Page 1
V1.2, June 2017
INSTALLATION MANUAL
M-GV/2, M-GV/3, M-GV/3+,
M-GV 8, M-GV 10 and M-GV 15
genverters for marine use
WHISPERPOWER BV
Kelvinlaan 82
9207 JB Drachten
Netherlands
Tel. : +31-512-571550
Fax : +31-512-571599
www.whisperpower.com
Art.no. 40200751
Page 2
CONTENTS
2 M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN
CONTENTS
1 INTRODUCTION .......................................................................................................................................................................... 3
1.1 Use of this manual ................................................................................................................................................................ 3
1.2 Validity of this manual .......................................................................................................................................................... 3
1.3 Installation parts ................................................................................................................................................................... 3
2 INSTALLATION ............................................................................................................................................................................ 4
2.1 General ................................................................................................................................................................................. 4
2.2 Location ................................................................................................................................................................................ 4
2.3 Protection against dirt, sand and bad weather conditions ................................................................................................... 4
2.4 Sound and vibration reduction ............................................................................................................................................. 4
2.4.1 Further recommendations ................................................................................................................................. 4
2.5 Ventilation ............................................................................................................................................................................ 5
2.6 Connections .......................................................................................................................................................................... 5
2.7 Fuel supply............................................................................................................................................................................ 6
2.7.1 Fuel tank ............................................................................................................................................................ 6
2.7.2 Fuel lift pump ..................................................................................................................................................... 6
2.7.3 Fuel pipes ........................................................................................................................................................... 6
2.7.4 Fuel filters .......................................................................................................................................................... 7
2.8 Cooling .................................................................................................................................................................................. 7
2.8.1 General .............................................................................................................................................................. 7
2.8.2 The internal cooling system ............................................................................................................................... 7
2.8.3 Keel cooling ........................................................................................................................................................ 7
2.8.4 Intercooling ........................................................................................................................................................ 7
2.9 Wet exhaust system ............................................................................................................................................................. 9
2.9.1 General .............................................................................................................................................................. 9
2.9.2 Standard exhaust system ................................................................................................................................... 9
2.9.3 Super silent exhaust system ............................................................................................................................ 10
3 ELECTRICAL INSTALLATION ....................................................................................................................................................... 12
3.1 Digital Diesel Control system .............................................................................................................................................. 12
3.2 Remote control ................................................................................................................................................................... 12
3.3 Acoustic alarm or warning lamp ......................................................................................................................................... 12
3.4 Connection for emergency stop / fire alarm switch ........................................................................................................... 12
3.5 Automatic starting and stopping ........................................................................................................................................ 13
3.5.1 General ............................................................................................................................................................ 13
3.5.2 Start/stop by external switch ........................................................................................................................... 13
3.6 Starter battery .................................................................................................................................................................... 13
3.7 Other recommendations and warnings .............................................................................................................................. 13
3.8 Alternating current ............................................................................................................................................................. 14
3.9 Cable protection (fuses) ..................................................................................................................................................... 14
3.10 Grounding ........................................................................................................................................................................... 14
3.11 Cable ................................................................................................................................................................................... 14
4 INSTALLATION SUMMARY ........................................................................................................................................................ 15
4.1 General ............................................................................................................................................................................... 15
4.2 Commissioning table .......................................................................................................................................................... 15
4.3 Technical data .................................................................................................................................................................... 15
4.4 Specification of the accessoiries ......................................................................................................................................... 15
4.5 Installation materials .......................................................................................................................................................... 16
5 DIAGRAMS & DRAWINGS ......................................................................................................................................................... 20
5.1 Electrical diagrams.............................................................................................................................................................. 20
5.2 Mechanical drawings .......................................................................................................................................................... 23
Page 3
INTRODUCTION
M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN 3
1 INTRODUCTION
1.1 USE OF THIS MANUAL
This manual serves as a guideline for the safe and effective
installation of the WhisperPower two and three cylinder
genverters for marine applications.
It is obligatory that every person who is involved with the
installation of the genverter must be completely familiar with
the contents of this manual, and that he/she carefully follows
the instructions contained herein.
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 only by qualified, authorized and trained personnel,
consistent with the locally applicable standards and taking into
consideration the safety guidelines and measures (Chapter 2 of
the user’s manual).
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.
Our policy is one of continued development and we re-serve
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 in a secure place!
1.2 VALIDITY OF THIS MANUAL
All of the specifications, provisions and instructions contained
in this manual apply solely to standard versions of the two and
three cylinder genverters delivered by WhisperPower.
This manual is valid for the following models:
Refer to the user’s manual for identification of the genverter.
For other models see our website: www.whisperpower.com.
WARNING!
During installation and commissioning of the
genverter, the Safety Guidelines & Measures are
applicable at all times. See Chapter 2 of the user’s
manual.
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 with possibly
severe personal injury or loss of life.
WARNING!
Before working on the system read the safety
instructions in the user’s manual.
1.3 INSTALLATION PARTS
Besides the parts that are included with the delivery you need
at least the parts listed at section 4.4 to install the genverter.
Please note that this listing may not be complete, as every
installation differs from the other. Oil is not included in the
supply. Refer to the user’s manual for the right specifications.
Part no.
Description
41001105
M-GV/2 K (Kubota Z482)
41001205
M-GV/2 M (Mitsubishi L2E)
41005005
M-GV 8, wet exhaust (Kubota Z482)
41005006
M-GV 8, ungrounded, wet exhaust (Kubota Z482)
41005030
M-GV 8, keel cooling, dry exhaust (Kubota Z482)
41001305
M-GV/3 K (Kubota D722)
41001405
M-GV/3 M (Mitsubishi L3E)
41009005
M-GV 10, wet exhaust (Kubota D722)
41009006
M-GV 10, ungrounded, wet exhaust (Kubota D722)
41009030
M-GV 10, keel cooling, dry exhaust (Kubota D722)
41001505
M-GV/3+, wet exhaust (Kubota D1105)
41007005
M-GV 15, wet exhaust (Kubota D1105)
41007055
M-GV 15, 120V/60Hz, wet exhaust (Kubota D1105)
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INSTALLATION
4 M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN
2 INSTALLATION
2.1 GENERAL
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.
WARNING!
The genverter incorporates powerful permanent
magnets. Cardiac patients, especially those living
with a pacemaker, should bear this in mind.
2.2 LOCATION
When looking for a proper place for a genverter in a vessel all
relevant aspects have to be taken into account
Accessibility
Solid foundation
Space to mount the exhaust (refer to 2.9)
A route to fit the fuel lines
Combustion air supply (refer to 2.6)
Because of their small dimensions, WhisperPower genverters
can be installed in tight locations. Please consider that even
almost maintenance-free machinery must still remain
accessible.
When selecting the location for the genverter, make sure there
is sufficient room to carry out any maintenance work. The unit
must be easily accessible on the service side.
All models can be serviced from one side. Oil filling can be done
on the service side and on the top. The top of the engine
(rocker cover) has to be accessible for adjustment of the valve
clearance.
Please also note that in spite of the automatic oil pressure
switch the oil level must checked regularly.
2.3 PROTECTION AGAINST DIRT, SAND AND BAD
WEATHER CONDITIONS
The unit is designed to be mounted inside a vessel rather than
on deck, where it could be exposed to (salt) water spray and
bad weather conditions. The best place is a dedicated engine
room. Even there, it should be protected against bilge water,
condensation, frost and other conditions that may affect the
engine and electronics.
The air inlet of the engine room must be protected against the
ingress of water and it is recommended to fit an air inlet
strainer for protection against dirt and dust .
2.4 SOUND AND VIBRATION REDUCTION
Position the genverter as low as possible in the vessel. The
genverter is secured to the base frame inside the canopy by
means of a flexible engine mountings system. This frame is
must be solidly mounted in the vessel, not using rubber
mountings again unless an additional base plate is inserted.
When it is possible to mount the unit directly on the vessel’s
frames this has advantages in preventing vibrations by
resonance.
2.4.1 Further recommendations
WhisperPower genverters are standard equipped with a sound
cover canopy. This sound cover has been designed to give
effective sound insulation. For optimum sound and vibration
dampening, the following factors should be considered.
1 Most importantly, the structure on which the genverter is
placed must be stiff. Directly below the base frame, the
structure should be supported by the vessel’s frames.
When this is not possible horizontal structures should be
made stiff by additional provisions (Figure 1).
2 In larger vessels a separate and insulated engine room for
the genverter will help to dampen the noise even further.
3 Avoid mounting the genverter in close proximity to thin
walls or floors that may cause resonance.
4 Sound dampening is extremely poor if the genverter is
mounted on a light weight flimsy surface such as plywood
which will only amplify vibrations. If mounting on a thinner
surface cannot be avoided, this should be 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.
5 Never connect the base of the genverter directly to
bulkheads or tanks (Figure 1).
Figure 1: Mounting of the WhisperPower genverter.
X = wrong, V = OK
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INSTALLATION
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2.5 VENTILATION
The genverter normally draws air from the engine room. An
engine room with natural ventilation must have vent openings
of adequate size and location to enable the genverter to
operate without overheating. To allow an ample supply of air
within the temperature limits of the genverter an opening of at
least 100 cm2 is required.
A "sealed" engine compartment must have a good extraction
ventilator to maintain reasonable ambient temperatures. High
temperature of intake air reduces engine performance and
increases engine coolant temperatures. Air temperatures above
40°C reduce the engine power by 2% for each 5°C of rise. At
higher temperatures the electric output will be lower. To
minimize these effects the engine room temperature must not
exceed the outside ambient air temperature by more than
15°C.
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 compartment to clear
fumes from the bilge and to circulate fresh air. Air outlets
should be at the top of the engine compartment to evacuate
the hottest air. An engine compartment blower should be used
as an extraction ventilator to remove air from the engine room.
In cases where it is impossible to meet the above mentioned
temperature limit by using engine compartment ventilation,
connections are to be made for an air inlet directly to the
genverter enclosure. With these connections the genverter can
be directly connected to an air duct.
Air inlets should be louvered, where appropriate, to protect the
engine room and to protect the genverter from water spray.
2.6 CONNECTIONS
The genverter comes with all supply lines and output cables (i.e.
electric cables, exhaust stub, fuel lines etc.) already connected.
The supply lines are fed through the capsule’s front base. The
connections are marked as shown in Figures 2-5.
Refer to Section 5.1 for a graphical overview of installation and
wiring connection requirements.
All electrical connections, cable types and sizes must comply
with the appropriate national regulations. Supplied cables are
rated for ambient temperatures up to 70°C. If the cables are
required to meet higher temperature requirements, they must
be run through conduits.
ATTENTION!
Before working on the system, read the safety
instructions.
Figures 2 and 3: Connections for genverters using Z482, L2E,
D722 and L3E engine blocks)
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INSTALLATION
6 M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN
Figures 4 and 5:
Connections for genverters using D1105 engine block
2.7 FUEL SUPPLY
2.7.1 Fuel tank
Fuel tanks should be made of appropriate material such as
(stainless) steel or plastic. Steel tanks should not be galvanized
or painted inside. Condensation can occur in metal tanks when
temperature changes. Therefore, water accumulates at the
bottom of the tank and provisions should be made for the
drainage of this water.
The tank will need a filling connection, a return connection and
an air ventilation connection which will require protection
against water entry.
Some official regulations do not allow connection points at the
base of the fuel tank; 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. When using the existing fuel tank of the
propulsion engine, fitting should be carried out with extra care.
Both a supply line and a return line should be installed and go
into the tank from the top. Interference of the two systems
(propulsion engine and genverter) should be avoided. Emptying
the tank below the level of the suction pipe of the genverter
could make it necessary to bleed the fuel system.
Figure 6: Fuel tank below the genverter
Figure 7: Fuel tank above the genverter
2.7.2 Fuel lift pump
All models are fitted with an external fuel lift pump. This should
be mounted close to the tank, in an angle or vertically to
prevent air bubbles from blocking the system. As the pump
makes clicking noises, it is recommended to use rubber
mountings. If the clicking noises of the pump are not
acceptable, a noiseless pump is available as an option (art. no.
50202200).
Figure 8: Fuel line assemblies with pump mounted vertically or
in an angle
2.7.3 Fuel pipes
When the tank is above the genverter (Figure 7) we
recommend ending the return line on the top of the tank.
When the return is on the top, siphoning of the return line is
impossible in case of a leakage. Only the fuel supply line will
need to be fitted with a fuel cock. When the tank is below the
genverter (Figure 6) we recommend ending the return line on
the bottom of the tank below the inlet of the supply line. This
will prevent the fuel supply line from being drained into the
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INSTALLATION
M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN 7
tank when the engine is stopped because air cannot enter into
the return line, thus avoiding starting trouble.
Both supply and return fuel pipe lines should be made of
appropriate material and have an 8 mm inner diameter. The
quality of the tubing of fuel pipes may be subject to local
regulations depending on the application of the vessel.
The fuel pipes can be connected to the flexible hoses which are
on the genverter and are prepared to be fitted to 8 mm pipe.
The resulting fuel line complies with CE standards as well as
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. The return line should be of 8 mm diameter and
go straight back via the top to the bottom of the tank. When
the return is too narrow, has too many bends and goes back to
the bottom of the fuel tank (i.e. bypassing the top), the backpressure may be too high. This results in irregular running of
the engine. When the engine runs irregularly, check if backpressure is the problem by disconnecting the return line just
outside the canopy and draining it in a canister. When the
engine runs smooth now, the return piping has to be changed.
It could also help to install a second (electrical 12V) fuel lift
pump in the supply line to increase the pressure.
2.7.4 Fuel filters
A fine fuel filter is installed which requires maintenance.
WhisperPower recommends installing an extra fuel filter/ water
fuel separator near the fuel tank.
Before starting your genverter for the first time
follow the fuel system bleeding procedure in the
user’s manual.
2.8 COOLING
2.8.1 General
For cooling a modern engine in a vessel, two methods are
available: intercooling and keel cooling. Keel cooling is basically
a direct extension of the engine’s internal cooling system.
Intercooling, on the other hand, is based on a raw water pump,
heat exchanger and water-injected exhaust. Cooling liquid in
the internal cooling system is cooled in a heat exchanger by
outboard water (raw water or seawater). After the raw water is
warmed up in the heat exchanger it is dumped overboard by
injecting it in the exhaust.
2.8.2 The internal cooling system
The internal cooling system should be filled with long-life G12+
cooling liquid. As the engine warms up the liquid expands and
the system is pressurized. When the pressure is sufficiently
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 under-pressure. Another 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 is a non-kinking hose made of heat resistant
plastic.
The hose passes through a hole in the canopy.
Figure 9: Expansion tank placement
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 used, the system will
not be pressurized and a cap without release valve should be
applied.
2.8.3 Keel cooling
Keel cooling involves circulating the hot coolant through a
space in the keel, through a double walled skin of the boat,
through a box cooler, using a big tank or any other external
cooler. Keel cooling systems are extensively described in a
separate manual (art. no. 40200251). For these particular
genverters, only a single external cooler is needed.
2.8.4 Intercooling
When applying intercooling the genverter should have its own
raw water inlet and should not be connected to any other
engine systems. A properly installed cooling system is critical to
keep engine temperatures within an acceptable range. Ensure
that the installation complies with the following installation
instructions.
2.8.4.1 Raw water supply
For raw water supply the following installation materials are
required:
skin fitting
MAX.
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INSTALLATION
8 M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN
sea cock
water strainer
hoses and clamps
In order to keep the suction resistance in the line at a
minimum, the sea water intake system (i.e. sea cock, troughhull fitting, inlet filter, etc.) must have an inner diameter
matching the genverter’s, i.e. at least 19 mm (3/4") or 25 mm
(1”), as applicable. The suction hose should be kept as short as
possible.
Bends should be avoided. 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 User’s Manual.
2.8.4.2 Through-hull fitting
It is good practice for yachts to use a hull inlet fitting with an
integrated strainer (water scoop). For propulsion engines in
motorboats the water scoop is often mounted against the
sailing direction to induce more water intake for cooling.
This should not be done in the case of a
generating set! When sailing at higher speeds,
water will be forced into the inlet and your
generating set will overflow! (see Figure 10).
Figure 10: Installing the water intake
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.
2.8.4.3 Water strainer
Use an appropriate water strainer with connections of well
accessible position, 5 cm above the waterline (Figure 13, ref. 6).
2.8.4.5 Siphon breaker (air vent)
When the point of water injection is below the waterline, then
– when the engine is stopped – there is a risk that the cooling
water may enter the engine as a result of siphoning. To avoid
this, the generating set is designed to accommodate a siphon
breaker (air vent). In the standard delivery the connections are
bypassed.
Figure 11: Hose bend for installation of syphon breaker
If the generating set cannot be mounted such that the bottom
of the set is above the waterline, an air vent must be installed.
Extend the water hose of the by-pass 60 cm above waterline
and install an air vent. Ideally, the air vent should be mounted
above the yacht keel centre line (i.e. to minimize the influence
of swaying on the water intake). Hose with an inner diameter of
19 mm (3/4") or 25 mm (1”), as applicable, should be used.
Fast motorboats will lay deeper when sailing at large speed
(non-planing) and have additional pressure on the water inlet.
This should be avoided to prevent water from entering into the
engine.
If the air vent is clogged, the water hoses will not
be vented when the generating set has stopped
and water can be forced into the engine. This
leads to immediate engine problems and possibly
severe damage!
DAMAGE CAUSED BY THE INGRESS OF WATER IN THE ENGINE
IS NOT COVERED BY GUARANTEE.
The siphon breaker that is delivered with the Whisper Power
siphon breaker installation kit does not require a connection for
a hose to drain the little water that could be spilled from the
valve. If you use another kind of siphon breaker that has a hose
connection, make sure that the drain should go downwards
OK !
WRONG !
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INSTALLATION
M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN 9
directly and that it may not end under water (refer to
Figure 12).
Figure 12: Wrong siphon breaker hose routing
(non-WhisperPower siphon breaker)
Water must flow out freely and air has to flow in freely as well.
Check the air vent at regular intervals. Open, clean and
lubricate the valve as required.
2.9 WET EXHAUST SYSTEM
2.9.1 General
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.
2.9.2 Standard exhaust system
The generating set exhaust system must remain completely
independent and separate from the exhaust system of any
other engine on board. A water lock prevents the generating
set from being flooded by cooling water and should be installed
as close to the generating set as possible. The lock must be
large enough to hold the entire water volume held in the hose
from the top of the goose neck to the water lock. The water
lock must be installed at the lowest point of the exhaust system
(see Figure 10, ref. 1).
The exhaust hose must have an inner diameter of 40 mm
(15/8”). The exhaust system must be installed so that the back
pressure inside the exhaust does not exceed 0,07 bar (1psi –
70 cm water column) and total length from the generator to
the top of the goose neck or water/separator does not exceed
3 m (10 ft.).
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 50 mm above the water line
(Figure 13, ref 5). The "goose neck" must be vertical and
situated preferable along the ship’s keel centre line. If the
generating set is mounted less than 600 mm (24") 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.
Because of the small gas flow of the small engine,
it is very important to keep strictly to the
instructions above. Some mufflers and water locks
cause too high back pressure. You are advised to
use a WhisperPower installation kit or check the
back pressure. Too high back pressure causes the
system to fill up with water that affects the outlet
valve and valve seat.
Figure 13: Standard exhaust system
1 Exhaust water lock;
2 Exhaust outlet muffler;
3 Exhaust line Ø 40 mm (15/8”);
4 Goose neck;
5 Through-hull exhaust outlet Ø 40 mm (15/8”);
6 Water level.
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2.9.3 Super silent exhaust system
In order to reduce the noise level of the generating set to a
minimum, an option to reduce the exhaust noise further
(especially exhaust water splashing) is an exhaust/water
separator. The exhaust/water separator allows the cooling
water to be ejected through a line (Figure 14, ref. 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 60 cm above the water level
an additional goose neck is not required.
If the through-hull exhaust outlet has to be mounted far from
the generating set (i.e. the length of the exhaust piping from
the generator to the top of the goose neck (water separator)
exceeds 3 m; see Figure 12), an exhaust/water separator must
definitely be installed. The sea water from the separator must
then run down along the shortest possible path to the throughhull outlet. Only after the exhaust/water separator the exhaust
hose may have a length of over 7,5 m (Figure 15).
However, water traps should be avoided as the fumes still
contain water and this should not accumulate in bends (see
Figure 16). An additional outlet exhaust muffler close to the hull
outlet will help further to reduce noise emission (Figure 13,
ref 2).
Figure 14: Super silent exhaust system
Figure 15: Hose lengths
A
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Figure 16: Water trap in exhaust system
Figure 17: Super silent exhaust system for genverter installed below waterline
If the generating set and the exhaust system have been
installed correctly, neighbouring boats will not be disturbed by
generating set noise. With the "super silent" exhaust system,
generating sets are almost inaudible. For optimal noise
reduction, the sea water outlet from the exhaust/water
separator (centre outlet on the unit, see Figure 17) 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 (see Figure 18).
Do not direct the outlet directly toward the water
surface.
Figure 18: Outlet direction
1 Exhaust through-hull;
2 Water/exhaust separator;
3 Seacock;
4 Water lock;
5 Air vent;
6 Water strainer;
OK !
WRONG !
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ELECTRICAL INSTALLATION
12 M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN
3 ELECTRICAL INSTALLATION
3.1 DIGITAL DIESEL CONTROL SYSTEM
The standard electrical control system is in 12 Volt with
negative earth. Non-earth return is available as an option. The
engine is controlled by a highly advanced microprocessor based
system: Digital Diesel Control, which has both a local control
and a remote panel.
3.2 REMOTE CONTROL
A remote control panel also containing a microprocessor is
included in the delivery, as well as a 10 m 8-pole
communication cable (Figure 19). Other lengths are available
on request. A longer (up to 30 m) cable can be connected if
required. For distances exceeding 30 m, please consult the
WhisperPower service department.
Figure 19: Remote control cable
The control panel can be mounted in the dashboard using the
plastic sawing template. For dimensions, refer to the drawings
in Chapter 5.
Two more remote control panels (slave panels) can be put in
parallel using the modular connectors on the back of the units.
Actually, the slaves are regular remote control panels offering
all functions again.
When using the factory settings, installation is very simple: just
plug in both end of the communication cable and the genverter
is ready to use.
3.3 ACOUSTIC ALARM OR WARNING LAMP
An external max. 150 mA relay can be connected in order to
generate an acoustic warning, light a warning lamp, etc. Be
aware of polarity as some relays have a diode inside and must
be connected positive to positive and negative to negative as
indicated (Figure 20).
Figure 20: Remote box terminals
3.4 CONNECTION FOR EMERGENCY STOP /
FIRE ALARM SWITCH
Figure 21: Connection for emergency stop / fire alarm switch
To connect an emergency stop button or to stop the generator
automatically in case of a fire alarm, you can use the bypass
connection between fastons J7 and J18 on the backside of the
local control panel (Figure 21). To do so, remove this bypass
connection and then replace it by an emergency switch or a
potential free fire alarm switch with normally closed contacts.
Remove bypass
between J7 - J18
Normal operation
Alarm / emergency
local control panel
(rear view)
Page 13
ELECTRICAL INSTALLATION
M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN 13
3.5 AUTOMATIC STARTING AND STOPPING
3.5.1 General
WhisperPower cannot be held responsible for
damage caused by the genverter running
unattended using the auto-start/stop mode or
interval mode.
Using the auto-start/stop or interval mode, the
genverter may 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.
Included in the delivery are warning stickers to be
applied on several parts of the electric installation
(transfer switch, distribution box, etc.) to warn
against possible automatic starting of the
genverter.
The WhisperPower Digital Diesel Control system offers several
options for automatic starting and stopping. This menu as well
as other DDC menus may be locked. For unlocking and setting
these options, refer to the APPENDIX of the DDC user’s manual.
3.5.2 Start/stop by external switch
At the back of the DDC remote control panel (40209102), you
will have the possibility to connect two wires in order to allow
the genverter being started by an external signal. This requires
the optional 12-pole green connector (part no. 50209119).
Two common options are shown in Figure 22, where the signal
can be provided by an external relay or by the Whisper Battery
Monitor (WBM).
Figure 22: Connection for start/stop by external signal
Another possibility is to monitor the voltage of a second battery
(not being the starter battery) and to start the genverter
automatically when this voltage drops below a set value. This
second battery is often called “auxiliary battery” or “service
battery”. It is referred to as BAT2 in the DDC menus. A sense
wire to monitor the second battery should be connected (check
polarity!) to the connector on the back of the remote panel
(Figure 20). The sense wires must be connected directly to the
second battery and be protected by a 3A fuse.
Settings: For settings other than the factory settings, refer to
the DDC user’s manual, especially to the APPENDIX.
3.6 STARTER BATTERY
For starting, the genverter requires a 12V starter battery of
80 Ah (smaller models) or 90 Ah (M-GV/3+ and M-GV 15).
The genverter can be connected to the main engine battery or
have its own battery. We strongly recommend the use of a
separate battery for the genverter and keeping the wiring
system for the main engine and the domestic DC supply system
completely separate and individually connected to separate
batteries.
However, the negatives of all batteries on the vessel should be
interconnected in order to prevent differences in earth voltage
levels on different places, which might cause trouble to
electronic devices in the system.
The above recommendation is not valid for vessels having the
starter battery of the main 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 charger will help to keep the battery in
good condition when the genverter is not used.
Figure 23: Starter battery
3.7 OTHER RECOMMENDATIONS AND WARNINGS
The battery should be secured for rough sea conditions and the
terminals should be insulated. For extra safety the battery can
be enclosed in a wooden, plastic, fiberglass etc. (non metal)
box. Even when the earth return system is applied a negative
battery cable should be used and the vessel should not to be
used as a conductor.
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.
Page 14
ELECTRICAL INSTALLATION
14 M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN
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 severe damage to both batteries
within a short time.
Disconnect the battery leads if electrical welding is to be carried
out, otherwise damage will be caused to the diodes of the
alternator.
As explosive hydrogen gases may be discharged
during charging, the battery should be located in
a well-ventilated space. Ensure that the supplied
battery cable connectors are properly fitted.
Never remove these during or shortly after
charging, as sparking may occur, igniting the
hydrogen gases.
3.8 ALTERNATING CURRENT
The electric power supplied by the genverter is
of a high voltage and dangerous to people.
Before working on the system read the sections
on safety in the users manual.
Generators used on vessels that are operated in
a hazardous environment often have to fulfil
special regulations and additional measures have
to be taken accordingly.
These genverters are designed to generate power for both AC
and DC installations, depending on the type of WhisperPower
PowerCube or Power Module installed with the genverter. Be
sure that all electrical installations (including all safety systems)
comply with all regulations required by the local authorities. All
electrical safety/shutdown and circuit breaking systems have to
be installed on-board as the genverter itself cannot be
equipped with such equipment for every possible variation.
The vessel’s power supply system should be suitable and safe
for the voltages 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
electrical system be properly installed by a qualified electrician.
3.9 CABLE PROTECTION (FUSES)
It is the installer's responsibility to protect the live wires
between the genverter and the PMG/DC PowerCube. Check the
electrical information on the identification plate in order to
calculate the right fuse size.
Please note that the above is in addition to any fuses required
between the PMG/DC PowerCube and the AC installation or
batteries, as applicable.
3.10 GROUNDING
The AC alternator windings are not grounded.
The housing of the alternator and all other metal parts are
grounded.
The electric installation in the vessel needs to be protected
against insulation failures. Methods of protection are subject to
rules that may differ depending on the use of the vessel and
local standards. Experts in this field should be consulted.
Be aware that insulation protection systems can be different for
different applications and even within the ship there could be
different standards for different spaces. Sometimes other
standards shall be complied with, e.g. for certification societies
such as Lloyd’s Register of Shipping or Veritas, regulations for
the protection of personnel, building legislation, etc. It is of the
greatest importance to have expert advice on this issue.
For safety reasons connect the main ships ground to the
negative of the generating set start battery. However, when a
ungrounded DC system or positive grounded DC system is
applied the battery negative should not be connected to the
main ships ground.
3.11 CABLE
For the power cable we recommend the use of 3 wire oil
resistant cable with a sufficient cross sectional area. For long
cables it is recommended to apply cables with a larger cross
section (refer to ISO 13297, Annex A).
Page 15
ELECTRICAL INSTALLATION
M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN 15
4 INSTALLATION SUMMARY
4.1 GENERAL
1 Mount the genverter directly, without additional vibration
dampers, on a solid surface.
2 Connect cooling system.
3 Connect exhaust system.
4 Connect ‘fuel supply line’ to the water separator/ fuel
filter.
5 Connect ‘fuel return line’ to the fuel tank.
6 Connect remote panel (just plug in).
7 Connect the AC cables to the PMG/DC PowerCube.
8 Connect the battery cables to the 12V starter battery’s
positive and negative terminals.
9 Install a WhisperPower battery charger (optional).
4.2 COMMISSIONING TABLE
1 Check if the air inlet is sufficient.
2 Check if the cooling system for the engine is properly
installed and properly filled with G12+ cooling liquid .
3 Check if the exhaust system is properly installed. Check
maximum length of exhaust hose, diameter of exhaust
piping.
4 Check all coolant connections.
5 Check the AC cables and the grounding.
6 If the genverter is installed with a WP-PMG, check if an AC
breaker is installed before or after the power source
selector. When there is only a circuit breaker, use it to
disconnect the generating set from the grid.
7 Check all DC connections, check if the battery switch/
circuit breaker is closed.
8 Open the fuel valve. Check if there are no air leaks in the
fuel supply line, and check if the lift of the fuel is less than
1 m. 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 colour of the oil.
11 To bleed the fuel system, push the “Start” button on the
local control (not on the remote panel) and hold at least
5 s and as long as necessary to bleed the system.
12 Start the engine by pushing the start button.
13 If the genverter is installed with a WP-PMG, check the
delay of 5 to 10 seconds in the power source selector
transfer.
14 Check voltage under ‘no load’ conditions.
15 Check if the genverter can bring the full load.
16 Check if the battery charger of the genverter is working
(max. 14.5 V).
17 Close the sound shield and check the noise level.
18 Stop the genverter and check the engine again for leakages
of oil, fuel or coolant and check the oil level again.
Installation checklist available on our website:
www.whisperpower.com.
Commissioning form available on our website:
www.whisperpower.com.
4.3 TECHNICAL DATA
Refer to the User’s Manual for an overview of general technical
specifications.
4.4 SPECIFICATION OF THE ACCESSOIRIES
Item
Size on M/GV2, M-GV/3, M-GV 8, M-GV 10
Size on M/GV/3+ and M-GV 15
Water pickup scoop
3/4” = 19 mm
1” = 25 mm
Inlet valve
3/4” in / 19 mm out
1” in / 25 mm out
Water strainer
19 mm in / 19 mm out
25 mm / 25 mm out
Air vent
19 mm
25 mm
Inlet suction hose
19 mm
25 mm
Fuel filter/water separator
30 micron
Fuel inlet and return
8 mm
Exhaust hose
Ø 40 mm inner
Water lock
Ø 40 mm
Water/gas separator
Ø 40 mm
Page 16
INSTALLATION SUMMARY
16 M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN
4.5 INSTALLATION MATERIALS
WATER INLET KITS
no
qty
article no
description
dimensions
1
1
50230052
Water pickup scoop
¾”
2
1
50230042
Lever operated ball valve f/f
¾”
3
1
50221004
Male hose connector
¾” × 20 mm
4 4 50221503
Hose clamp, stainless
19-29 mm
5
3
50220056
Raw water hose
19x28 mm
6
2
50221007
Male hose connector
½” × 20 mm
7
1
50230060
Nickel plated brass intake strainer
½”
TOTAL
40230211
WATER INLET KIT 20 mm (¾”)
for M-GV/2, M-GV/3, M-GV 8 and M-GV-10
no
qty
article no
description
dimensions
1
1
50230053
Water pickup scoop
1”
2
1
50230043
Lever operated ball valve f/f
1”
3
1
50221010
Male hose connector
1” × 25 mm
4 4 50221503
Hose clamp, stainless
25-40 mm
5
3
50220050
Raw water hose
25 ×33 mm
6
2
50221008
Male hose connector
¾” × 25 mm
7
1
50230061
Nickel plated brass intake strainer
¾”
TOTAL
40230221
WATER INLET KIT 25 mm (1”) for M-GV/3+ and M-GV 15
Page 17
INSTALLATION SUMMARY
M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN 17
SYPHON BREAKER KITS
no
qty
article no
description
dimensions
1 1 50230019
Syphon breaker (including valve assembly)
20 mm
2
4
50221502
Hose clamp
19-29 mm
3
3 m
50220056
Raw water hose
19 × 28 mm
TOTAL
40230273
SYPHON BREAKER KIT 20 mm (¾”)
for M-GV/2, M-GV/3, M-GV 8 and M-GV-10
no
qty
article no
description
dimensions
1 1 50230025
Syphon breaker (including valve assembly)
25 mm
2
4
50221503
Hose clamp
25-45 mm
3
3 m
50220056
Raw water hose
25 × 33 mm
TOTAL
40230274
SYPHON BREAKER KIT 25 mm (1”) for M-GV/3+ and M-GV 15
Page 18
INSTALLATION SUMMARY
18 M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN
WATER SEPARATOR AND WET EXHAUST KITS (40 mm)
no
qty
article no
description
dimensions
22 8 50221504
HD hose clamp
35-50 mm
23
3m
50220033
Marine exhaust hose
40 mm
24 1 40230193
Delta-shaped water lock
40 × 40 mm
25
1
50230038
Brass through hull fitting
1¼” × 40 mm
TOTAL
40230251
WET EXHAUST KIT (40 mm)
22
8
50221504
HD hose clamp
35-50 mm
23
2,5m
50220033
Marine exhaust hose
40 mm
31
1
50221015
Male hose connector
1¼” × 40 mm
32
1
50230044
Lever operated ball valve f/f
1¼”
33
1
50230033
Brass through hull fitting
1¼” × 70 mm
34 1 40230197
Delta-shaped water separator
40 × 40 × 40 mm
TOTAL
40230093
WATER SEPARATOR KIT (40 mm)
OPTIONAL INSTALLATION PARTS
21 1 50230087
Elbow 90° exhaust hose adapter
40 mm
22 4 50221504
HD hose clamp
35-50 mm
27 1 50230113
Brass straight coupling f/f
40 mm
28 1 50230112
Brass elbow f/f
40 mm
According to ABYC recommendations all hose connections should be
made using double clamps.
Maximum torque for hose clamps: 6.0Nm
Page 19
INSTALLATION SUMMARY
M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN 19
FUEL KIT
no
qty
article no
description
dimensions
42
1
50230091
Filter head for fuel strainer/water separator
M14x1.5 mm
43
2
50221618
Parallel male coupling
M14 - 8 mm
44 2 50221619
Parallel male coupling
M14 - 10 mm
45 2 50221620
Hose connection, outer cone
M16 × 1.5 mm, 8 mm
46 50230092
Filter for fuel strainer/water separator
48 4 50221522
Hose clamp, stainless
10-16 mm
49 2 50221632
Gasket ring
18 × 14 × 1.5 mm
not shown
2
50221203
Straight coupling
8 mm
not shown
2
50221252
Barbed-smooth hose nipple
8 mm
TOTAL
40230205
FUEL KIT
OPTIONAL INSTALLATION MATERIALS
no
qty
article no
description
dimensions
48 1 50221522
Hose clamp, stainless
10-16 mm
not shown
per m
50222020
copper fuel pipe
6 × 8 mm
not shown
per m
50220063
fuel hose
8 × 16 mm
BATTERY INSTALLATION KIT
article no
description
dimensions
61112002
WBC-Handy 20 charger 12V / 2A
157 × 33 × 34 mm
40290093
battery terminal (NEG-)
40290094
battery terminal (POS+)
40290099
M8 battery pole adapter set
40290098
isolation caps (red & black)
502144701
WP-Compact Manual Battery Switch, 300A
72 × 72 × 78 mm
40290106
INSTALLATION KIT FOR BATTERIES UP TO 100 Ah
RECOMMENDED BATTERIES
article no
description
dimensions
40290061
AGM-Power 12V 80Ah Absorbed Glass Matt
350 × 167 × 180 mm
40290030
AGM-Power 12V 90Ah Absorbed Glass Matt
307 × 169 × 211 mm
Page 20
DIAGRAMS & DRAWINGS
20 M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN
5 DIAGRAMS & DRAWINGS
5.1 ELECTRICAL DIAGRAMS
Figure 24: Layout of M-GV 8 and M-GV 10 genverter systems
Page 21
DIAGRAMS & DRAWINGS
M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN 21
Figure 25: Layout of M-GV 15 genverter system
Page 22
DIAGRAMS & DRAWINGS
22 M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN
Figure 26: Electrical control diagram
Page 23
DIAGRAMS & DRAWINGS
M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN 23
5.2 MECHANICAL DRAWINGS
Figure 27: M-GV/2 and M-GV 8
Page 24
DIAGRAMS & DRAWINGS
24 M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN
Figure28: M-GV/3 and M-GV 10
Page 25
DIAGRAMS & DRAWINGS
M-GV/2, M-GV/3, M-GV/3+, M-GV 8, M-GV 10 and M-GV 15 — June 2017 — EN 25
Figure 29: M-GV/3+ and M-GV 15
Page 26
Page 27
Page 28
Kelvinlaan 82, 9207 JB Drachten, Netherlands
Tel : + 31-512-571550 / Fax : + 31-512-571599
www.whisperpower.com / info@whisperpower.com
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