Mastervolt WHISPER 6 ULTRA User Manual

Marine diesel generating set 230v / 50hz digital diesel control

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Installation manual (48 pages)

User manual (36 pages)

Installation manual (36 pages)

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Summary of Contents for Mastervolt WHISPER 6 ULTRA

Page 1 USERS MANUAL WHISPER 6 ULTRA - 1500 RPM - Marine diesel generating set 230V / 50Hz Digital Diesel Control MASTERVOLT Snijdersbergweg 93, 1105 AN Amsterdam The Netherlands Tel.: +31-20-3422100 Fax.: +31-20-6971006 V5 December 2009 www.mastervolt.com...
Page 2: Table Of Contents
2.5.11 Oil information ..........................13 2.5.12 Cooling liquid........................... 13 2.5.13 Technical data ..........................14 2.5.14 Wiring codes and colours ........................ 15 2.5.15 Lay out control wiring........................16 Copyright © 2009 Mastervolt / December 2009 / WHISPER 6 ULTRA / EN...
Page 3 Adjusting valve clearance and retightening the cylinder head bolts..........32 5.4.3 Measuring exhaust backpressure....................32 5.4.4 Disassembling instructions ......................33 SPARE PARTS LIST ..............................34 MAINTENANCE LOG ................................36 EN / WHISPER 6 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
Page 4: Introduction
Sometimes the seal of the raw water pump starts leaking. life. Mostly this begins with a little drip and slowly gets worse. Regular visual inspection of the generator is necessary to Copyright © 2009 Mastervolt / December 2009 / WHISPER 6 ULTRA / EN...
Page 6: Identification Plate
When this number is available the manufacturer can trace the specifications of the generating set. On the identification plate are also some basic features of the set: Copyright © 2009 Mastervolt / December 2009 / WHISPER 6 ULTRA / EN...
Page 7: Information
Warning signs indicate parts which could be battery, proper fitting of the cooling system and fuel pipes live. etc. Refer to the installation manual. EN / WHISPER 6 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
Page 8: Operation
When exposed to abnormal high temperatures in • Keep a fire extinguisher on hand. excess of 400°C an extremely corrosive acid is produced which cannot be removed from the Copyright © 2009 Mastervolt / December 2009 / WHISPER 6 ULTRA / EN...
Page 9: Transport, Lifting And Storage
2.3.4 Accessories included in the standard delivery • Expansion tank, hose and fittings • Special hose connector for measuring exhaust backpressure (refer to paragraph 5.4.3) EN / WHISPER 6 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
Page 10: Components
Injection pump air bleeding screw Engine speed adjustment screw Fuel solenoid Raw water pump Fuel lift pump Engine oil filter Fig. 4: Front view main components Whisper 6Ultra. Copyright © 2009 Mastervolt / December 2009 / WHISPER 6 ULTRA / EN...
Page 11 Bypass cooling water out Bypass cooling water in Generator Exhaust hose Ø40mm AC power output Remote control Engine air intake Fig. 6: Rear View main components Whisper 6Ultra EN / WHISPER 6 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
Page 12: Generator Control Panel
This current is rectified to charge the battery. The voltage Stop button is regulated at ±14.4V. Display Select button Set button Fig. 9: Digital Diesel remote control panel Copyright © 2009 Mastervolt / December 2009 / WHISPER 6 ULTRA / EN...
Page 13: Alarms And Shut Down
One can fill the engine via the filling cap on the exhaust manifold. Fill up till the level is just below the filling cap. When the EN / WHISPER 6 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
Page 14: Technical Data
Digital remote panel (+15 m cable), fuel filter, fuel lift pump, user and installation manuals Optional mobile Installation kits, mobile (vehicle) version, non earth return (ungrounded), spare part kits Copyright © 2009 Mastervolt / December 2009 / WHISPER 6 ULTRA / EN...
Page 15: Wiring Codes And Colours
DDC > LCP red/green 1,5 mm2 DDC > generator AC output brown 1 mm2 DDC > generator AC output blue 1 mm2 DDC=Digital Diesel Control Unit LCP=Local Control Panel EN / WHISPER 6 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
Page 16: Lay Out Control Wiring
INFORMATION 2.5.15 Lay out control wiring Fig 10: Electrical Diagram control wiring Whisper 6 Ultra Copyright © 2009 Mastervolt / December 2009 / WHISPER 6 ULTRA / EN...
Page 17: Electrical Diagram 230 V Ac / 50 Hz
INFORMATION 2.5.16 Electrical diagram 230 V AC / 50 Hz Figure 11: Electrical diagram 230 V AC / 50 Hz : EN / WHISPER 6 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
Page 19: Operation
Switch on battery switch (when installed). Fuel valve: open. Starting: Push the start button to initiate the full automatic starting procedure. You can monitor the procedure on the display. EN / WHISPER 6 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
Page 20: Extended Operating Instructions
A restart protection prevents starting the engine when it is already running, which could cause damage. Copyright © 2009 Mastervolt / December 2009 / WHISPER 6 ULTRA / EN...
Page 22: Maintenance
(so not on the remote Fig. 15 panel) Hold as long as necessary to bleed the system. Retighten the bleed screw when no further air bubbles are expelled. Copyright © 2009 Mastervolt / December 2009 / WHISPER 6 ULTRA / EN...
Page 23: Readjustment V-Beltplacing Oil Filter
Turn the blades in the direction of rotation of the pump i.e. anti clockwise looking at the impeller. Minimum oil level Maximum oil level Fig. 18: EN / WHISPER 6 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
Page 25: Putting Out Of Service
Drain the water from the water lock. Repeat steps 2, 3, and 4, every 6 months. Change oil Crank the engine having the raw water inlet sucking before using the engine again. EN / WHISPER 6 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
Page 26: Trouble Shooting
Check the diode in the rotor and replace (refer to special procedures). Generator output voltage too • Generator is overloaded. Switch off a load; (part off) consumers. Copyright © 2009 Mastervolt / December 2009 / WHISPER 6 ULTRA / EN...
Page 27: Engine Faults
Generator AC output voltage is either too high or too low AC VOLTAGE Generator is in overload HIGH CURRENT Output frequency of the generator is too low FREQUENCY EN / WHISPER 6 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
Page 28: Trouble Shooting Table
• Choked exhaust system, exhaust Check the exhaust hose blocked, rubber exhaust hose kinked. • Air in the fuel pipes Bleed air from fuel system (refer to maintenance section). Copyright © 2009 Mastervolt / December 2009 / WHISPER 6 ULTRA / EN...
Page 29 • Blocked air or fuel filter. • Loss of compression by wear out or Repair by Mastervolt service. damage. • V-belt broken or loose. Readjust or replace V-belt EN / WHISPER 6 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
Page 30: Warnings
● Motor RPM suddenly rises or drops. ● Unusual noise comes from generating set. ● Exhaust gases suddenly colour dark. ● Engine failure warning light is on Copyright © 2009 Mastervolt / December 2009 / WHISPER 6 ULTRA / EN...
Page 31: Special Procedures Alternator
A healthy diode will indicate a very high resistance (infinity) in the reverse direction, and EN / WHISPER 6 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
Page 32: Adjusting Valve Clearance And Retightening The Cylinder Head Bolts
If the rocker arms move piston no.1 is on the T.D.C. of the intake or exhaust stroke. In such case turn the crankshaft Copyright © 2009 Mastervolt / December 2009 / WHISPER 6 ULTRA / EN...
Page 33: Disassembling Instructions
One can take off the complete alternator housing. Before the alternator can be taken off all cables and wiring have to be loosened first. Figure 25: exploded view sound shield Whisper 6 Ultra EN / WHISPER 6 ULTRA / December 2009 / Copyright © 2009 Mastervolt...
Page 34: Spare Parts List
Fuel pump (high pressure) complete (***) 50203045 Thermostat (**) 50203038 Gasket thermostat (**) 50204037 Gasket rocker cover (**) More extensive parts list on the internet: MASTERVOLT.COM (fast moving parts) Copyright © 2009 Mastervolt / December 2009 / WHISPER 6 ULTRA / EN...
Page 36: Maintenance Log
MAINTENANCE LOG MAINTENANCE LOG first service after 50 hours: hour counter: remarks next service (every 150 hours) hour counter: Copyright © 2009 Mastervolt / December 2009 / WHISPER 6 ULTRA / EN...
Page 40 Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands Tel : + 31-20-3422100 Fax : + 31-20-6971006 Email : info@mastervolt.com...

Mastervolt WHISPER 6 ULTRA User Manual

1 Introduction

2 Information

3 Operation

4 Maintenance

5 Trouble Shooting

6 Spare Parts List

Maintenance Log