Mastervolt Whisper 6 Bedienungsanleitung

INSTALLATION MANUAL U.S.A EDITION

WHISPER 6 / 8 / 11

- 3600 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

V7. July 2009

Art.nr. 50200364

CONTENTS

Reproduction, transfer, distribution or storage of part or all of the contents in this document in any form without the prior written

permission of Mastervolt is prohibited.

CONTENTS:

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

1.1 General .............................................................................................................................................................. 3

1.2 Location.............................................................................................................................................................. 3

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

1.3.1 Steel base plate................................................................................................................................. 3

1.3.2 Further recommendations ................................................................................................................. 3

1.4 Ventilation........................................................................................................................................................... 4

1.5 Connections ....................................................................................................................................................... 5

1.5.1 Fuel supply ........................................................................................................................................ 5

1.5.2 Cooling .............................................................................................................................................. 7

1.5.3 Exhaust system ............................................................................................................................... 10

1.5.4 Digital Diesel Control system (12 Volt) ............................................................................................ 13

1.5.5 AC power system (120 - 240 Volt)................................................................................................... 16

2INSTALLATION SPECIFICATIONS.............................................................................................................................. 18

2.1 Installation table ............................................................................................................................................... 18

2.2 Commission table............................................................................................................................................. 19

2.3 Installation specifications Whisper 6, 8 and 11 – 3600RPM............................................................................. 20

2.4 Specification of the accessories ....................................................................................................................... 20

2.5 Installation materials Whisper 6/8/11................................................................................................................ 21

3DIAGRAMS & DRAWINGS ........................................................................................................................................... 25

3.1 DC wiring diagram............................................................................................................................................ 25

3.2 Wiring codes and colours ................................................................................................................................. 26

3.3 Diagram electronic governor Whisper 8 and 11 3600 rpm ............................................................................... 27

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

3.5 Remote control panel drawings ........................................................................................................................ 29

3.6 Dimensions Whisper 6, 8 and 11...................................................................................................................... 30

INSTALLATION

1 INSTALLATION

1.1 GENERAL

This installation manual is valid for the following models:

Part number Description

50902055 Whisper 6 / 120/240V 3600rpm

50902056 Whisper 6 / 120/240V 3600rpm –

ungrounded

50903055 Whisper 8 / 120/240V 3600rpm

50903056 Whisper 8 / 120/240V 3600rpm –

ungrounded

50604055 Whisper 11 / 120/240V 3600rpm

50604056 Whisper 11 / 120/240V 3600rpm –

ungrounded

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

To ensure reliability and durability of the equipment, it is

very important that the installation is carried out with the

utmost care and attention. To avoid problems, such as

temperature problems, noise levels, vibration, etc. the

instructions set out in this manual must be followed and all

installation work must be carried out professionally.

1.2 LOCATION

Since Whisper generating sets have extremely compact

dimensions, they can be installed in tight locations. Please

consider that even almost maintenance-free machinery

must still remain accessible.

When selecting the location area in which to mount the

generating set, make sure there is sufficient room to carry

out any maintenance work. The unit must be easily

accessible on the service side and on the distribution side

to have access to the V-belt

Please also note that in spite of the automatic oil pressure

sensor it is still essential that the oil level is checked

regularly.

1.3 INSTRUCTIONS FOR OPTIMAL SOUND

AND VIBRATION INSULATION

Position the generating set as low as possible in the

vessel. As the generating set is already secured to the

base frame by means of flexible engine mountings, the

frame can be mounted directly to the vessel’s main

structure.

1.3.1 Steel base plate

However to keep resonant vibrations at a minimum, it is

recommended to mount the generating set on a solid steel

base plate, approx. 3/4” (20 mm) weighing approx. 130Lbs

(60 kg) or 50% of the weight of the generating set. The

engine draws its inlet combustion air through several holes

in the capsule base. Therefore the capsule must be fitted

with sufficient clearance between the capsule underside

and the base plate. For the Whisper 6/8-3600rpm a steel

base plate is available from Mastervolt as an optional

accessory (ref. fig. 20, page 18)

1.3.2 Further recommendations

Whisper generating sets are standard equipped with a

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

canopy has been designed to give effective sound

insulation. For optimum sound and vibration dampening,

the following factors should be considered.

1 Avoid mounting the generating set in close proximity

to thin walls or floors that may cause resonance.

2 Sound dampening is extremely poor if the generating

set is mounted on a light weight flimsy surface such

as plywood which will only amplify vibrations. If

mounting on a thinner surface cannot be avoided, this

should at least be reinforced with stiffening struts or

ribbing. If possible, holes should be bored or cut

through the surface to help reduce the resonance.

Covering the surrounding walls and floors with a

heavy coating plus foam will certainly improve the

situation.

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

INSTALLATION

3 Never connect the base of the generating set directly

to bulkheads or tanks.

1.4 VENTILATION

The generating set normally draws air from the engine

room. Engine rooms with natural ventilation must have

vent openings of adequate size and location to enable the

generating set to operate without overheating. To allow an

ample supply of air within the temperature limits of the

generating set an opening of at least 16 sq inch (100 cm2)

is required.

A "sealed" engine compartment must have a good

extraction ventilator to maintain reasonable engine room

temperatures. High temperature of intake air reduces

engine performance and increases engine coolant

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

reduce the engine power by 1% for each 5°F of rise. To

minimise these effects the engine room temperature must

not be more than 27ºF (15 ºC) above the outside ambient

air temperature.

Apply a combination of ventilators, blowers and air intake

ducting to meet the temperature limit. The air inlet ducts

should run to the bottom of the engine room to clear fumes

from the bilge and to circulate fresh air. Air outlets should

be at the top of the engine room to remove the hottest air.

An engine room blower should be used as an extraction

ventilator to remove air from the engine room.

In cases where it is impossible to meet the above

mentioned temperature limit by using machine room

ventilation, connections are to be made for an air inlet

directly to the enclosure. With these connections the

generating set can be directly connected to an air duct.

Air inlets should be louvered, where appropriate, to protect

the engine room and to protect the generating set from

water spray. As an extra precaution, the fitting of a cowl

ventilator with a cover box located as high as possible, is

recommended.

EXHAUST (1)

40 mm REMOTE CABLE (2)

12x0,3 mm2

AC CABLE (3)

FUEL RETURN (6)

16 mm2

BATTERY - (7)

8 mm

FUEL IN (4)

8 mm

16 mm2

BATTERY + (5)

AIRVENT IN (10)

19 mm

AIRVENT OUT (9)

WATER IN (8)

19 mm

WHISPER 6/8

EXHAUST (1)

1 5/5” (40 mm)

AC CABLE (3)

REMOTE CABLE (2)

12xAWG22 (0.25mm2)

FUEL IN (4)

5/16” 8mm)

BATTERY + (5)

AWG2 (25mm²)

FUEL RETURN (6)

5/16” 8mm)

BATTERY – (7)

AWG2 (25mm²)

WATER IN (8)

3/4” (19mm)

AIRVENT OUT (9)

3/4” (19mm)

AIRVENT IN (10)

3/4” (19mm)

EXHAUST (1)

1 5/5” (40 mm)

REMOTE CABLE (2)

12xAWG22 (0.25mm2)

AC CABLE (3)

FUEL IN (4)

5/16” 8mm)

BATTERY + (5)

AWG2 (25mm²)

FUEL RETURN (6)

5/16” 8mm)

BATTERY – (7)

AWG2

(

25mm²

)

AIRVENT IN (8)

3/4” (19mm)

AIRVENT OUT (9)

3/4” (19mm)

WATER IN (10)

3/4” (19mm)

Figure 2

Whisper 6 and 8

Whisper 11

INSTALLATION

1.5 CONNECTIONS

The generating set comes supplied with all supply lines

and output cable (i.e. electric cables, cooling water

connections, exhaust, fuel lines etc.) already connected to

the engine and generator. The supply lines are fed through

the capsule’s front base. The connections are marked as

shown in fig. 2.

All electrical connections, cable types and sizes must

comply with the appropriate national regulations. Supplied

cables are rated for ambient temperatures up to 158ºF

(70°C). If the cables are required to meet higher

temperature requirements, they must be run through

conduits.

ATTENTION!

Before working (installation) on the system

read the section safety instructions

1.5.1 Fuel supply

1 FUEL TANK

Fuel tanks should be made of appropriate material such as

(stainless) steel or plastic. Steel tanks should not be

galvanised or painted inside. Condensation can occur in

metal tanks when temperature changes. Therefore, water

accumulates at the bottom of the tank and provisions

should be made for the drainage of this water.

The tank will need a filling connection, a return connection

and an air ventilation connection which will require

protection against water entry.

Some official regulations do not allow connection points at

the base of the fuel tank; in this instance connections are

to be made at the top of the tank with internal tubing down

to a few cm above the bottom of the tank.

2 FUEL LIFT PUMP

The generating set itself is equipped with a fuel lift pump;

therefore the tank can be installed at a lower level than the

generating set. The maximum suction height is 3ft (1m).

If the pump has to lift the fuel higher than 3ft (1m) an

external fuel lift pump must be installed. The control board

is already prepared to connect an extra fuel pump.

3 FUEL PIPES

When the tank is above the generating set (figure 3)`we

recommend ending the return line on the top of the tank .

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

return line cannot overflow because of siphoning. One will

only need a fuel cock in the fuel supply line.

When the tank is below the generating set (figure 4) we

recommend ending the return line on the bottom of the

tank (A) below the inlet of the supply line to discharge

under the lowest fuel level. This prevents air getting into

the fuel line. Here also one needs a fuel cock only in the

supply line

Both supply and return fuel pipe lines should be

appropriate material and 5/16” (8 mm) outer diameter

tubing. The quality of the tubing of fuel pipes could be

submitted to local regulations depending on the application

of the vessel.

The fuel pipes can be plumbed to the flexible hoses which

are on the generating set and have a connection to fit to

5/16” (8 mm) pipe. This fuel lines fulfils CE standards and

are according to ISO 7840 A2.

It is important to avoid bends in the pipes, as they could

trap air bubbles. The return pipe should never be

connected to the suction pipe. Other consumers of diesel

fuel, such as the propulsion engine and heaters, have to

be connected to separate suction and return pipes.

4 FUEL FILTERS

A fine fuel filter is installed which requires maintenance.

Mastervolt advises to install an extra fuel filter/ water fuel

separator near the fuel tank.

Before starting your generating set for the first time follow

the fuel system bleeding procedure in the users manual.

INSTALLATION

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

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

1 Fuel return;

2 Fuel supply;

3 Prefilter / water separator (optional);

5 Fuel tank;

pp y

1 Fuel return;

2 Fuel supply;

3 Prefilter / water separator (optional);

4 Extra fuel lift pump (optional);

5 Fuel tank;

INSTALLATION

1.5.2 Cooling

Intercooling is based on a raw water pump, heat

exchanger and water-injected exhaust. Cooling liquid in

the internal cooling system is cooled in a heatexchanger

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

water is warmed up in the heatexchanger it is dumped

overboard by injecting it in the exhaust.

The generating set should have its own sea water (coolant

water) inlet and should not be connected to any other

engine systems. A properly installed cooling system is

critical to keep engine temperatures within an acceptable

range. Ensure that the installation complies to the

following installation instructions.

1 THE INTERNAL COOLING SYSTEM

The internal cooling system should be filled with cooling

liquid. (Refer to the users manual 2.5.12) When the engine

becomes hot the liquid expands and the system is

pressurised. After the pressure becomes too 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 hose is made of heat resistant

plastic and is not sensitive for kinks.

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

lower part of the canopy close to the place where the tank

is mounted.

See figure 5. The tank has to be placed close to the

generator. When it is mounted above the top of the

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

on the manifold is taken off. When keel cooling or radiator

cooling is applied the system will not be pressurised. A

Afb. 4a.

Fig 5.

1 Water level 5 Air vent;

2 Water/exhaust separator 6 Water strainer;

3 Seacock 7 Seacock.

4 Waterlock

Fig. 6.

MAX. 10CM (4")

MIN. 60CM (24")

MAX. 150CM (60")

MIN. 3CM (1,2")

5CM (2")

INSTALLATION

cap without release valve should be applied. Refer to the

special manual for these applications.

2 RAW WATER SUPPLY

For raw water supply the following installation materials

are required: -a skin fitting - a sea cock - a water strainer -

hoses and clamps. In order to keep the suction resistance

in the line at a minimum, the sea water intake system (i.e.

sea cock, tru-hull fitting, inlet filter, etc.) must have the

following inner diameter at least

Model Minimum inner diameter

Whisper 6 – 3600 rpm 3/4" (19 mm)

Whisper 8 – 3600 rpm 3/4" (19 mm)

Whisper 11 – 3600 rpm 3/4" (19 mm)

The suction hose should be kept as short as possible.

Raw water plumbing should avoid bends as much as

possible.

Restriction of raw water flow, caused by kinked hoses,

undersized pipes or connections, will reduce the engine

cooling capability. This is the main cause for overheating

of an engine.

After running the generating set for the first time, check the

coolant flow rate using a stopwatch and by holding a pail

of a known volume under the wet-exhaust outlet. The flow

rate should be according to the data in the users manual

3 INSTALLATION OF THROUGH HULL FITTING

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

an integrated strainer (water scoop). For 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!

Fig. 7 Installing 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.

Use a sealant when mounting the skin fitting.

4 WATER STRAINER

Use an appropriate water strainer with connections of the

following dimensions:

Model Inner dimensions

Whisper 6 – 3600 rpm 3/4" (19 mm)

Whisper 8 – 3600 rpm 3/4" (19 mm)

Whisper 11 – 3600 rpm 3/4" (19 mm)

Install the water strainer in a well accessible position,

(refer to fig. 6-6) 5 cm above the waterline.

SAILING DIRECTION

FLOW DIRECTION

INSTALLATION

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 happening, the generating set is

designed to accommodate a siphon breaker (air vent). In

the standard delivery the connections are bypassed.

Hoses with the following inner diameter should be used:

Model Inner dimensions

Whisper 6 – 3600 rpm 3/4" (19 mm)

Whisper 8 – 3600 rpm 3/4" (19 mm)

Whisper 11 – 3600 rpm 3/4" (19 mm)

If the generating set cannot be mounted such that the

bottom of the generating set is placed above the waterline,

an air vent must be installed.

Extend the water hose of the by-pass 24” (60 cm) above

waterline and install an air vent. Ideally, the air vent should

be mounted above the yacht keel center line (i.e. to

minimize the influence of swaying on the water intake).

The hose of the drain should go downwards. Water must

flow out freely and air has to flow in freely as well.

Fast motorboats will lay deeper when sailing at large

speed and can cause pressure on the waterinlet. This

should be avoided to prevent fleeding the engine.

If the air vent is clogged the water hoses will

not be vented when the generating set has

stopped and water can be forced into the

engine. This leads to immediate engine

problems and eventually severe damage!

DAMAGE CAUSED BY THE INGRESS OF WATER IN

THE ENGINE IS NOT COVERED BY WARRANTEE

On the valve is a little hose to drain a little water that could

be spilled from the valve. This hose should go down and

may not end under water, because it should ventilate air

into the valve to break the siphoning (figure 8).

OPEN

Fig 8: Wrong siphon breaker hose routing

Check the air vent at regular intervals. Open, clean and

lubricate the valve as required.

OPEN

Fig. 9 Mastervolt siphon breaker

INSTALLATION

1.5.3 Exhaust system

Water is injected in the exhaust system of the generating

set. In this way the cooling water that has passed the heat

exchanger is mixed with the exhaust gases. Temperature

and volume of the gases are thereby reduced

considerably, so that a rubber exhaust hose can be used

and the level of noise is reduced as well.

1 STANDARD EXHAUST SYSTEM INSTALLATION

The generating set exhaust system must remain

completely independent and separate from the exhaust

system of any other engine on board. A water lock

prevents the generating set from being flooded by cooling

water and should be installed as close to the generating

set as possible. The lock must be large enough to hold the

entire water volume held in the hose from the top of the

goose neck to the water lock. The water lock must be

installed at the lowest point of the exhaust system (ref. to

fig. 10-1). The exhaust hose must have an inner diameter

of 1 5/8” (40mm), no less, no more. The exhaust system

must be installed so that the back pressure inside the

exhaust does not exceed 1psi (2 inches mercury, 27

inches – 70 cm watercolumn) and total length from the

genearot to the top of the goose neck or or

water/separator does not exceed 10ft (3m). (Refer to

paragraph 5.4.3 of the users manual).

The exhaust hose descends from the capsule to the water

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

through-hull exhaust outlet, situated minimum 2" (5 cm)

above the water line (ref. to fig. 10-5.) The "goose neck"

must be vertical and situated preferable along the ship’s

keel center line. If the generating set is mounted less than

24" (60 cm) 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.

1 Exhaust water lock; 4 Goose neck;

2 Exhaust outlet muffler; 5 Through-hull exhaust outlet Ø 1 5/8” (40mm);

Fig 10 3 Exhaust line Ø 1 5/8” (40mm) 6 Water level.

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

Minimum 60cm (24")

Maximum 150cm (60")

5 cm (2")

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