Mastervolt whisper 20 ultra User Manual
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Mastervolt whisper 20 ultra User Manual

Mastervolt whisper 20 ultra User Manual

Marine diesel generating set 120/208v / 60hz
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USERS MANUAL U.S.A EDITION
WHISPER 20 ULTRA
- Three phase - 1800 RPM -
Marine diesel generating set 120/208V / 60Hz
Digital Diesel Control
MASTERVOLT
Snijdersbergweg 93,
1105 AN Amsterdam
The Netherlands
Tel.: +31-20-3422100
Fax.: +31-20-6971006
V4. November 2008
www.mastervolt.com

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  • Page 1 USERS MANUAL U.S.A EDITION WHISPER 20 ULTRA - Three phase - 1800 RPM - Marine diesel generating set 120/208V / 60Hz Digital Diesel Control MASTERVOLT Snijdersbergweg 93, 1105 AN Amsterdam The Netherlands Tel.: +31-20-3422100 Fax.: +31-20-6971006 V4. November 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 Overview of AC terminal modes Whisper 20 Ultra Three phase ............. 18 Copyright © 2008 Mastervolt / November 2008 / WHISPER 20 ULTRA Three phase / US...
  • Page 3 Adjusting valve clearance and retightening the cylinder head bolts..........35 5.4.3 Measuring exhaust backpressure....................36 5.4.4 Disassembling instructions ......................36 SPARE PARTS LIST ..............................38 MAINTENANCE LOG ................................40 US / WHISPER 20 ULTRA - Three Phase / November 2008 / Copyright © 2008 Mastervolt...

  • Page 4: Introduction

    The ultimate responsibility will injury or loss of life. always be with the owner to ensure a safe and compliant installation. If in doubt ask! Copyright © 2008 Mastervolt / November 2008 / WHISPER 20 ULTRA Three phase / US...

  • Page 5: Liability

    The cost for returning faulty goods is not covered under guarantee. US / WHISPER 20 ULTRA - Three Phase / November 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 / November 2008 / WHISPER 20 ULTRA Three phase / US...

  • Page 7: Information

    3 Amp fuse must be removed from the control panel and the battery plus cable must be removed from the battery. US / WHISPER 20 ULTRA - Three Phase / November 2008 / Copyright © 2008 Mastervolt...

  • Page 8: Operation

    When exposed to abnormal high temperatures in • Keep a fire extinguisher on hand. excess of 750°F (400°C) an extremely corrosive acid is produced which cannot be removed from Copyright © 2008 Mastervolt / November 2008 / WHISPER 20 ULTRA Three phase / US...

  • 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) US / WHISPER 20 ULTRA - Three Phase / November 2008 / Copyright © 2008 Mastervolt...

  • Page 10: Components

    Rocker cover Filler cap engine coolant Temperature switch coolant Engine oil pressure switch Engine serial number Fig. 4: Rear view main components Whisper 20 Ultra. Copyright © 2008 Mastervolt / November 2008 / WHISPER 20 ULTRA Three phase / US...
  • Page 11 Fuel bleeding screw Starter motor solenoid Starter motor Fuel lift pump for manual priming Fuel injection pump Fig. 6: Front view main components Whisper 20 Ultra US / WHISPER 20 ULTRA - Three Phase / November 2008 / Copyright © 2008 Mastervolt...

  • Page 12: Generator Control Panel

    Generator load indicator Failure LED Start button Stop button Display Select button Set button Fig. 9: Digital Diesel remote control panel Fig. 10 Automatic Voltage Regulator (AVR). Copyright © 2008 Mastervolt / November 2008 / WHISPER 20 ULTRA Three phase / US...

  • Page 13: Engine

    Further technical data on the design of the alternator can Refer to the operating of the Digital Diesel Control be found in drawings and diagrams in this manual US / WHISPER 20 ULTRA - Three Phase / November 2008 / Copyright © 2008 Mastervolt...

  • Page 14: Control

    Refer to the manual on keel cooling and radiator cooling. Copyright © 2008 Mastervolt / November 2008 / WHISPER 20 ULTRA Three phase / US...

  • Page 15: Technical Data

    Digital remote panel (+45 feet (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 US / WHISPER 20 ULTRA - Three Phase / November 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 / November 2008 / WHISPER 20 ULTRA Three phase / US...

  • Page 17: Lay Out Control Wiring

    INFORMATION 2.5.16 Lay out control wiring Fig 12: Electrical Diagram control wiring Whisper 20 Ultra Three Phase US / WHISPER 20 ULTRA - Three Phase / November 2008 / Copyright © 2008 Mastervolt...

  • Page 18: Overview Of Ac Terminal Modes Whisper 20 Ultra Three Phase

    INFORMATION 2.5.17 Overview of AC terminal modes Whisper 20 Ultra Three phase Fig. 13 Terminal modes Whisper 20U Three phase Copyright © 2008 Mastervolt / November 2008 / WHISPER 20 ULTRA Three phase / US...

  • Page 19: Electrical Diagram 120 / 208 V Ac / 60 Hz Three Phase (Star Configuration)

    2.5.18 Electrical diagram 120 / 208 V AC / 60 Hz three phase (star configuration) Fig 14. AC wiring diagram three phase 3 x 120/208 Volt with AVR (Double Star) US / WHISPER 20 ULTRA - Three Phase / November 2008 / Copyright © 2008 Mastervolt...

  • Page 20: Ac Wiring Diagram Split-Phase 120 - 240Volt / 60Hz With Avr (Double Delta)

    2.5.19 AC wiring diagram Split-Phase 120 – 240Volt / 60Hz with AVR (DOUBLE DELTA) Figure 15: AC wiring diagram Split-Phase 120 – 240Volt / 60Hz with AVR (DOUBLE DELTA) Copyright © 2008 Mastervolt / November 2008 / WHISPER 20 ULTRA Three phase / US...

  • Page 21: 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. US / WHISPER 20 ULTRA - Three Phase / November 2008 / Copyright © 2008 Mastervolt...
  • Page 22 "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 / November 2008 / WHISPER 20 ULTRA Three phase / US...
  • Page 23 If the engine is not running and ‘failure’ and ‘charging’ LED is blinking, reset by stop button, otherwise it will drain the start battery US / WHISPER 20 ULTRA - Three Phase / November 2008 / Copyright © 2008 Mastervolt...

  • Page 24: Maintenance

    When the engine is in cold condition both valves (inlet and outlet) should have a clearance between 0.25 mm. The adjustment has to be done at TDC (refer to § 5.4.2). Copyright © 2008 Mastervolt / November 2008 / WHISPER 20 ULTRA Three phase / US...

  • Page 25: Replacing Fuel Filter

    A smeer of oil has to be put on the seal of the filter before fitting the filter. The filter should be fastened manually: when the rubber touches the metal turn 3/4 further. Fig. 19 US / WHISPER 20 ULTRA - Three Phase / November 2008 / Copyright © 2008 Mastervolt...

  • Page 26: Regular Maintenance

    PTO driven impeller pump through the cooler elements in the generator housing. All parts of the cooling system are of corrosion free and seawater Copyright © 2008 Mastervolt / November 2008 / WHISPER 20 ULTRA Three phase / US...

  • Page 27: 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 US / WHISPER 20 ULTRA - Three Phase / November 2008 / Copyright © 2008 Mastervolt...

  • Page 28: Trouble Shooting

    • Rotor diode(s) broken. Check the diodes in the rotor (refer to special procedures). The Whisper 20 ULTRA Three Phase has six diodes in the rotor.. Copyright © 2008 Mastervolt / November 2008 / WHISPER 20 ULTRA Three phase / US...
  • Page 29 "soft-start". Inquire at your nearest Mastervolt dealer or directly at the manufacturer, Mastervolt in the Netherlands. US / WHISPER 20 ULTRA - Three Phase / November 2008 / Copyright © 2008 Mastervolt...

  • Page 30: 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 / November 2008 / WHISPER 20 ULTRA Three phase / US...
  • Page 31 Faulty Digital Diesel Control unit. Stop the command • Loss of control engine manually by the stop handle. Check wire connections to fuel solenoid. Check solenoid function. Replace if necessary US / WHISPER 20 ULTRA - Three Phase / November 2008 / Copyright © 2008 Mastervolt...
  • Page 32 • Injector blocked. Have the injector checked. • Loss of compression, sticking or Have the compression measured. damaged piston ring. Clean or replace the rings. Copyright © 2008 Mastervolt / November 2008 / WHISPER 20 ULTRA Three phase / US...

  • Page 33: Warnings

    Another trimmer “ST” allows to adapt the regulator to the generator parameters. The regulator has been built to suppress the voltage surges on releasing the load that are below 20% at nominal load. US / WHISPER 20 ULTRA - Three Phase / November 2008 / Copyright © 2008 Mastervolt...

  • Page 34: 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 / November 2008 / WHISPER 20 ULTRA Three phase / US...

  • Page 35: Special Procedures Engine

    It is very important to identify the correct setting assembly (refer to fig. 25). The screw is to be locked in position with the lock-nut. Fig. 27 Finding TDC US / WHISPER 20 ULTRA - Three Phase / November 2008 / Copyright © 2008 Mastervolt...

  • Page 36: Measuring Exhaust Backpressure

    The water column should be no more than 27 inches (69 cm.) of water (1 PSI - 0,07 bar) Copyright © 2008 Mastervolt / November 2008 / WHISPER 20 ULTRA Three phase / US...
  • Page 37 TROUBLE SHOOTING Figure 29: exploded view sound shield Whisper 20 Ultra Three Phase US / WHISPER 20 ULTRA - Three Phase / November 2008 / Copyright © 2008 Mastervolt...

  • Page 38: 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 / November 2008 / WHISPER 20 ULTRA Three phase / US...
  • Page 39 SPARE PARTS LIST Figure 30: Raw water pump complete Mastervolt type M16 US / WHISPER 20 ULTRA - Three Phase / November 2008 / Copyright © 2008 Mastervolt...

  • Page 40: Maintenance Log

    MAINTENANCE LOG MAINTENANCE LOG first service after 50 hours: hour counter: remarks next service (every 150 hours) hour counter: Copyright © 2008 Mastervolt / November 2008 / WHISPER 20 ULTRA Three phase / US...
  • Page 41 NOTES NOTES US / WHISPER 20 ULTRA - Three Phase / November 2008 / Copyright © 2008 Mastervolt...
  • Page 42 NOTES NOTES Copyright © 2008 Mastervolt / November 2008 / WHISPER 20 ULTRA Three phase / US...
  • Page 43 NOTES NOTES US / WHISPER 20 ULTRA - Three Phase / November 2008 / Copyright © 2008 Mastervolt...
  • Page 44 Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands Tel : + 31-20-3422100 Fax : + 31-20-6971006 Email : info@mastervolt.com...

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