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Summary of Contents for Mastervolt WHISPER 9,5 ULTRA
- Page 1 USERS MANUAL U.S.A. EDITION WHISPER 9,5 / 12,5 ULTRA -1800 RPM- Marine diesel generating set 120/240V-60 Hz Digital Diesel Control MASTERVOLT Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel.: +31-20-3422100 V1. September 2004 Fax: +31-20-6971006 www.mastervolt.com...
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Page 2: Table Of Contents
CONTENTS This manual applies to the Mastervolt Whisper 9,5 / 12,5 ULTRA marine generating set controlled by Digital Diesel Control. First launched in September 2004. CONTENTS INTRODUCTION ..............4 General . - Page 3 CONTENTS 2.5.13 Technical data ..............12 2.5.14 Wiring, codes and colours .
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Page 4: Introduction
When one find serious damage after weeks of neglect warrantee claims will not be honoured. GUARANTEE Mastervolt guarantees that this generating set has been Example 4: Neglect built according to good workmanship, according to the Whisper generators have an option for an auto start/stop specifications in this manual and according to European mode or interval mode. -
Page 5: Liability
INTRODUCTION Warranty means that faulty parts are repaired or replaced by additional measures. Mastervolt does not accept liabi- free of charge. If necessary the whole generator unit will lity for damage due to use of the generator, possible errors be exchanged. Labour necessary to complete repairs on in the manuals and the results thereof. -
Page 6: Information
INFORMATION 2 POWER 6 WEIGHT shows the net dry weight (approximately) in The nameplate gives the nominal maximum load in kg. This is without fuel, oil, cooling liquid, packing and kVA = kW calculated with the indicated power factor external installation equipment. one. -
Page 7: Installation
INFORMATION used in the U.S.A. This installation is beyond the • Always consult the manual before executing influence of Mastervolt and Mastervolt cannot held maintenance. responsible for any consequence as a result of the installation. • Do not change the settings without consulting the In all situations the transfer switches manufacturer. -
Page 8: Transport Lifting And Storage
INFORMATION THE WHISPER 15 ULTRA acid is produced which cannot be removed from the skin. If signs of decomposition are evident, or if in doubt, always wear disposable heavy duty 2.3.1 Features gloves. This generating set includes a diesel engine which is connected by close coupling to an alternator in a sound TRANSPORT, LIFTING AND STORAGE attenuated capsule. -
Page 9: Components
INFORMATION COMPONENTS 33 32 30 31 29 24 7 15 19 14 8 27 16 9 18 36 2.4.1 Main components to identify 1 Air inlet; 2 Starter motor; 3 Battery connection ( negative); 4 Battery connection ( positive); 5 AC 120/240V wiring; 6 AC 120/240V output connection box;... -
Page 10: Remote Control Panel
(sea) water are made of seawater resistant material like naval brass and gunmetal. The engine has been specially adapted for the Mastervolt application and is very different from the standard engine as supplied for industrial applications! The engine fullfills EPA emission standards and is certified and labeled as such. -
Page 11: Battery Charger
INFORMATION 2.5.4 Battery charger 2.5.9 Load indicator On the engine is an alternator generating 40 Amp 12V. On the remote control the load will be indicated on the This current is rectified to charge the battery. The display and by the LED-bar. The load is measured by a voltage is regulated at 14.2V. -
Page 12: Cooling Liquid
3,07 x 3,62 inches (78x92 mm) Combustion air consumption 46 cf/m (1,3 m3/min.) Continuous power 60Hz Whisper 9,5 ULTRA 9,5 kW; Whisper 12,5 ULTRA 12,5 kW Cooling system indirect cooling by raw water, 4,8 - 6 US gpmin (18-22 l/min.) Cooling water pump... -
Page 13: Wiring Codes And Colours
INFORMATION 2.5.14 Wiring codes and colours AWG (American Wire Gauge) Cable code number colour cross section battery > starter motor 25 mm2 starter motor > DCC 6 mm2 starter motor > LCP 2,5 mm2 battery > ground black 25 mm2 ground >... -
Page 14: Lay Out Control Pcb
INFORMATION 2.5.14 Lay out control PCB PUMP REGULATOR START/STOP RED (PULL) BLUE (COM.) WHITE (HOLD) Fig. 6: Lay out control PCB. May 2004 / WHISPER 15 ULTRA / USA... -
Page 15: Electrical Diagram 120-240V 60Hz
INFORMATION 2.5.15 Electrical diagram 120-240V 60Hz STATOR EXCITATION CAPACITOR WINDING CURRENT TRANSFORMER EARTH AND NEUTRAL CONNECTED BLACK (11) (11) 120-240V 60Hz DCC/ct-1 MAIN WINDING ROTOR BROWN YELLOW/GREEN BLUE BLACK MAIN WINDING DCC/AC-1 DCC/AC-2 CURRENT TRANSFORMER YELLOW/GREEN BLACK (22) (22) DCC/ct-2 EARTH AND NEUTRAL NOT CONNECTED CURRENT CURRENT... -
Page 16: Diagram Electronic Governor (Optional)
INFORMATION 2.5.17 Diagram electronic governor Whisper 10 ULTRA Fig. 9: May 2004 / WHISPER 15 ULTRA / USA... -
Page 17: Operation
OPERATION OPERATION GENERAL In operation checks: The generating set is operational after full installation and 1 Check for abnormal noise or vibration filling up with: fuel, engine lubricating oil and cooling li- 2 Check the voltage quid, filling the starter battery with acid, and connecting 3 Check sea water flow at exhaust outlet the battery to earth and connecting the digital remote 4 Power source selector switch (off/shore power/gene-... - Page 18 OPERATION 2 Check sea water cocks. Do not forget the valve of the system by listening for the noise of the water which is water outlet in case of a water/exhaust gas separator. expelled. 3 Check the water strainer. 4 Check for leakage’s. Be aware that especially in harbours the 5 Regularly check the siphon vent in the cooling water coolant water inlet can easily be blocked...
- Page 19 OPERATION disconnect the battery with the engine stopped and all switches in "OFF" position. Stopping the generating set: 1 Avoid stopping of the generator abruptly after a long period of operation at high load! Doing so, you avoid unnecessary thermal load to your generating set! Act as follows: Prior to switching off the generating set, decrease the generator load (i.e.
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Page 20: Maintenance And Care
MAINTENANCE MAINTENANCE ALTERNATOR The alternator does not require any maintenance. Perio- dic inspection and cleaning is recommended, depending on environmental conditions. However when the alternator has been idle for a long period attention to winding condition is recommended. The condition of windings can be assessed by measure- ment of insulation resistance to earth. -
Page 21: Readjusting V-Belt
MAINTENANCE A smeer of oil has to be put on the seal of the filter before CHECK DAILY: fitting the filter. The filter should be fastened manually: • Level cooling liquid. when the rubber touches the metal turn 3/4 further. •... -
Page 22: Maintenance Schedule
MAINTENANCE EVERY 300 HOURS: Check oil level daily • Replace the impeller of the raw water pump. Check water strainer daily • Check valve clearance. Check the level of the cooling liquid daily • Replace the oil filter. Retighten cylinderheadbolts , change oil, replace oil filter •... -
Page 23: Trouble Shooting
Check capacitors specification and replace if capacitors. necessary. • Presence of a strong capacative load Compensate for this capacity and seek for experts (leading power factor). advice.(MASTERVOLT customers service). • Defective voltageregulator Replace voltage regulator USA / WHISPER 15 ULTRA / May 2004... -
Page 24: Engine Malfunctions
"soft-start". Inquire at your nearest Mastervolt dealer or directly at the manufacturer, Mastervolt in the Netherlands. ENGINE FAULTS water injected exhaust. When the water Remove 3 Amp. - Page 25 Water has entered the exhaust port or backpressure is too high. (refer to paragraph 5.4.3) Contact Mastervolt service department for advice. • Blocked injector. Have the injector tested and cleaned if necessary.
- Page 26 Generator must be sent to manufacturer for repair or other). of damaged bearing or winding. • Damaged engine. Repair by Mastervolt service. Faulty Digital Diesel Control or sto solenoid. Engine does not stop • Fuel solenoid is not switching off.
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Page 27: Warnings
If you cannot correct a problem with the aid of the mal- rotating rectifier diode should be tested and a winding re- function table, contact your Mastervolt Service Centre or sistant test should be executed. Mastervolt Amsterdam for an extended service list, tel: INT +31-20-3422100. -
Page 28: Windings Resistance Values
TROUBLE SHOOTING and a low resistance in the forward direction. A faulty Under no circumstances the RPM under full load should diode will give a full deflection reading in both directions be below 1770 RPM = 59 Hz. When no cause can be with the test meter on the 10,000 ohms scale, or an found for a wrong speed, the setting can be adjusted: infinity reading in both directions. -
Page 29: Measuring Exhaust By Backpressure
TROUBLE SHOOTING If the rocker arms move piston no.1 is on the T.D.C. of Following instructions will help: the intake or exhaust stroke. In such case turn the 1 The design of the Whisper 15 makes it possible to do crankshaft 360°... -
Page 30: Spare Parts List
Fuel lift pump (***) 50205120 V-belt (*) 50203121 Oilfilter (*) 50201450 Raw water pump complete Mastervolt type M12 (***) (refer to fig. 22) 50209011 Impeller + gasket (*) (4,3,5) 50201401 Cover type M12 (**) (2) 50209018 Bolts cover (**) (1) (6 pcs.) 50201851 Pump repair kit A consisting of: Shaft (13), Bearings (2 pcs) (10), O-ring (9), Seals (2 pcs.) (8),... - Page 31 SPARES 10 11 Fig. 21: Water pump type M. 12 Spare parts water pump type M. 12, article no 50201450: description article no screw cover, 6x 50209018 cover type M12, 1x 50201401 screw impeller, 1x refer to impeller Impeller (1x), including screw (3) 50209013 Gasket, 1x 50209012...
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Page 32: Maintenance Log
MAINTENANCE LOG first service after 50 hours: hour counter: remarks: next service (every 150 hours) hour counter: remarks: May 2004 / WHISPER 15 ULTRA / USA... -
Page 33: Notes
NOTES USA / WHISPER 15 ULTRA / May 2004... - Page 34 NOTES May 2004 / WHISPER 15 ULTRA / USA...
- Page 35 NOTES USA / WHISPER 15 ULTRA / May 2004...
- Page 36 MASTERVOLT Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands Tel.: +31-20-3422100 / Fax: +31-20-6971006 www.mastervolt.com / info@mastervolt.com May 2004 / WHISPER 15 ULTRA / USA...
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