European Community safety regulations. This includes the regulations regarding the safety of pleasure craft, safety of machinery, electric safety and electric magnetic compatibility (EMC) and other relevant directives.

Safety also relies on the installation, application and circumstances. See also the remarks in this manual under SAFETY

Before changing a factory setting you are advised to consult the manufacturer. When the generating set you have to identify is not new you have to take into account the possibility that former users may have changed the settings. Check the settings (voltage, frequency, rpm) when there is any doubt.

SERIAL NO: : WO22A001

version “A”

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INFORMATION

2 INFORMATION

2.1 SAFETY

2.1.1 General

When correctly installed and used in normal circumstances this generating set fulfils EC safety regulations. This generating set could be part of an installation or could be used in a way that additional regulations of the EC or other authorities have to be taken into account.

Circumstances could make it also necessary to take additional measures. Be aware of wet conditions and hazardous environments caused by explosive gases etc

2.1.2 Electrical safety

The voltage of 120/240 Volt generated by this generating set is dangerous and if instructions and procedures are not strictly observed may result in electrical shock which will result in severe personal injury or loss of life.

• Check all wiring at least once a year. Defects, such as loose connections, burned cables etc. must be repaired immediately.

• Do not work on the electrical system if it is still connected to a current source. Only allow changes in your electrical system to be carried out by qualified electricians.

• Connection and protection must be done in accordance with local standards.

• 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.

Warning signs indicate parts which could be live.

2.1.3 Earth insulation failures

According to local regulations and depending on the application it could be necessary to take measures for protection against earth insulation failures. With the USA versions “neutral” and “ground” are connected with each other on the alternator. This requires an insulation protection device as commonly used in the U.S.A. This installation is beyond the influence of Mastervolt and Mastervolt cannot be held responsible for any consequence as a result of the installation.

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 Mass Systemswitch.

2.1.4 Installation

Whisper generating sets are not self contained and have to be properly installed in enclosed areas such as a machine room.

Installation includes measures to be taken to outlet exhaust fumes which contain carbon

monoxide and are extremely dangerous. Carbon monoxide (CO) is an invisible odourless gas. Inhalation produces headache, nausea or death. Installation includes measures for proper ventilation, safe electric connections, safe installation of the starting battery, proper fitting of the cooling system and fuel pipes etc. Refer to the installation manual.

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INFORMATION

2.1.5 Operation

External moving parts like fans and V-belts are covered by the soundshield and therefore the Whisper 9.5 / 11 ULTRA is very safe when the soundshield is closed.

Nevertheless take note of the signs on the generating set which show symbols in a triangle indicating danger.

When service has to be carried out while the engine is running, be aware of moving parts like V-belts.

• The generating set should be operated by authorised personnel only.

• Be aware of hot parts and especially parts of the exhaust system and the cooling system.

• If the generating set is unsafe, fit danger notices and disconnect the battery positive (+) lead so that it cannot be started until the condition is corrected.

• Do not attempt to operate the generating set with a known unsafe condition. Disconnect the battery positive (+) lead prior to attempting any repairs or cleaning inside the enclosure.

• Always consult the manual before carrying out maintenance.

• Do not change the settings without consulting the manufacturer. Keep a record of setting changes in this manual.

2.1.6 Fire and explosion

Fuels can be flammable. Proper handling limits the risk of fire and explosion.

• Avoid refilling the fuel tank while the engine is running. When oil or fuel is leaking do not use the generating set.

• Do not run the engine close to explosives or gasses.

• Hydrogen gas generated by charging batteries is explosive. Ensure for proper ventilation. Do not smoke or allow sparks, flames, or other sources of ignition around batteries.

• Keep a fire extinguisher on hand.

IN CASE OF FIRE, DO NOT OP EN SOU NDSHIELD. TO AVOID SERIOUS INJURY OR D EA TH FR OM FIRE

IMMEDI ATELY DISCHARGE ENTI RE CONTENTS OF GASEOUS

SHUT DOWN ENG INES, GENERATO R SETS AND BLO WERS.

PORTAB LE FIRE E XTINGUISHER THRO UGH THIS PORT.

THROUG H

HERE

FIRE EXTINGUISHER PO R T :

BREAK

Fig. 2: Fire extinguisher port.

• In case of fire do not open the soundshield. To avoid serious injury or death from fire, shut down engines, generator sets and blowers. Break through the label which is indicated by BREAK THROUGH HERE and then immediately discharge entire contents of gaseous portable fire extinguisher through the fire extinguisher port. On the generating set this fire extinguisher port is indicated by the label as shown in figure 2.

• Poor electrical connections or using wiring which is not suited for the rated currents can cause overheating and possibly fire.

2.1.7 Chemicals

• Fuels, oils, coolants, and battery electrolyte can be hazardous to personnel if not treated properly. Do not swallow or have skin contact with these liquids. Do not wear clothing that has been contaminated by fuel or lubricating oil.

• Gaskets may be manufactured from asbestos. Particles of this material should not be inhaled as this may result in fatal diseases.

• On no account allow any unprotected skin to come into contact with the injector spray as the fuel may enter the blood stream with fatal results.

• Engines may be fitted with seals or O-rings manufactured from "viton" or similar material. When exposed to abnormal high temperatures in excess of 750°F (400°C) an extremely corrosive acid is produced which cannot be removed from

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INFORMATION

the skin. If signs of decomposition are evident, or if in doubt, always wear disposable heavy duty gloves.

2.2 TRANSPORT, LIFTING AND STORAGE

When lifting the generating set avoid any risk of personal injuries, do not stand under the generating set.

• Use soft slings to avoid damage

• On the engine are two hoist eyes which can be

used to take the generator out of the capsule. They can also be used to lift the complete generating set including the capsule.

• After transporting the generating set check for damage before installation.

• Long term storage can have detrimental effects on engine and alternator. The engine should be put through an engine preservation procedure. (Refer to the maintenance chapter)

• The alternator windings tend to condense. To minimise condensation, store the generating set in a dry and warm storage area.

• After removing the generating set from long term storage perform an insulation check. (Refer to the alternator maintenance paragraph for procedures)

• While the battery is stored it should be recharged every 12 weeks.

2.3 THE WHISPER 9.5 / 11 ULTRA

2.3.1 Features

This generating set includes a diesel engine which is connected by close coupling to an alternator in a sound attenuated capsule. The set is mounted on a steel base frame and mounted securely on anti vibration mounting pads to the capsule base. All cables and hoses are guided through the capsule’s sides. The set is not self contained and is only operable after proper installation using additional accessories and installation materials. Installation accessories are listed in the installation manual and are available through the supplier of the generating set. The full automatic Digital Control is based on microprocessor technology. Several automatic start/stop functions can be programmed and monitored (refer to Digital Diesel Control users manual).

2.3.2 Remote control

The full automatic remote control panel including 15 mtr cable comes as standard with the Whisper generating set.

2.3.3 Documentation

Included in the delivery is:

• This users manual (number: 50200227)

• An installation manual (number: 50200237)

• A users manual for DCC (number: 50200261).

• A quick reference guide for DDC (number

50200275)

Not included in the standard delivery but available as options are:

• Parts manual; number: 50200185

• Workshop manual; number: 50200172

However in this manual there is a list of important parts for maintenance and spare parts as well as a chapter on maintenance and problem solving.

2.3.4 Accessories included in the standard delivery

• Expansion tank, hose and fittings

• Special hose connector for measuring exhaust

back pressure (refer to paragraph 5.4.3)

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INFORMATION

2.4 COMPONENTS

2.4.1 Main components to identify

Fig. 3 Front View main components Whisper 9.5 Ultra and 11 Ultra

Fig. 4: Rear view main components Whisper 9.5 Ultra and 11 Ultra.

01 Temperature switch

exhaust

02 Cooling water injection

bend

03 Exhaust manifold (water-

cooled) 04 Starter motor solenoid 05 Heat exchanger 05a Starter motor 06 Alternator (12VDC) 07 Rubber engine mounting

08 Bypass cooling water in 09 Expansion tank 10 Bypass cooling water out 11 Exhaust hose Ø51mm 12 Remote control 13 AC power output 14 Power take off (PTO) 15 Injection pump air

bleeding screw 16 Hoist eye front 17 Fuel injection pump 18 Engine speed adjusting

screw 19 Fuel solenoid (Whisper

9.5 Ultra)

20 Electronic governor

(Whisper 11 Ultra) 21 Fuel filter 22 Engine oil filter 23 Fuel lift pump 24 Oil sump hand pump

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INFORMATION

Fig. 5: Rear view main components Whisper 9.5 Ultra and 11 Ultra

Fig. 6: Top View main components Whisper 9.5 Ultra and 11 Ultra

25 Digital Diesel Control

(DDC) 26 Control panel 26a Identification plate 27 Fuses 27a Air cleaner element 28 Fuel injector (3x) 29 Glow plug (3x) 30 V-belt 31 Engine coolant pump 32 Raw water pump 33 Engine serial number 34 Filler cap engine oil 35 Battery 36 Battery + 37 Raw water inlet 38 Fuel in 39 Fuel out 40 Coolant drain plug 41 Engine oil pressure switch 42 Engine oil dipstick

43 Hoist eye rear 44 Filler cap engine coolant 45 Rocker cover 46 Filler cap engine oil 47 Temperature switch 48 Thermostat housing 49 Failsafe 50 Rubber engine mounting

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INFORMATION

2.4.2 Generator control panel

Start / Stop

Remove fuse

Internal fuel pump Fuse 3A

befo re main tenan c e

Digital Di esel Control Fuse 3A

A ux ilia r y Fuse 10A

Ex tern al Fuel Pump Fuse 3A

O b serve instruc tion s in th e manu al

Rep lac e fuses with sam e type a nd ratin g

Whispe r Digita l Diesel Oper a t ion Unit

Fig: 9 Control panel.

Fig. 10 Digital Diesel Control unit

Fig. 11: Digital Diesel remote control panel

2.4.3 Remote control panel

1 Start button; 2 Stop button; 3 Select button; 4 Set button; 5 Failure lamp; 6 Generator load indicator. 7 Display

2.5 TECHNICAL INFORMATION

2.5.1 AC alternator

The single phase alternator is directly coupled, one bearing, brushless, rotating field design, four poles (1800 RPM) and self regulating. Residual magnetism causes a small voltage over the stator windings and allows a current to flow in the windings, which is magnified because of the feed back effect between rotor and stator. The field windings in the rotor are short-circuited over a diode to rectify the current. A capacitor over an additional winding in the stator which is at an angle with the power-winding keeps the voltage stable within 5 % at the specified rpm and provides voltage fall off with speed, preventing over-excitation at low engine speeds and softening the effect of load switching to relieve the burden on the engine. Further technical data on the design of the alternator can be found in drawings and diagrams in this manual.

2.5.2 Engine

The Whisper 9.5 / 11 ULTRA generating set is based on the Mitsubishi S3L2 3 cylinder diesel engine. The engine is indirectly injected. The engine is water cooled and the cooling liquid is cooled by a heat exchanger and raw water. The heat exchanger and all other parts which are in direct contact with the raw (sea) water are made of seawater resistant material like naval brass and gunmetal. The engine has been specially adapted for the Mastervolt application and is very different from the standard engine supplied for industrial applications! The engine fulfills EPA emission standards and is certified and labelled as such..

2.5.3 Digital Diesel Control system

The standard electrical engine control system is 12 Volt negative earth, non earth return (ungrounded) is available as optional. Check your identification data to determine which system is applied. The system is designed according to the "energise to run" system. The Digital Diesel Control is a very advanced microprocessor based full automatic system. Besides automatic start the system offers many monitoring options. Refer to the separate Digital Diesel Control users manual. The microprocessor unit is located in the black box on top of the alternator

2.5.4 Battery charger

On the engine is an alternator generating 50 Amp 12V. This current is rectified to charge the battery. The voltage is regulated at ±14.4V.

1 2 6 5

3 4 7

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INFORMATION

2.5.5 Alarms and shut down

In the event of malfunctioning this will be indicated by the failure light, details will be shown on the display and the engine will be shut down. There are three functions guarded: oil pressure, oil temperature and exhaust temperature. Exhaust temperature too high indicates the cooling water to be blocked. All alarm switches are closed when no malfunction occur. A contact is cut in the event of an alarm. This means that the generating set will not work when the alarm switches are broken or there is a loose wire. The system therefore is intrinsically safe. The panel will display details about the alarm.

2.5.6 Control

The generating set can be operated by push buttons on the panel on the alternator or by the remote control. By pushing the START button the control system is activated and will start the engine automatically. Pushing the STOP button will stop the engine and the electrical system will be deactivated.

2.5.7 Remote control

All wiring connections from the remote control to the board are made by plug in connectors. An intermediate communication cable is in the standard supply. If necessary an optional longer 8 wire communication cable can be connected if the standard length does not suit the required distance. Numerous remote control units can be put in parallel by using the connectors on the back of the units. (Refer to installation instructions)

2.5.8 Hour counter

The remote control offers several timer functions that helps to schedule maintenance.

2.5.9 Load indicator

On the remote control the load will be indicated on the display and by the LED-bar. The load is measured by a current transformer on the alternator.

2.5.10 Fuel specification

The engine must only be used with diesel fuel oil which conforms to the standards for use in modern diesel engines. Fuel free from water and contaminants is of the utmost importance.

2.5.11 Oil information

1 Specification:

The oil must be suitable for oil changes as specified in the maintenance chapter. The Mitsubishi engine must be run on heavy duty lubricating oil meeting the requirements of API class CC, CD, CF or CF_4.

It is very important to use the correct oil specification. Very often local oil suppliers recommend a higher class, because they assume that a higher class is allowed. This is not the case. One should not follow these recommendations. Using the wrong specification will cause high oil consumption.

2 Oil viscosity:

We recommend a multigrade oil 15W40.

3 Oil capacity:

Excluding the oil filter the content of the crankcase is

3.9 U.S.qts (3.7 l). Including the oil filter it is 4.4 U.S.qts (4.2 l). Note that the engine may contain some residual oil due to testing at the factory.

While filling, check the lubricating oil level by means of the engine oil dipstick. Do not overfill with lubricating oil as this may have a detrimental effect on engine performance

4 Oil pressure

• Minimum at idle 98kPa (1 kgf/cm² - 14psi) (1 bar).

• Normal at 1800 RPM ±350kPa (3.5 kgf/cm² - 50

psi) (3.5 bar).

2.5.12 Cooling liquid

The engine is cooled by cooling liquid. The capacity of this system of the Whisper 9.5 / 11 ULTRA is 3,7 US qts. (3.5 litres).

Always use coolant which is compatible with aluminum components of the cooling system. Do not mix coolants with different kinds of chemical compound, as this may cause congelation of the coolant. In case of doubt refresh the content of the entire cooling system.

We recommend not using water but cooling liquid that is marketed for the use in combustion engines. Cooling liquid protects the engine against frost to minus 13 °F (minus 25°C). Also it protects the engine block against corrosion. One can fill the engine via the filling cap on the exhaust manifold. Fill up till the level is just below the filling cap.

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INFORMATION

When the engine is on temperature the liquid will expand and the redundant liquid will be pressed into the expansion tank. This tank has to be filled up till the mark. When cooling liquid is not available clean fresh water could be used with an additive of anti freeze. When using water with anti freeze the right mixture has to be calculated according to the information of the supplier of the anti freeze. When the cooling is based on keel cooling or radiator cooling the capacity of these coolers and piping has to be taken into account calculating the right mixture.

The cooling liquid in the engine is pressurised and has a boiling point above 212°F (100°C). The temperature switch in the thermostat housing switches at 230°F (110°C). When keel cooling or radiator cooling is applied the cooling system is not pressurised. There should be a special cap on the manifold without valves leaving the connection to the expansion tank open. Refer to the manual on keel cooling and radiator cooling.

2.5.13 Technical data

GENERAL

Model WHISPER 9.5ULTRA WHISPER 11 ULTRA

RPM 1800 1800

Alternator water cooled, synchronous water cooled, synchronous

Engine Mitsubishi diesel, model S3L2 (Japan) Mitsubishi diesel, model S3L2 (Japan)

Number of cylinders 3 3

Displacement 80.4 cubic inches (1318 cm3) 80.4 cubic inches (1318 cm3)

Bore X stroke 3.07 x 3.62 inches (78x92 mm) 3.07 x 3.62 inches (78x92 mm)

Combustion air consumption 46 cf/m (1.3 m³/min.) 46 cf/m (1.3 m³/min.)

Continuous power engine 9.5 kW 11 kW

Cooling system indirect cooling by raw water, 4.8 – 6 US gpmin (18-22 l/min.)

Cooling water pump PTO driven Mastervolt self priming impeller pump, type M12

Fuel lift pump engine electric pump (12 V DC), additional pump available upon request

Starting battery (optional) 70 Ah 12V 70 Ah 12V

Fuel consumption 0.53 – 1.2 US gph 2-4.5 litre/hour, load dependent

Control Digital Diesel Control including automatic start/stop

ELECTRICAL SPECIFICATIONS

Model WHISPER 9.5ULTRA WHISPER 11 ULTRA

Output voltage 120V/240V 60 Hz alternating current (AC) single phase – dual voltage

Output rating at power factor cos phi = 1 9.5 kVA = 9.5kW 11 kVA = 11kW

Voltage tolerance ± 5% ± 5%

Frequency tolerance ± 5% ± 1%

Alternator Brushless, four pole, synchronous Brushless, four pole, synchronous

Voltage regulation: Capacitor Capacitor

MECHANICAL SPECIFICATIONS

Supply includes Sound shield with steel base, mounted on rubber anti vibration mounts. (Generator

set without sound shield is optional)

Dimensions hxwxd 25.0 x 35.4 x 22.6 inch (640 x 900 x 575 mm)

Colour Metallic silver / grey

Weight 340 kg including sound shield

Max. installation angle 25 degrees

Standard supplies Digital remote panel (approx.45 feet / 15m cable), fuel filter, fuel lift pump, user and

installation manuals

Optional: Installation kits, mobile (vehicle) version, non earth return (ungrounded), spare part

kits, PTO to drive a hydraulic pump

Page 15

INFORMATION

2.5.14 Wiring codes and colours

number colour AWG cross section

battery > starter motor red 2 25 mm2

starter motor > DDC 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 plug 3 brown 12 4 mm2

DDC > starter solenoid 4 yellow 14 2,5 mm2

LCP > fuel lift pump + 5 grey 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

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

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

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

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

DDC >R terminal alternator 18 white 16 1,5 mm2

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

DDC > current measuring transformer 11 black 17 1 mm2

DDC > current measuring transformer 11 red 17 1 mm2

DDC > current measuring transformer 22 black 17 1 mm2

DDC > current measuring transformer 22 red 17 1 mm2

DDC > LCP 12 black 16 1,5 mm2

DDC > LCP 14 red 16 1,5 mm2

DDC > LCP 16 red/green 16 1,5 mm2

DDC > generator AC output 33 brown 17 1 mm2

DDC > generator AC output 33 blue 17 1 mm2

DDC > generator AC output 44 brown 17 1 mm2

DDC > generator AC output 44 blue 17 1 mm2

DDC=Digital Diesel Control Unit LCP=Local Control Panel

Page 16

INFORMATION

2.5.15 Lay out control wiring

Fig 12a: Electrical Diagram control wiring Whisper 9.5 Ultra

Page 17

INFORMATION

Fig 12b: Electrical Diagram control wiring Whisper 11 Ultra

See also chapter 2.5.17

Page 18

INFORMATION

2.5.16 Electrical diagram 120V – 240 V AC / 60 Hz

Fig. 13: Electrical diagrams AC

Page 19

INFORMATION

2.5.17 Diagram electronic governor Whisper 11 ULTRA

The Whisper 11 Ultra is equipped with an electronic governor in addition to the mechanical governor that is on other 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 =60 Hz) of the alternator. Under full load the RPM of the Whisper models that has only a mechanical governor can drop 75 RPM (=2.5 Hz) at full load and will go further down or collapse when further loaded. However the engines with the electronic governor will keep the RPM and frequency at the set value. As the voltage is related to the frequency, the voltage will be more stable as well. The RPM represents power and the alternator performs better as well on a higher speed. Whisper models with an electronic governor will bring more power. So the electronic governor offers three advantages: a more stable frequency and voltage and more power.

The electronic governor system contains two parts: 1 The actuator controls the engine speed. This actuator

replaces the standard hold solenoid that is on all other mechanical controlled Whisper engines. The actuator controls the RPM directly on the fuel rack inside the fuel pump without levers and other mechanical transmissions.

2 A microprocessor keeps the speed at the set value by

controlling the actuator. The microprocessor is programmed at the Mastervolt factory and many parameters are set to perform well. It should not be necessary to make adjustments. When adjustments are necessary this can only be done with the help of an interface to a computer and special software to get access to the microprocessor.

The Mastervolt electronic governor does not need a pickup device in the flywheel housing that counts the passing tooth of the flywheel and determines the exact RPM of the engine, because the processor uses the 60 Hz of the AC output voltage as a reference. Note: If you there is a pick up on your generator than you have another model than referred to in this chapter; see figure 12b

Fig 14: Diagram electronic governer

Page 20

OPERATION

3 OPERATION

3.1 GENERAL

The generating set is operational after full installation and filling up with: fuel, engine lubricating oil and cooling liquid, connecting the battery to earth and connecting the digital remote control panel.

Fig. 15:

3.2 OPERATING INSTRUCTIONS

3.2.1 Summarised operating instructions (daily use)

Routine "pre-start" checks:

1 Check oil level (refer to fig. 15). 2 Water inlet (all valves open). 3 Power source selector switch (off/shore

power/generator power). Switch to power source switch "OFF", or switch off all consumers in the usual way. If a Mass Systemswitch is installed, this operates

automatically. 4 Switch on battery switch (when installed). 5 Fuel valve: open.

Starting:

Push the start button to initiate the full automatic

starting procedure. You can monitor the procedure on

the display.

In operation checks:

1 Check for abnormal noise or vibration 2 Check the voltage 3 Check sea water flow at exhaust outlet 4 Power source selector switch (off/shore

power/generator power). Switch to power source generator. If a Mass Systemswitch is installed, this operates automatically.

5 Before loading the generating set up to maximum,

have it run warm. Continuous load should be restricted to 70 % of maximum load.

Stopping generator:

1 Switch off all electrical devices (consumers). If the

generating set has been running under full load for a longer period, do not shut it down abruptly. Reduce the electrical load to about 30% of the rated load and

let it run for approx. 5 minutes. 2 Press the STOP button. 3 Close the inlet sea water cock. 4 Switch to an other AC power source, if available. If a

Mass Systemswitch is installed, this is done

automatically.

3.2.2 Extended operating instructions

Check when starting the first time or after a longer period of rest:

1 If there is any damage caused by transport or

installation. 2 Check if the installation conforms to the installation

instructions. 3 Ensure the generating set is free to turn without

obstruction. 4 Check all hoses and hose connections for leaks. 5 Check all cables and cable end terminal connections. 6 Check the engine and generator mounting bolts.

Routine "pre-start" checks:

1 Check engine oil level.

The generator switches off in the event of insufficient

oil-pressure. Even when the oil level is too low the oil

pressure can be high enough. Do not run the

generator with the oil below the lowest mark in the,

because a smaller volume of oil will become

contaminated considerably quicker than a larger

volume. Therefore we recommend daily oil-checks.

Check oil level prior to starting the engine or at least 5

minutes after the engine has stopped.

1 2

1 Maximum oil level 2 Minimum oil level

Page 21

OPERATION

2 Check sea water cocks. Do not forget the valve of the

water outlet in case of a water/exhaust gas separator. 3 Check the water strainer. 4 Check for leaks. 5 Regularly check the siphon vent in the cooling water

supply. 6 If no Mass Systemswitch is used: Switch main Power

Source Selector switch to "OFF" or switch off all

devices. 7 Switch on the battery switch.

Starting the generator:

By pushing the start button briefly the electric system

is activated, the fuel lift pump starts pumping and the

starting procedure will begin (by pushing the Stop

button the system is deactivated).

The first time starting up or after running out of fuel it

could be necessary to prime the fuel system. (Refer to

bleeding fuel system instructions in the maintenance

chapter).

A restart protection prevents starting the engine when it is already running, which could cause damage.

In the event of starting problems (numerous attempts are made), close the sea-water inlet cock while cranking to prevent the outlet system and engine to fill up with water.

During the starting process, the cooling water pump is driven with the engine. The cooling water is discharged to the exhaust outlet, because the engine does not run, the exhaust pressure is not high enough to expel this water. Open the valve directly when the engine starts to prevent damaging the impeller. Water in the cylinder will cause serious damage to the engine. For instance; a bent piston rod or a cracked cylinder head. In fact water in the cylinder is the main cause for engine damage in pleasure craft.

Checks once the generator is in operation:

1 Check for abnormal noise or vibration. 2 Check the voltage. 3 Check coolant flow.

Always check immediately after starting the generator

if cooling water flows at the exhaust outlet. If this is

not the case, check the cooling water pump. After

having become acquainted with the generator you will

be able to recognise the coolant flowing through the

system by listening for the noise of the water which is

expelled.

Be aware that especially in harbours the coolant water inlet can easily be blocked by floating objects.

4 Power source selector switch (off/shore

power/generator power). Switch to power source generator. If a Mass Systemswitch is installed, this operates automatically. Before loading the generating set up to maximum, have it run warm. The first 50 hours of running the continuous load should be restricted to 70 % of maximum load. Running for long periods at no load or light load in the first 50 hours can cause cylinder glazing and high oil consumption.

Engine load during longer operation:

Please ensure that the generating set is not overloaded. Overloading occurs when the electrical load (demand) is so high that the generator cannot be turned around properly by the diesel engine. Overloading causes the engine to run rough, while using oil and excessive fuel and producing soot by the exhaust. The engine can even stop.

The generator should therefore only be loaded at the maximum rated power for short periods (2-3 hours) only! The high peak current is meant for the ability to start electrical devices that need a high current for starting especially electric motors and compressors (from a still stand state).

In order to prolong the generating set’s life expectancy, the nominal electrical demand on the system should be about 70% or the rated generating set’s maximum load. Please note this when switching on your electrical devices! Nevertheless, the Whisper 9.5 / 11 ULTRA is designed so as not to overheat, even under extreme conditions.

Do not run the generator for very long periods at no load or at very low load. When this is necessary do load the generator at least one hour in 10 hours for minimum 70%. Long term running at too low load will cause the exhaust to be choked by carbon.

Never remove the battery while the engine is running or any electrical cable while the battery is connected in the circuit. Only disconnect the battery with the engine stopped and all switches in "OFF" position

Page 22

OPERATION

Stopping the generating set:

1 Avoid stopping of the generator abruptly after a long

period of operation at high load! Doing so, you avoid

unnecessary thermal load to your generating set!

Act as follows:

Prior to switching off the generating set, decrease the

generator load (i.e. turn off most electrical users) and

let the generator run at low load for approx. 5 minutes

to allow the engine to get properly cool (the influent

sea water must flow through the system in order to

cool the engine).

If the generator is operating in a hot environment and

you do not act as given above, the excessive heat in

the engine can trip the "high temp" alarms. In that

case, a restart of the engine is not possible for some

time. It is also recommended to switch off electrical

users prior to stopping the generator because of the

voltage drop that occurs as the engine comes to a

halt. Such voltage drops may cause damage to

electric motors, compressors (in refrigerators or air

conditioners etc.).

2 Press the STOP button.

3 Close the inlet sea water cock.

4 Switch to an other AC power source, if available. If a

Mass Systemswitch is installed, this is done

automatically.

Page 23

MAINTENANCE

4 MAINTENANCE

4.1 ALTERNATOR

The alternator does not require any maintenance. Periodic inspection and cleaning is recommended, depending on environmental conditions. However when the alternator has been idle for a long period attention to winding condition is recommended. The condition of windings can be assessed by measurement of insulation resistance to earth. The CAPACITOR should be disconnected during this test. A 500V ‘megger’ or similar instrument should be used. The insulation resistance to earth of all windings should be in excess of 1.0 MOhm. Should the insulation resistance be less than this value, drying out the generator windings is essential. Drying out can be carried out by direct warm air from a fan heater or similar apparatus into the generator air inlets or outlets. All bearings are greased for life and not regreasable.

4.2 ENGINE

4.2.1 Preliminary instructions

All regular maintenance can be carried out when the enclosure is open. When oil and dirt has gathered in the enclosure measures have to be taken to avoid spilling oil and polluting the environment. The first service on the engine should be carried out after 50 hours of its life and after a major overhaul. In the first 50 hours the engine should receive special attention:

Long periods of light or no load running in the first 50 hours may lead to cylinder glazing and high oil consumption.

For the same reason it is of the greatest importance to use the right oil specification

The first time starting up or after running out of fuel it could be necessary to prime the fuel system.

4.2.2 Bleeding fuel lines

Ensure there is sufficient fuel. The system is self bleeding. The first time starting up or after running out of fuel it could be necessary to prime the fuel system. 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 remote panel) Hold as long as necessary to bleed the system. Retighten the bleed screw when no further air bubbles are expelled.

Fig. 16: Bleeding fuel lines 1 = Fuel bleeding screw

4.2.3 Valve clearance

When the engine is in cold condition both valves (inlet and outlet) should have a clearance between 0.25 mm. The adjustment has to be done at TDC (refer to § 5.4.2).

4.2.4 Replacing fuel filter

Filter change depends on contamination of the fuel, but should be done however, at least every 300 running hours. Before changing the filter, clamp off the supply line. Remove the hoses from filter and attach them on the new filter again. The arrow on the filter housing indicates the direction of the flow. A clogged filter results in a lack of output of the generating set.

4.2.5 Replacing oil filter

The oil filter is in front of the service side. Replacement has to be executed according to the schedule in this manual. Drain the oil using the sump pump and put some tissues under the filter.

Fig. 17

Page 24

MAINTENANCE

A smeer of oil has to be put on the seal of the filter before fitting the filter. The filter should be fastened manually: when the rubber touches the metal turn 3/4 further.

4.2.6 Readjustment V-beltplacing oil filter

The alternator bracket allows for readjust of the V-belt. Deflections should be 10 mm (refer to fig. 19)

4.3 REGULAR MAINTENANCE

CHECK DAILY:

• Oil level (see fig. 20)

Take care the oil level is never

below the mark. Do not add oil

when the level is still above

the mark

1 Minimum oil level 2 Maximum oil level

Fig. 20:

CHECK DAILY:

• Level cooling liquid

• Hoses for loose connections or deterioration.

• Water inlet filter.

AFTER FIRST 50 HOURS:

• Change oil and replace the oil filter. Have the engine run until it is on temperature and stop it. Replace the oil filter. Drain oil by the sump pump into a suitable retainer and fill up with fresh oil. Start the engine again and have it run for 5 minutes. Stop the engine again and pause for a few minutes to let the oil gather in the crankcase. Check the level again and add oil when necessary.

• Check and tighten nuts, bolts, and unions, paying particular attention to the fuel system.

• Observe the exhaust at the normal full load. The exhaust must be free from soot. Do not allow the engine to run with a dirty exhaust without investigating the cause as this may result in an expensive breakdown.

• Check air vent on a regular basis. When the air vent it not working properly the engine can fill up with water by siphoning. Water in the combustion chamber causes serious damage to the engine.

• Check and readjust V-belt.

• Check the electrical connections.

EVERY 150 HOURS:

• Change oil.

• Check the battery acid level (not applicable when

Mastervolt batteries are used).

• Check battery terminals for corrosion

• Check and readjust V-belt

• Check impeller raw water pump (durability

depends on the purity of the sea water. In sandy water and warm water wear will increase).

When replacing the impeller the gasket between the pump case and the cover should be replaced as well. So when ordering a spare impeller order a gasket as well. Remove the cover to get access to the impeller. Remove the old impeller with the help of two screwdrivers. Install the new impeller and add some grease. Turn the blades in the direction of rotation of the pump i.e. anti clockwise looking at the impeller.

Fig. 18

10 mm

Fig. 19

1 2

Page 25

MAINTENANCE

EVERY 300 HOURS:

• Replace the impeller of the raw water pump.

• Retighten the cylinder head bolts and adjust the

valve clearance. (Refer to § 5.4.2).

• Replace the oil filter.

• Replace the fuel filter

Replacement depends or the condition of the fuel. We recommend replacement every 300 hours. Isolate the fuel supply and change the element.

EVERY 1000 HOURS:

• Replace the V-belt.

• Retighten cylinder head bolts/adjust + valve

clearance.

EVERY 2000 HOURS:

• Check lubricating oil pressure

• Clean and check or replace fuel injector nozzles

and check injection pressure.

• Check the air filter element: The air is taken in via the cover on the alternator. Below this cover is a spongy material which filters the air and holds some electrical components which are cooled by the inlet air. This filter does not require regular maintenance. Only in very dusty circumstances this filter should be cleaned. The spongy material can be washed in solvent or replaced.

• Check the cooling system: The engine cooling liquid is indirectly cooled by raw water via a heat exchanger. The alternator is cooled by seawater which is pumped by the PTO driven impeller pump through the cooler elements in the generator housing. All parts of the cooling system are of corrosion free and seawater resistant materials such as brass and gunmetal. In case of gathering of dirt in the system it could be cleaned by compressed air. When overhauling the engine one could clean the parts thoroughly or replace.

When the generator set runs less than 100 hours a year the oil should be changed yearly

4.3.1 Maintenance schedule

Check oil level daily

Check water inlet filter daily

Check the level of the cooling liquid daily

Change oil and oil filter after first 50 hours

Check and tighten nuts, bolts, etc. after first 50 hours

Check exhaust after first 50 hours

Check air vent after first 50 hours

Check and readjust V-belt after first 50 hours

Check electrical connections after first 50 hours

Change oil 150 hours

Check battery 150 hours

Check air vent 150 hours

Check and readjust V-belt

150 hours

Check impeller water pump 150 hours

Replace impeller water pump 300 hours

Retighten cylinderhead bolts and readjust valve clearance

300 hours

Replace oil filter 300 hours

Replace fuel filter 300 hours

Retighten cylinderhead bolts , adjust valve clearance 1000 hours Replace the V-belt 1000 hours

Check lubricating oil pressure 2000 hours

Check injector and injection pressure 2000 hours

Check inlet air filter 2000 hours

Check cooling system 2000 hours

Page 26

MAINTENANCE

4.3.2 Putting out of service

When not using the generating set for a longer period it is recommended to execute an engine preservation procedure.

1 Clean the engine.

2 Loosen the fuel suction pipe and fuel return and put

them in a can with preservation diesel fuel. Start the engine and run the engine warm.

3 Drain the hot engine oil and refill with preservation oil.

4 Stop the engine and take loose the inlet of the raw

water pump. Drain the water from the water lock. Crank the engine having the raw water inlet sucking anti freeze from a can until the pump, heat exchanger and manifold are filled.

5 The coolant can stay in the engine

6 Disconnect the battery and store it in a place free of

frost and dry and charge it regularly.

7 Close inlet- and outlet openings with tape.

8 Protect the generating set against the influences of

bad weather conditions.

This method of preservation will be sufficient for 6 months. Repeat steps 2, 3, and 4, every 6 months. Change oil before using the engine again.

Page 27

TROUBLE SHOOTING

5 TROUBLE SHOOTING

5.1 ALTERNATOR/ ELECTRICAL FAULTS

Beware of parts which are live!

Remove 3 Amp. Fuse in the control panel while working on the generator to prevent the engine from starting

A failure code is displayed when a hardware failure at the generator is detected

5.1.1 General

If any problem should occur, check basic conditions and examine all external wiring, switch gear and circuit breakers. Also check if measuring instruments give the correct value. If in doubt, measure directly on the alternator terminals with an independent instrument. This should only be carried out by an experienced electrician. If during these measurements the engine immediately stops after starting and an error code is displayed at the remote control panel ( “AC VOLTAGE”), one can start the generator by means of a “service start” at the service

menu (see paragraph “service start” of the user’s manual of the Digital Diesel Control). By doing this, the generator will keep running for 2 minutes before it stops. This offers you the possibility to carry out measurements to investigate the cause of the failure. Check if the engine is running correctly at 1800 RPM (60 Hz) according to its settings and does as well under load.

• Whisper 9.5 Ultra: A RPM drop of 5% at full load is

acceptable. Therefore a no load setting should be at 1875 RPM = 62.5 Hz. Under no circumstances should the RPM under full load drop below 1770 RPM = 59 Hz.

• Whisper 11 Ultra: A RPM drop of 1% at full load is

acceptable. Therefore a no load setting should be at 1818 RPM = 60.6 Hz. Under no circumstances should the RPM under full load drop below 1782 RPM = 59.4 Hz.

When the problem is in the RPM refer to the engine fault finding paragraph. Digital Diesel Control system will help to indicate failures and display causes.

Failure code Problem

COMMUNICATION Communication error between the panel end the generator LOW START BAT Starter battery voltage too low ALTERNATOR No output battery charging voltage EXHAUST TEMP Exhaust temperature is too high WATER TEMP Coolant temperature is too high OIL PRESSURE Oil pressure failure AC VOLTAGE Generator AC output voltage is either too high or too low HIGH CURRENT Generator is in overload FREQUENCY Output frequency of the generator is too low

5.1.2 Trouble shooting table

Problem Possible cause What to do?

• Circuit breaker "off" or faulty fuse

Check switches and fuses and measure directly on the alternator to exclude external causes.

• Low engine RPM.

Check the engine RPM and adjust (refer to special procedures).

• Loss of residual magnetism.

Check the residual magnetism and flash the alternator (refer to special procedures).

• Capacitor loose or broken.

Check by independent excitation if the problem is in the capacitor or in the windings.

No output (Voltage) at all

• Rotor diodes broken.

Check the diode in the rotor (refer to special procedures). The Whisper 9.5/11 ULTRA has one diode in the rotor.

• No load at all or very low load.

Switch on a load and check voltage. Generator output voltage too

low when no load is on it (less

• Engine is not reaching the rated RPM.

Refer to special procedures to readjust RPM.

Page 28

TROUBLE SHOOTING

Problem Possible cause What to do?

• Defective capacitor.

Check capacitor and replace if necessary (refer to special procedures).

than 105V/210V).

• Defective diode

Check the diode in the rotor and replace (refer to special procedures).

• Generator is overloaded.

Switch off a load; (part off) consumers.

• Engine is not reaching the rated RPM.

Refer to engine RPM problems

• Defective capacitor

Check capacitor and replace if necessary (refer to special procedures).

Generator output voltage too low under load (less than 105V/210V). In no load condition it is ok

• Only Whisper 11 Ultra: Defective electronic governor, actuator controlbox or pickup.

RPM will be too low as well Replace faulty part

• Engine is running too fast (RPM too high).

Check engine speed and adjust (refer to special procedures).

• Over-energising due to defective capacitors

Check capacitor specification and replace capacitors if necessary.

Generator voltage too high, (more than 130V/260V)

• Presence of a strong capacitive load (leading power factor)

Compensate for this capacity and seek for experts advice (MASTERVOLT customers service)

• Disturbances on the electrical system/ user side.

Check if electrical load is fluctuating Generator voltage fluctuates.

• Engine runs irregularly.

When engine runs irregularly refer to section: "Engine runs irregularly".

Generator is not able to start an electric motor

If the generator is unable to supply enough power to start an AC electric motor, this is usually because this motor draws too much current during starting

Check the electric motor’s current draw required for starting. This should not exceed the rated generator peak output current. This could be remedied by providing stronger capacitors to the motor or using a "soft-start". Inquire at your nearest Mastervolt dealer or directly at the manufacturer, Mastervolt in the Netherlands.

5.2 ENGINE FAULTS

Remove 3 Amp. fuse in the control panel while working on the generator to prevent the engine from starting.

5.2.1 General

Most electrical problems relating to Voltage or Frequency are due to wrong engine speed. Note that RPM and Hz are basically the same. Use the problem solving table to find the cause of a wrong engine speed. When there is no obvious cause one can adjust the RPM (refer to special procedures). The engine speed of the Whisper 11 is controlled by an electronic governor should be within a tight tolerance of 1%. When not, this indicates the electronic governor to be faulty or need adjustment (refer to 2.5.17). When the engine is not cranking well, starting problems almost always originate from battery problems or poor battery cable connections.

When the engine is cranking, well starting problems almost always originate from lack of fuel or air bubbles in the fuel pipes.

When the engine does not start instantly, prolonged cranking can fill up the exhaust system with cooling water because of the water injected exhaust. When the water enters the cylinder through the valves this will bring severe damage to the engine. When the engine does not start and repeated cranking is necessary shut off the seawater inlet. Open the valve immediately after the engine has started.

A failure code is displayed when a hardware failure at the generator is detected.

Page 29

TROUBLE SHOOTING

Failure code Problem

5.2.2 Trouble shooting table

Problem Possible cause What to do?

• Almost certainly this is an electrical problem. Display will indicate “LOW START BAT”

• One other possibility is that the engine is locked by water in the cylinder or there is other severe damage..

Check on water in the cylinder and further damage by cranking. When there is water in the cylinder, then deactivate the control system, disconnect the battery, remove the glow plugs. Crank the engine to remove the water through the opening of the glow plugs. Check oil on the presence of water and change oil. Find out how the water did enter the cylinder (check the air vent). Take precautions to prevent it from happening again. When there is no mechanical malfunction the problem must be an electric malfunction.

• Starter battery switched "OFF".

Check position of the battery switch and switch "ON".

• Starter battery voltage insufficient (battery too weak).

Check battery voltage. Recharge the battery. Inspect battery terminals and cables for a good electrical connection (inspect against corrosion, tattered wires, etc.)

• Faulty fuse on the control panel

Replace fuse

• Wiring control system faulty

During the normal starting process, the battery voltage drops to 11V (with a fully charged battery). If the voltage does not drop during starting, the electrical connection is faulty. If the battery voltage drops lower than 11V, then the battery has been discharged too deep.

• Starter broken

Repair the starter motor

Diesel engine fails to crank, the starter makes clicking noises, or the engine cranks very slowly

• To thick engine lubricating oil.

Change oil for a lower viscosity.

• Out of fuel or faulty fuel, water in the fuel.

Fill up with fuel or replace with better quality.

• Fuel solenoid is not opening (no “click” can be heard).

Check wire connections and circuitry to solenoid. (Refer to DC wiring diagram)

• Fuel lift pump is not working.

• Fuel filter is blocked.

• Air in fuel lines.

Check fuel filter and fuel lift pump: clean or replace if necessary. Bleed air from fuel system (refer to maintenance section).

• Wrong valve clearance.

Adjust valve clearance,

• Low compression because of dirty valves.

Clean valves. Take off the injection bent and inspect the outlet port. When little rust in the port clean the valve by taking off the valve spring and rotate until rust is removed. When the outlet port is strongly affected by rust, the exhaust system is not properly installed (refer to paragraph 5.4.3). Contact Mastervolt service department for advice.

• Blocked injector.

Have the injector tested and cleaned if necessary.

Starter is turning engine smoothly, but engine fails to start

• Loss of compression by wear out or damage

Repair by Mastervolt service

Page 30

TROUBLE SHOOTING

Problem Possible cause What to do?

• Unsuitable contaminated fuel

• Lack of fuel.

Fill up with fuel or replace by better quality.

• Choked fuel filter.

Check fuel filter and fuel lift pump: clean or replace if necessary.

• Disturbances on the electrical system/ user side.

Check if electrical load is fluctuating

• Faulty fuel lift pump.

Check and repair

• Choked air filter.

• Lack of air.

Check the air intake

• Choked exhaust system, exhaust blocked, rubber exhaust hose kinked.

Check the exhaust hose

• Air in the fuel pipes

Bleed air from fuel system (refer to maintenance section).

• Faulty electronic governor (Whisper 11 only)

Replace faulty parts.

• Blocked injector.

Have the injector tested and cleaned if necessary.

• Wrong valve clearance.

Adjust valve clearance.

• Temporarily hunting (this will disappear when engine has run in).

Engine runs irregularly.

• Ongoing hunting caused by faulty electronic governor (Whisper 11 only)

Replace faulty parts.

• Faulty electronic governor (Whisper 11 only)

Replace faulty parts.

• Too much oil.

Drain oil to proper level

• Lack of fuel.

Check fuel supply system: fuel pump and filter.

• Lack of intake air.

Check air intake.

• Choked exhaust system, exhaust blocked, rubber exhaust hose kinked.

Check the exhaust system.

• Generator overloaded

Reduce the electrical load (switch off some consumers).

• Generator over energised.

Check that the proper capacitor type is installed and that it is connected correctly.

• Defective generator (windings, bearings or other)

Generator must be sent to manufacturer for repair of damaged bearing or winding.

Engine speed drops

• Damaged engine

Repair by Mastervolt service

Engine does not stop on command

• Fuel solenoid is not switching off •

• Loss of control

Faulty Digital Diesel Control unit. Stop the engine manually by the stop handle. Check wire connections to stop solenoid. Check solenoid valve function. Replace if necessary

Engine exhaust smokes

• Faint blue smoke - generally the result of light load

Increase load.

• Heavy blue smoke - caused by lubricating oil: Overfull oil sump or worn cylinder bore, stuck broken or worn rings.

Check the oil level. Check the compression.

• Black smoke –incomplete combustion caused by: Overload, choked air filter, inlet temperature too high, unsuitable fuel or water in fuel.

Check the fuel . Check for overload.

Engine starts, but stops after 10 up to 30 seconds

• Protection system stops the engine; this can be caused by oil pressure failure, lack of cooling water (exhaust temperature alarm). Overload, loose wire or faulty alarm switch. Digital Diesel Control will help to indicate failure.

Refer to paragraph 2.5.5. and 3.2.2 for information on the alarm system. Bypassing the switches can help to confirm the failure.

• Overload or short circuit.

Switch off the consumers and test for short circuit. Engine stops by itself

• Lack of fuel.

Check fuel supply system: fuel lines, pump, filter, valves, tank level, etc.

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Problem Possible cause What to do?

• Oil pressure low. (oil pressure switch tripped).

Check oil level. Check engine’s oil pressure and have it repaired by Mastervolt.

• Excessive heat in cooling system (thermo-switch tripped).

• Lack of cooling water (exhaust switch tripped).

• Impeller broken.

• Cooling water blocked.

• Water strainer blocked.

• Air or water in the fuel.

• Blocked air or fuel filter.

Check cooling water system flow: water pump, inlet water filter, coolant flow.

• Loss of compression by wear out or damage.

Repair by Mastervolt service.

• V-belt broken or loose.

Readjust or replace V-belt

• Thermostat faulty

Check thermostat and replace

• Generator is being overloaded. Digital Diesel Control will indicate “

HIGH

CURRENT

”.

Check electrical load and switch off some consumers

• Insufficient intake air.

• Choked air filter.

Check intake air paths and filter, clean and replace if necessary.

• Fuel injector faulty.

Replace injector.

• Valve clearance incorrect.

Readjust valve clearance

• Poor fuel quality.

Use better quality diesel.

• Poor quality lubricating oil.

Use better quality oil.

Sooty, black exhaust.

• Continuous running with very low load.

Increase load and have the engine run for a few hours

● Wrong measurement. Check if the load is measured correctly. Does the Amp meter show the correct value? When calculating the load by multiplying voltage and amps this should be done by using the exact values, taking into account the power factor of the consumers. When any doubt, measure the power directly with an appropriate instrument.

• Overfull oil sump.

Bring the oil to the correct level

• Choked fuel filter.

Replace the fuel filter.

• Choked air filter.

Check air inlet openings; clean air filter.

• Exhaust blocked.

Check the exhaust system.

• Injector blocked.

Have the injector checked.

• Loss of compression, sticking or damaged piston ring.

Have the compression measured. Clean or replace the rings.

Loss of power

• Wear out of cylinder.

Have the compression measured and have the engine overhauled.

• Overload.

Take away the overload.

• Low level of cooling oil or air in the cooling system

Fill up with liquid and release air bubbles. Check if there are air blocks in the system; refer to the installation manual

• Water inlet system blocked.

• Broken impeller.

• Water strainer choked

• Heat exchanger choked.

Check the cooling system thoroughly.

• Broken or slipping V-belt.

Replace and adjust the V-belt tension.

Over-temperature

• Faulty thermostat

Check the thermostat or replace.

5.2.3 Warnings

Generator must be shut off immediately if:

● Motor RPM suddenly rises or drops.

● Unusual noise comes from generating set.

● Exhaust gases suddenly colour dark.

● Engine failure warning light is on

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5.2.4 Service address

If you cannot correct a problem with the aid of the malfunction table, contact your Mastervolt Service Centre or Mastervolt Amsterdam for an extended service list, tel: INT +31-20-3422100.

5.3 SPECIAL PROCEDURES ALTERNATOR

5.3.1 Residual voltage check / excitation procedure (Whisper 9.5 Ultra only)

When residual magnetism disappears there is no residual voltage. Residual magnetism can disappear after the generating set being out of service for a long period or a short circuit. This can be solved by charging the capacitor ("flashing") independently with a small 9 Volt battery. This can be done while the engine is stationary and the wiring is connected.

If the generating set battery is used for flashing one must take care. A short circuit can cause heavy sparking, fire and injuries

When flashing does not bring back voltage, the capacitor(s) should be renewed. When this does not help, the rotating rectifier diodes should be tested and a winding resistant test should be executed.

5.3.2 Testing rotary rectifier diodes

The diodes in the rotor can be checked with a multimeter. When the diode is faulty the alternator will not generate any voltage.

The flexible lead connected to the diode should be disconnected at the terminal end, and the forward and reverse resistance checked. A healthy diode will indicate a very high resistance (infinity) in the reverse direction, and a low resistance in the forward direction. A faulty diode will give a full deflection reading in both directions with the test meter on the 10,000 ohms scale, or an infinity reading in both directions. Replace the diode.

5.3.3 Winding resistant values

If after establishing and correcting any fault on the capacitor and diode output is still low when separately excited, then the main rotor, stator and exciter stator winding resistance should be checked as the fault must be in one of these windings. The respective leads must be disconnected before taking the readings. Resistance values should be within 10% of the values given in the table below:

Whisper 9.5/11 ULTRA

Resistance 60Hz

• Resistance both main stator windings in series

0.29 Ohm

• Resistance both rotor windings

2.6 Ohm

• Resistance exciter stator winding

0.75 Ohm

5.3.4 Meggering

One can try to measure resistance between the housing and the windings with a multimeter which should read infinity. When readings are infinity but a fault is suspected one can do a high voltage resistance test (MEGGERING) This procedure should be carried out by an expert

DIODE

Fig. 22

Fig. 21.

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5.4 SPECIAL PROCEDURES ENGINE

5.4.1 Setting the RPM

RPM is set by the manufacturer and should not need readjustment! However with the Whisper 9.5 Ultra a very slight offset after running in could occur. RPM can be measured by a frequency meter.

Whisper 11 Ultra: When adjustments are necessary this can only be done with the help of an interface to a computer and special software to get access to the microprocessor. If readjustment of the RPM is necessary, please contact your Mastervolt Service Centre for advice

Whisper 9.5 Ultra: Before readjustment check any other explanation for the wrong speed. Engine speed is set at the factory at nominal 1800 (60 Hz) RPM. A RPM drop of 5% at full load is acceptable. Therefore a no load setting should be at ± 1875 RPM = 62.5 Hz. Under no circumstances should the RPM be under full load below 1770 RPM = 59 Hz. When no cause can be found for a wrong speed, the setting can be adjusted:

Fig. 23 2 = adjustment screw RPM

It is very important to identify the correct setting assembly (refer to fig. 23). The screw is to be locked in position with the lock-nut.

5.4.2 Adjusting valve clearance and retightening the cylinder head bolts.

Both procedures have to be carried out with a cold engine. When both procedures are carried out be sure to retighten the cylinder head bolts before adjusting the valve clearance. When retightening the cylinder head bolts, drain the coolant by removing the drain plug (ref. to fig. 2).

Loosen the bolts slightly, remove the rocker assembly (the rocker arms, shaft, and stays) and then retighten the bolts to the specified torque in the numerical order illustrated (ref. to fig. 24).

Tightening torque cylinder head bolt: 88 ± 5 Nm Rocker stay tightening torque: 14.7 ± 2 Nm

Fig 24 Cylinder head bolts

The clearance of both (intake and exhaust) valves should be 0.25 mm in cold condition. Set the piston of the first cylinder to be adjusted to top dead centre (T.D.C.) of compression stroke.

8427

613 5

10 9 11

FRONT

MOTOR

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The T.D.C. of compression stroke can be found by aligning the T.D.C. mark (notch) on the crankshaft pulley with the mark on the gear case (ref. to fig. 25). First align the T.D.C. mark for the No. 1 cylinder. Confirm that the valves do not move up or down when the crankshaft is turned about 20 degrees in normal and reverse direction of rotation.

If the rocker arms move piston no.1 is on the T.D.C. of the intake or exhaust stroke. In such case turn the crankshaft 360° in the direction of engine rotation again. No. 1 piston is now at T.D.C. of the compression stroke. After adjusting the valves of cylinder 1 adjust the valve clearance of the remaining cylinders in firing order 1 – 3 –

2. Turn the crankshaft 240 degrees clockwise from the T.D.C of cylinder 1 to the T.D.C of cylinder 3. Adjusts the valves of cylinder 3 and turn the crankshaft further clockwise to the T.D.C of cylinder 2.

5.4.3 Measuring exhaust backpressure

The exhaust system must be of adequate size -2”/ 51 mm

- and maximal length (refer to installation manual). When

any doubt; backpressure has to be measured. An easy way to measure for back-pressure is to use a water column. A water column can be made visible in a plastic tube along a yardstick and fitting the end to a hose connection to fit in the adaptor on the injection bent after removing the exhaust temperature switch.

Fig 26: Measuring exhaust backpressure

The bent A hanging down should not be too short helping to damp the pulsating effect of the gas discharge that is characteristic for a one cylinder engine. The water column should be no more than 27 inches (69 cm.) of water (1 PSI

- 0,07 bar)

MAXIMUM

69cm

Mark on timing gearcase

IT (injection timing) mark

TDC mark piston 1

TDC mark piston 2 and 3

Fig. 25

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5.4.4 Disassembling instructions

It could be necessary to disassemble the generating set for repair or checks. Following instructions will help:

1 The design of the Whisper 9.5 / 11 Ultra makes it

possible to do most repairs on the spot. The heat exchanger is accessible and can be removed. The connections of the alternator are very accessible as well.. The same is true for the diode of the rotor

2 The sound shield can be disassembled according to

exploded view below (figure 27).

3 To take the generating set out of the canopy all hose

and cable connections have to be taken off. The set is fixed to its base by four rubber mountings and can be loosened by removing the four nuts from the bolts of these mountings. The easiest way to get the generator out of its capsule is by lifting the set with the aid of the lifting eyes.

4 One can take off the complete alternator housing.

Before the alternator can be taken off all cables and wiring has to be taken loose first.

5 The rotor can be taken off by removing the bold which

goes through the shaft (normal clockwise threaded). The end of the shaft is specially threaded to push off the rotor from the conic stub shaft, which is on the flywheel, using a 0.39 inch (10mm) rod of 6.9 inch (175 mm) length and a M24x2 bolt.

6 Reassembling the generating set one should take

care of alignment, cleaning the surfaces between engine and alternator and tighten the bolts crosswise and gradually.

7 Use Loctite 577 to seal the fittings, which should first

be cleaned and made free of oil and grease.

8 Test the generating set first outside its capsule and

check very carefully for leakages before putting it back in its enclosure.

Figure 27: exploded view sound shield Whisper 9.5 and 11 Ultra

Page 36

SPARE PARTS LIST

6 SPARE PARTS LIST

A complete parts manual in English is available as an option number: number: 50200185 (***) A work shop manual in English is available as an option number: 50200172 (***).

We recommend the following spares for service and maintenance.

• Kit A: parts for regular maintenance parts marked (*) article no. 50201460

• Kit B: parts for maintenance + spare parts: all parts marked (*)+(**) article no. 50201653

• Kit C: parts for "world travellers" all parts marked (*)+(**)+(***) article no. 50201654

ARTICLE NO DESCRIPTION

50209030 Fuel filter (*)

50201031 Fuel lift pump (***)

50205120 V-belt (*)

50203121 Oil filter (*)

50201450 Raw water pump complete Mastervolt type M12 (***) (refer to fig. 28)

50209011 Impeller (50209013) + gasket (50209012) (*)

50201401 Cover type M12 (**)

50209018 Bolts cover (**) (6 pcs.)

50201851 Pump repair kit A consisting of: Shaft (50201811), Bearings (2 pcs) (50209014), O-ring (50209017),

Seals (2 pcs.) (50209015), Clips (1 set) (50209019), O-ring (50201814)

50209010 Pump repair kit B (**)(same as repair kit A excluding the shaft(5021811) and O-ring (50201814))

50201413 Heat exchanger complete with appendages (***)

50207022 Water hoses with clamps (**)

50201060 Capacitor xx micro-farad, 2 pcs (**) (xx = give value when ordering)

50209132 Measuring coil (***)

50201890 Rotary diode (**)

50201482 Alternator bearing including O-ring (**)

50209140 Voltage regulator (optional)

50209104 Local control panel (***)

50209100 Digital Diesel Control Unit (***)

50212170 Fuses 10 Amps(*)

50212154 Fuses 3 Amps (*)

50201466 Wiring loom complete (***)

50209102 Digital Diesel Remote control panel (***)

130010915 Cable remote control 15 mtr, including connectors

50207033 Overhaul gasket kit / Seal kit (***)

50207030 Cylinder head gasket kit

50206040 Glow plug, 3pcs (**)

50203050 Nozzle injector, 3pcs (**)

50207060 Fuel pump (high pressure) complete (***)

50205045 Thermostat (**)

50205038 Gasket thermostat (**)

50207037 Gasket rocker cover (**)

More extensive parts list on the internet: MASTERVOLT.COM (fast moving parts)

Page 37

SPARE PARTS LIST

50201814 O-ring

50209015

Seal

50201450 RAW WA TER PUMP M 12

Screw impelle r

50209011 Impeller kit

Bea r ing

50209014

50209016 Circlip

50201811 Shaft

Male hose connector

50221031

Pump housing50201414

Seal

50209015

50209018 Screw co ver

Cover type M12

50201401

Gasket

50209012

Impe l ler K+ M

50209013

50221007

Male hos e connector

O-r ing

50209017

Bear ing

50209014

50209019 Circlip

Figure 28: Raw water pump complete Mastervolt type M12

Page 38

MAINTENANCE LOG

first service after 50 hours: hour counter: remarks

next service (every 150 hours) hour counter:

Page 39

NOTES

Page 40

Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands

Tel : + 31-20-3422100

Fax : + 31-20-6971006

Email : info@mastervolt.com