Mastervolt WHISPER 25 ULTRA Bedienungsanleitung

INSTALLATION MANUAL

WHISPER 25 ULTRA

- 1500 RPM -

Marine diesel generating set 230/400V / 50Hz

Digital Diesel Control

MASTERVOLT

Snijdersbergweg 93,

1105 AN Amsterdam

The Netherlands

Tel.: +31-20-3422100

Fax.: +31-20-6971006

www.mastervolt.com V3. November 2008

Art.nr. 50200451

TABLE OF 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.

TABLE OF CONTENTS:

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

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

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

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

1.3.1 Further recommendations .................................................................................................................3

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

1.5 Connections .......................................................................................................................................................4

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 (230 / 400 Volt)................................................................................................... 16

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

2.1 General ............................................................................................................................................................ 18

2.2 Commission table............................................................................................................................................. 18

2.3 Installation specifications Whisper 25 ULTRA.................................................................................................. 19

2.4 Specifications of the accessories ..................................................................................................................... 19

2.5 Installation materials Whisper 25 ULTRA......................................................................................................... 20

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

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

3.2 Terminal modes Whisper 25 ultra 115V / 400V 50Hz....................................................................................... 26

3.3 AC wiring diagram Tri-Phase with AVR 230V / 400V 50Hz (Star)....................................................................27

3.4 AC wiring diagram Single Phase with AVR (Double Delta) .............................................................................. 28

3.5 Whisper remote panel ...................................................................................................................................... 29

3.6 Whisper 25 ULTRA dimensions and footprint................................................................................................... 30

INSTALLATION

1 INSTALLATION

1.1 General

This manual applies to the Mastervolt Whisper 25 ULTRA

Marine Diesel Generating set controlled by Digital Diesel

Control first launched in September 2005. This manual is

valid for the following models:

Part number Description

51101005 Whisper 25 Ultra 230 Volt Single phase

– 1500rpm / Marine

51101006 Whisper 25 Ultra 230 Volt Single phase

– 1500rpm / Marine -ungrounded

51101305 Whisper 25 Ultra 230 / 400 Volt 3 phase

– 1500rpm / Marine

51101306 Whisper 25 Ultra 230 / 400 Volt 3 phase

– 1500rpm / Marine -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. The generating set is already secured to the base

frame by means of flexible engine mountings. The base

frame can be mounted to the vessel’s main structure on a

second set of rubber mountings that is included in the

delivery. Use the included mounting template to determine

the mounting spots.

1.3.1 Further recommendations

Whisper generating sets are standard equipped with a

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 Most important is the structure on which the generator

is places to be stiff. See figure 1. Directly below the

rubber mountings the structure should be supported

vertically to the superstructure of the ship.

2 Avoid mounting the generating set in close proximity

to thin walls or floors that may cause resonance.

3 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 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.

4 Never connect the base of the generating set directly

to bulkheads or tanks.

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

INSTALLATION

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 a half square meter

(0,5 m2) is required.

A "sealed" engine compartment must have a good

extraction ventilator to maintain reasonable engine room

temperatures. High temperature of intake air reduces

engine performance and increases engine coolant

temperatures. Air temperatures above 40°C reduce the

engine power by 2% for each 5°C of rise. To minimise

these effects the engine room temperature must not be

more than 15ºC above the outside ambient air

temperature.

Apply a combination of ventilators, blowers and air intake

ducting to meet the temperature limit. The air inlet ducts

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

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

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

An engine room blower should be used as an extraction

ventilator to remove air from the engine room.

In cases where it is impossible to meet the above

mentioned temperature limit by using machine room

ventilation, connections are to be made for an air inlet

directly to the enclosure. With these connections the

generating set can be directly connected to an air duct.

Air inlets should be louvered, where appropriate, to protect

the engine room and to protect the generating set from

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

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

recommended.

1.5 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 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 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

01 Remote control 05 Bypass cooling water out Ø25.4mm 09 Fuel out Ø8mm

02 AC power output 06 Bypass cooling water in Ø25.4mm 10 Fuel in Ø8mm

03 Exhaust connection Ø63mm 07 Battery positive + 35mm2 11 Raw water inlet

04 Expansion tank 08 Battery negative - 35mm2 12 Rubber engine mounting

Fig. 2 Connections

INSTALLATION

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 1 m.

If the pump has to lift the fuel higher than one meter an

external electrical fuel lift pump must be installed. The

control board is already prepared to connect an extra fuel

pump.

3 FUEL PIPES

When the tank is above the generating set we recommend

ending the return line on the top of the tank.

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 (see figure 3).

When the tank is below the generating set we recommend

ending the return line on the bottom of the tank (A) below

the inlet of the supply line (see figure 4)

1 Fuel return

2 Fuel supply

3 Prefilter / Water separator (optional)

5 Fuel Tank

Fig. 3 Fuel supply

INSTALLATION

1 Fuel return

2 Fuel supply

3 Prefilter / Water separator (optional)

4 Extra fuel lift pump (optional)

5 Fuel tank

Fig. 4 Fuel supply

Both supply and return fuel pipe lines should be

appropriate material and 8 mm outer diameter tubing. The

quality of the tubing of fuel pipes could be submitted to

local regulations depending on the application of the

vessel.

The fuel pipes can be plumbed to the flexible hoses which

are on the generating set and have a connection to fit to 8

mm pipe. This fuel lines fulfils CE standards and are

according to ISO 7840 A2. It is important to avoid bends in

the pipes, as they could trap air bubbles. The return pipe

should never be connected to the suction pipe or to other

consumers of diesel fuel, such as the propulsion engine

and heaters 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

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 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.

The generating set should have its own sea water (coolant

water) inlet and should not be connected to any other

engine systems. A properly installed cooling system is

critical to keep engine temperatures within an acceptable

range. Ensure that the installation complies with the

following installation instructions.

1 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 in the canopy

MAX.

Fig. 5: 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 applied the

system will not be pressurised. A cap without release

valve should be applied. Refer to the special manual for

these applications.

Fig. 6. Internal cooling system

1 Water level;

2 Water/exhaust separator;

3 Seacock;

4 Waterlock;

5 Air vent;

6 Water strainer;

7 Seacock.

MIN. 60CM (24")

MAX. 150CM (60")

5 CM (2”)

MIN. 60CM (24")

INSTALLATION

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, trough-hull fitting, inlet filter, etc.) must have an

inner diameter of at least 25.4 mm diameter (1"). 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! (see figure

7).

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.

SAILING DIRECTION

FLOW DIRECTION

INSTALLATION

4 WATER STRAINER

Use an appropriate water strainer with connections of 25.4

mm (1"). Install the water strainer in a well accessible

position, 5 cm above the waterline (see fig. 6, ref. 6).

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). See

figure 2. In the standard delivery the connections are

bypassed. Hose of 25.4 mm (1") inner diameter should be

used.

If the generating set cannot be mounted such that the

bottom of the generating set is placed above the waterline,

an air vent must be installed.

Extend the water hose of the by-pass 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).

See figure 6, ref. 5.

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 GUARANTEE

OPEN

Fig 8: Wrong siphon breaker hose routing

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

be spilled from the valve. See figure 8. This hose should

go down and may not end under water, because it should

ventilate air into the valve to break the siphoning.

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

lubricate the valve as required.

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, ref. 1). The exhaust hose must have an inner

diameter of 63 mm (2½”). The exhaust system must be

installed so that the back pressure inside the exhaust does

not exceed 0.07 bar (1psi – 70 cm watercolumn) and total

length from the genearot to the top of the goose neck or or

water/separator does not exceed 3m (10 ft.). (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 50 mm

above the water line (see fig. 10, ref 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

60 cm (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.

1 Exhaust water lock;

2 Exhaust outlet muffler;

3 Exhaust line Ø 63 mm (2½”);

4 Goose neck

5 Through-hull exhaust outlet Ø 63 mm (2½”);

6 Water level.

Fig. 10. Exhaust system

Minimum 60cm (24")

Maximum 150cm (60")

5 cm (2")

Maximum length A-B =

3 meter (10 feet)

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