Mastervolt WHISPER 6 Installation Manual
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Mastervolt WHISPER 6 Installation Manual

Mastervolt WHISPER 6 Installation Manual

Mobile diesel generating set 230v-50hz
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INSTALLATION MANUAL FOR MOBILE APPLICATIONS
6/8/10/12/16 ULTRA
Mobile diesel generating set 230V-50Hz
MASTERVOLT
Snijdersbergweg 93
1105 AN Amsterdam
The Netherlands
Tel.: +31-20-3422100
Fax: +31-20-6971006
http://www.mastervolt.com
WHISPER 6 / 12
-3000 RPM-
-1500 RPM-
Digital Diesel Control
V2. November 2004

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  • Page 1 INSTALLATION MANUAL FOR MOBILE APPLICATIONS WHISPER 6 / 12 -3000 RPM- 6/8/10/12/16 ULTRA -1500 RPM- Mobile diesel generating set 230V-50Hz Digital Diesel Control MASTERVOLT Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel.: +31-20-3422100 Fax: +31-20-6971006 V2. November 2004 http://www.mastervolt.com...

  • Page 2: Table Of Contents

    4.6.2 Whisper 6/12/ 6 ULTRA dimensions ........

  • Page 3: Introduction

    5° to 12° down. The The exhaust is of the dry type and includes a stainless returning “cold” coolant therefore has a minimum flexible bellow and high quality mufflers. temperature of 75° Celsius. November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN...

  • Page 4: Installation

    . A heavy base plate is available as an set, make sure there is sufficient room to carry out any optional installation kit for Whisper 6/3000 rpm. (ref. fig. maintenance work. The unit must be easily accessible on 27, item 62).

  • Page 5: Further Recommendations

    Before working (installation) on the system read the section safety instructions. WHISPER 6/3000RPM Fig. 5. WHISPER 6 ULTRA / 12-3000 RPM Fig. 6 November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN...

  • Page 6: Fuel Supply

    Using Fig. 9. Fuel line assembly with vertical mounted pump and fuel lift pump mounted in an angle. EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004...
  • Page 7 The pump makes clicking noises and therefore could > 1m 1 Fuel return; 2 Fuel supply; 3 Prefilter / water separator (optional); 4 Extra fuel lift pump (optional); Fig. 11. 5 Fuel tank; November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN...

  • Page 8: Radiator Cooling

    The fuel pipes can be plumbed to the flexible hoses which are on the generating set and have a connec- tion to fit to 8 mm pipe. The fuel lines Mastervolt supplies are according to ISO 7840 A2. No bent of piping above the radiator It is important to avoid bends in the pipes, as they could trap air bubbles.
  • Page 9 7 litres and an alarm for low coolant level expansion tanks should be mounted a little higher. that can be supplied as an option. (refer to figure 15). (refer to figure 17 detail B). November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN...
  • Page 10 An other capacity of the radiators. Refer to figure.19 disadvantage is that the piping has to go through the roof EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004...

  • Page 11: Dry Exhaust System

    When a dry exhaust has its outlet on the roof, all the these factors into account. pipes inside the vehicle has to be insulated. The exhaust pipes will be very hot and all accessible pipes mufflers dangerous to people when not insulated. November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN...

  • Page 12: Electric Installation 12 Volt

    DC supply EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004...

  • Page 13: Ac Power System 230 Volt

    Special attention has to for voltage reduction. be paid on dividing the system in branches which are fused individually. Wire colors should comply with AC standards. It is absolutely essential that each and every November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN...
  • Page 14 3 Cable Mastervolt Masterswitch. For the power cable in single phase installations we recommend the use of flexible 3 wire oil resistant cable with a sufficient cross sectional area. One wire EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004...

  • Page 15: Installation Specifications

    W 8 ULTRA: 1 kW, 230V 50 HZ W 12 ULTRA: 12 kW, 230V 50 Hz power factor cos phi =1 W 10 ULTRA: 1 kW, 230V 50 HZ W 16 ULTRA: 16 kW, 230V 50Hz Battery charging alternator including regulator (50 Amps) November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN...

  • Page 16: Installation Materials

    INSTALLATION SPECIFICATIONS 3.2 INSTALLATION MATERIALS Fig. 27. EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004...
  • Page 17 Bolt hexagonal socket ZP M10x25 50211447 Washer spring SP M10 50211410 Washer SP M10 large outer diameter 50230217 Rubber dampening kit up to 250kg Whisper 6-12/6-8-10 Ultra article no description 50230552 Rubber mounting up to 70 kg 50211449 Washer spring SP M12...
  • Page 18 INSTALLATION SPECIFICATIONS Fig. 28. EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004...
  • Page 19 Bracket expansion tank for 50230531 50230531 Expansion tank 20 mm 50230532 Cap tank 0502 30531 50201872 Radiator cooling kit alternator 12VDC Whisper 6/6 ULTRA 50201868 Radiator cooling kit alternator 24VDC Whisper 6/6 ULTRA November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN...
  • Page 20 Cap tank 0502 30531 50220011 “Hose vacum SAE100R4 (3/4”) 19x31,5mm 50221532 Hose clamp stainless mini 9-11 50201871 Radiator cooling kit engine 12VDC Whisper 6/6 Ultra 50201880 Radiator cooling kit engine 24VDC Whisper 6/6 Ultra EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004...

  • Page 21: Diagrams And Drawings

    Expansion tank 20 mm 50230532 Cap tank 0502 30531 50220011 “Hose vacum SAE100R4 (3/4”) 19x31,5mm 50221532 Hose clamp stainless mini 9-11 Optional 50230535 Expansion tank 7L + low level alarm switsch November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN...

  • Page 22: Layout Dc Control System

    & DIAGRAMS DRAWINGS DIAGRAMS END DRAWINGS 4.1.1 Lay out generator control with 230VAC fan Whisper 6/ 12/ 6-8-10 Ultra BLACK (11) ct-1 ct-1 RED (11) ct-2 ct-2 RED/GREEN 1 (16) str. BLUE 1 (7) BLUE/GREEN 1 (8) PURPLE 1 (6) ORANGE 1,5 (19) alt.
  • Page 23 & DIAGRAMS DRAWINGS 4.1.2 Lay out generator control with 12VDC fan Whisper 6/ 12/ 6 Ultra 3xPUMP OUTPUT REGULATOR START/STOP RED (PULL) BLUE (COM.) WHITE (HOLD) Fig. 30. November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN...
  • Page 24 & DIAGRAMS DRAWINGS 4.1.3 Lay out generator control with 24VDC fan Whisper 6/ 12/ 6 Ultra 3xPUMP OUTPUT REGULATOR START/STOP RED (PULL) BLUE (COM.) WHITE (HOLD) Fig. 31. EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004...
  • Page 25 & DIAGRAMS DRAWINGS 4.1.4 Lay out generator control with 230VAC fan Whisper 12 Ultra 3xPUMP OUTPUT REGULATOR START/STOP RED (PULL) BLUE (COM.) WHITE (HOLD) Fig. 32. November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN...
  • Page 26 & DIAGRAMS DRAWINGS 4.1.5 Lay out generator control with 230VAC fan Whisper 16 Ultra PUMP REGULATOR START/STOP WHITE (PULL) BLACK (COMM.) RED (HOLD) Fig. 33. EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004...
  • Page 27 80-70∞C 45-35∞C THERMOSTAT COOLER RADIATOR COOLER ENGINE ALTERNATOR ENGINE ALTERNATOR TERMINAL BLOCK JUCTION BOX AIR FANS CU0,75 CU2,5 CU0,75 CU0,75 CU2.5 FUSE 20/40A 80-70∞C 45-35∞C DIMENTION BOX: 160x160x90 MM Fig. 34. November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN...
  • Page 28 6,3A 6,3A CU0,75 CU1,5 CU1,5 CU0,75 CU0,75 CU1.5 CU1.5 DIMENTION BOX: 360x200x150 MM 45-35C POWER SUPPLY 230 VAC MAIN 80-70C 230VAC 230VAC CIRCUIT BREAKER GENERATOR CIRCUIT BREAKER AIRFAN AIRFAN Fig. 35. EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004...
  • Page 29 1,5 mm2 DCC > LCP red/green 1,5 mm2 DCC > generator AC output brown 1 mm2 DCC > generator AC output blue 1 mm2 DDC=Digital Diesel Control Unit LCP=Local Control Panel November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN...

  • Page 30: Codes And Colors

    1,5 mm2 DCC > LCP red/green 1,5 mm2 DCC > generator AC output brown 1 mm2 DCC > generator AC output blue 1 mm2 DDC=Digital Diesel Control Unit LCP=Local Control Panel EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004...

  • Page 31: Diagram Electronic Governov (W 10 Ultra)

    BLACK (4) YELLOW/GREEN RED (3) BLUE MAIN WINDING DCC/AC-1 BLACK (4) YELLOW/GREEN EARTH AND NEUTRAL CONNECTED CURRENT TRANSFORMER BLACK (11) (11) 230V 50Hz DCC/ct-1 BROWN YELLOW/GREEN BLUE DCC/AC-1 YELLOW/GREEN Fig. 36. November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN...

  • Page 32: Ac Wiring Diagram Whisper 230V 50Hz

    TO LOCAL CONTROL PANEL TWISTED PAIR WIRE VBAT(11) PUMP OUTPUT (J24) GND(9) GND(16) MAGNETIC PICKUP TWISTED PAIR SHIELDED WIRE WHITE RPM+(16) BLACK RPM-(8) PROPORTIONAL ACTUATOR TWISTED PAIR WIRE WHITE TAC+(10) WHITE TAC-(1) Fig. 37. EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004...
  • Page 33 & DIAGRAMS DRAWINGS 4.6.1 WHISPER DDC REMOTE PANEL DRAWINGS The remote panel comes in a carton that can be used as a template to drill the mounting hole. Fig. 38. November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN...

  • Page 34: Whisper 6-12/6 Ultra Dimensions

    Fig. 40. CONNECTIONS WHISPER 6/6 ULTRA 12: • exhaust Whisper 6: 1” • exhaust Whisper 6 ULTRA 12 / 3000 RPM 1 1/2” • fuel hose: 8 mm • radiator alternator: 19 mm / 3/4” • radiator engine Whisper 6/6 ULTRA: 25 mm / 1”...
  • Page 35 • weight 290 kg • weight Whisper 16 ULTRA 420 kg BOX DIMENSIONS WHISPER 12 ULTRA: • length 1060 mm • width 615 mm • height 690 mm • weight 320 kg November 2004 / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / EN...
  • Page 36 MASTERVOLT Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands Tel.: +31-20-3422100 / Fax: +31-20-6971006 www.mastervolt.com / info@mastervolt.com EN / MOBILE WHISPER 6/12-6/8/10/12/16 ULTRA / November 2004...

This manual is also suitable for:

Whisper 12Whisper 12 ultraWhisper 16 ultraWhisper 6 ultraWhisper 8 ultraWhisper 10 ultra

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