Mastervolt whisper 12 ultra User Manual

Marine diesel generating set 230/400v-50 hz

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Page 1 USERS MANUAL WHISPER 12 ULTRA - Three phase - 1500 RPM - Marine diesel generating set 230/400V-50 Hz Digital Diesel Control MASTERVOLT Snijdersbergweg 93, 1105 AN Amsterdam The Netherlands Tel.: +31-20-3422100 Fax.: +31-20-6971006 V5. December 2008 www.mastervolt.com...
Page 2: Table Of Contents
Wiring codes and colours ........................ 16 2.5.16 Lay out control wiring........................17 2.5.17 Electrical diagrams AC connections (alternator models with 6 wires) ..........18 Copyright © 2008 Mastervolt / December 2008 / WHISPER 12 ULTRA - Three Phase / EN...
Page 3 Adjusting valve clearance and retightening the cylinder head bolts..........37 5.4.3 Measuring exhaust backpressure....................38 5.4.4 Disassembling instructions ......................38 SPARE PARTS LIST ..............................40 MAINTENANCE LOG ................................42 EN / WHISPER 12 ULTRA - Three Phase / December 2008 / Copyright © 2008 Mastervolt...
Page 5: Liability
If any problem arises which could be subject of guarantee, procedures should be followed as described in the guarantee conditions, unauthorised repairs could lead to further damage and violate the guarantee conditions. EN / WHISPER 12 ULTRA - Three Phase / December 2008 / Copyright © 2008 Mastervolt...
Page 6: Identification Plate
When calculating a load one should always take into account the power factor or cos phi of this load. The power should never exceed the Copyright © 2008 Mastervolt / December 2008 / WHISPER 12 ULTRA - Three Phase / EN...
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 © 2008 Mastervolt / December 2008 / WHISPER 12 ULTRA - Three Phase / EN...
Page 9: Transport, Lifting And Storage
Accessories included in the standard delivery • Expansion tank, hose and fittings • Special hose connector for measuring exhaust back pressure (refer to paragraph 5.4.3) EN / WHISPER 12 ULTRA - Three Phase / December 2008 / Copyright © 2008 Mastervolt...
Page 10: Components
Cooling water injection bend Rubber engine mounting Starter motor solenoid Starter motor Heat exchanger Fig. 4: Rear view main components Whisper 12 Ultra – Three phase. Copyright © 2008 Mastervolt / December 2008 / WHISPER 12 ULTRA - Three Phase / EN...
Page 11 Filler cap engine coolant Rocker cover Filler cap engine oil Temperature switch coolant Thermostat housing Fig. 6: Top View main components Whisper12 Ultra – Three phase EN / WHISPER 12 ULTRA - Three Phase / December 2008 / Copyright © 2008 Mastervolt...
Page 12: Generator Control Panel
Fig. 9: Digital Diesel remote control panel It is not possible to take off the full power from the Whisper 12 ULTRA Three Phase by reconnecting the alternator to Copyright © 2008 Mastervolt / December 2008 / WHISPER 12 ULTRA - Three Phase / EN...
Page 14: Fuel Specification
• Minimum at idle 98kPa (1 kgf/cm² - 14psi) (1 bar). • Normal at 1500 rpm ±350kPa (3.5 kgf/cm² - 50 psi) (3.5 bar). Copyright © 2008 Mastervolt / December 2008 / WHISPER 12 ULTRA - Three Phase / EN...
Page 15: Technical Data
Digital remote panel (+15 m cable), fuel filter, fuel lift pump, user and installation manuals Optional: Installation kits, mobile (vehicle) version, non earth return (ungrounded), spare part kits, PTO to drive a hydraulic pump EN / WHISPER 12 ULTRA - Three Phase / December 2008 / Copyright © 2008 Mastervolt...
Page 16: Wiring Codes And Colours
DDC > generator AC output AC3 brown 1 mm2 DDC > generator AC output AC3 blue 1 mm2 DDC=Digital Diesel Control Unit LCP=Local Control Panel Copyright © 2008 Mastervolt / December 2008 / WHISPER 12 ULTRA - Three Phase / EN...
Page 17: Lay Out Control Wiring
INFORMATION 2.5.16 Lay out control wiring Fig 12: Electrical Diagram control wiring Whisper 12Ultra – three phase EN / WHISPER 12 ULTRA - Three Phase / December 2008 / Copyright © 2008 Mastervolt...
Page 18: Electrical Diagrams Ac Connections (Alternator Models With 6 Wires)
Only valid for alternator models with 6 wires Fig 13a: Electrical Diagram 230 / 400 V AC / 50 Hz three phase (Star configuration) Copyright © 2008 Mastervolt / December 2008 / WHISPER 12 ULTRA - Three Phase / EN...
Page 19 INFORMATION Only valid for alternator models with 6 wires Fig 13b: Electrical Diagram 230 V AC / 50 Hz three phase (Delta configuration) EN / WHISPER 12 ULTRA - Three Phase / December 2008 / Copyright © 2008 Mastervolt...
Page 20: Electrical Diagrams Ac Connections (Alternator Models With 12 Wires)
Only valid for alternator models with 12 wires Fig 14a: Electrical Diagram 230 / 400 V AC / 50 Hz three phase (Star configuration) Copyright © 2008 Mastervolt / December 2008 / WHISPER 12 ULTRA - Three Phase / EN...
Page 21 INFORMATION Only valid for alternator models with 12 wires Fig 14b: Optional configuration modes of the AC wiring for alternator models with 12 wires EN / WHISPER 12 ULTRA - Three Phase / December 2008 / Copyright © 2008 Mastervolt...
Page 22: Diagram Electronic Governor
Refer to our website for the correct manual.) The actuator controls the engine speed. This actuator replaces the standard hold solenoid that is on all other Fig 15: Diagram electronic governer Copyright © 2008 Mastervolt / December 2008 / WHISPER 12 ULTRA - Three Phase / EN...
Page 23: Operation
Therefore we recommend daily oil-checks. Check oil level prior to starting the engine or at least 5 minutes after the engine has stopped. EN / WHISPER 12 ULTRA - Three Phase / December 2008 / Copyright © 2008 Mastervolt...
Page 24 "OFF" position be able to recognise the coolant flowing through the system by listening for the noise of the water which is expelled. Copyright © 2008 Mastervolt / December 2008 / WHISPER 12 ULTRA - Three Phase / EN...
Page 26: Maintenance
The arrow on the filter housing indicates the direction of the flow. A clogged filter results in a lack of output of the generating set. Copyright © 2008 Mastervolt / December 2008 / WHISPER 12 ULTRA - Three Phase / EN...
Page 27: Replacing Oil Filter
A smeer of oil has to be put on the seal of the filter before Fig. 20 fitting the filter. The filter should be fastened manually: when the rubber touches the metal turn 3/4 further. Fig. 19 EN / WHISPER 12 ULTRA - Three Phase / December 2008 / Copyright © 2008 Mastervolt...
Page 28: Regular Maintenance
PTO driven impeller pump through the cooler elements in the generator housing. All parts of the cooling Copyright © 2008 Mastervolt / December 2008 / WHISPER 12 ULTRA - Three Phase / EN...
Page 29: Maintenance Schedule
Check lubricating oil pressure 2000 hours Check injector and injection pressure 2000 hours Check inlet air filter 2000 hours Check cooling system 2000 hours EN / WHISPER 12 ULTRA - Three Phase / December 2008 / Copyright © 2008 Mastervolt...
Page 30: Trouble Shooting
Phase has six diodes in the rotor. Generator output voltage too • Engine is not reaching the rated RPM. Refer to special procedures to readjust RPM. Copyright © 2008 Mastervolt / December 2008 / WHISPER 12 ULTRA - Three Phase / EN...
Page 31 "soft-start". Inquire at your nearest Mastervolt dealer or directly at the manufacturer, Mastervolt in the Netherlands. EN / WHISPER 12 ULTRA - Three Phase / December 2008 / Copyright © 2008 Mastervolt...
Page 32: Engine Faults
Inspect battery terminals and cables for a good (battery too weak). electrical connection (inspect against corrosion, tattered wires, etc.) • To thick engine lubricating oil. Change oil for a lower viscosity. Copyright © 2008 Mastervolt / December 2008 / WHISPER 12 ULTRA - Three Phase / EN...
Page 33 Reduce the electrical load (switch off some consumers). • Defective generator (windings, Generator must be sent to manufacturer for repair of damaged bearing or winding. bearings or other) EN / WHISPER 12 ULTRA - Three Phase / December 2008 / Copyright © 2008 Mastervolt...
Page 34 When any doubt, measure the power directly with an appropriate instrument. • Overfull oil sump. Bring the oil to the correct level • Choked fuel filter. Replace the fuel filter. Copyright © 2008 Mastervolt / December 2008 / WHISPER 12 ULTRA - Three Phase / EN...
Page 35: Warnings
If the bottom speed is set at too low a frequency the generator may be damaged. On the other hand, too high a frequency can cause voltage drops with high load. EN / WHISPER 12 ULTRA - Three Phase / December 2008 / Copyright © 2008 Mastervolt...
Page 36: Residual Voltage Check / Excitation Procedure (Flashing)
In case of faulty diodes replace the rectifier unit. One can get access to the diode unit by taking off the backend cover of the alternator. Copyright © 2008 Mastervolt / December 2008 / WHISPER 12 ULTRA - Three Phase / EN...
Page 37: Meggering
Tightening torque cylinder head bolt: 88 ± 5 Nm Rocker stay tightening torque: 14.7 ± 2 Nm FRONT MOTOR Figure 26: Cylinder head bolts EN / WHISPER 12 ULTRA - Three Phase / December 2008 / Copyright © 2008 Mastervolt...
Page 38: Measuring Exhaust Backpressure
Test the generating set first outside its soundshield and check very carefully for leakages before putting it back in its enclosure. Copyright © 2008 Mastervolt / December 2008 / WHISPER 12 ULTRA - Three Phase / EN...
Page 40: Spare Parts List
Nozzle injector, 4pcs (**) 50206045 Thermostat (**) 50206038 Gasket thermostat (**) 50206034 Gasket rocker cover (**) More extensive parts list on the internet: MASTERVOLT.COM (fast moving parts) Copyright © 2008 Mastervolt / December 2008 / WHISPER 12 ULTRA - Three Phase / EN...
Page 42: Maintenance Log
MAINTENANCE LOG MAINTENANCE LOG first service after 50 hours: hour counter: remarks next service (every 150 hours) hour counter: Copyright © 2008 Mastervolt / December 2008 / WHISPER 12 ULTRA - Three Phase / EN...
Page 44 Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands Tel : + 31-20-3422100 Fax : + 31-20-6971006 Email : info@mastervolt.com...

Mastervolt whisper 12 ultra User Manual

1 Introduction

2 Information

3 Operation

4 Maintenance

5 Trouble Shooting

6 Spare Parts List

Maintenance Log

Quick Links

Troubleshooting

Need help?

Questions and answers

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