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- Page 1 USERS MANUAL WHISPER 16 ULTRA -1500 RPM- Marine diesel generating set 230V-50 Hz Digital Diesel Control MASTERVOLT Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel.: +31-20-3422100 V1. July 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 16 ULTRA marine generating set controlled by Digital Diesel Control. First launched in April 2004. For earlier models refer to other manuals available on our website: www.mastervolt.com CONTENTS INTRODUCTION ..............4 General . - Page 3 CONTENTS 2.5.14 Wiring, codes and colours ............13 2.5.15 Lay out control PCB .
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Page 4: Introduction
When one find serious damage after weeks of neglect GUARANTEE warrantee claims will not be honoured. Mastervolt guarantees that this generating set has been built according to good workmanship, according to the Example 4: Neglect specifications in this manual and according to European Whisper generators have an option for an auto start/stop Community safety regulations. -
Page 5: Liability
WEIGHT 420 kg by additional measures. Mastervolt does not accept liabi- lity for damage due to use of the generator, possible errors Fig. 1: Nameplate. in the manuals and the results thereof. -
Page 6: Information
INFORMATION The power should never exceed the nominal Power kg. This is without fuel, oil, cooling liquid, packing and in kW as shown on the nameplate. Power is rated at external installation equipment. an ambient temperature of 40°C and a seawater tem- perature of 25ºC. -
Page 7: Installation
Keep record of changing of the set- should switch both neutral and L1. Of tings in this manual. course this is the case when using a Mastervolt Masterswitch. 2.1.6 Fire and explosion 2.1.4 Installation Fuels can be flammable. Proper handling Whisper generating sets are not self contained and have limits the risk of fire and explosion. -
Page 8: Transport Lifting And Storage
INFORMATION come into contact with the injector spray as the connected by close coupling to an alternator in a sound fuel may enter the blood stream with fatal results. attenuated capsule. The set is mounted on a steel base frame and mounted securely on anti vibration mounting •... -
Page 9: Components
INFORMATION COMPONENTS 2.4.1 Main components to identify 19 14 18 1 Air inlet; 2 Starter motor; 3 Battery connection ( negative); 4 Battery connection ( positive); 5 AC 230V wiring; 6 AC 230V output connection box; 7 Fuel filter; 8 Fuel pipe inlet; 9 Fuel pipe return;... -
Page 10: Generator 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! 2.5.3 Digital Diesel Control system... -
Page 11: Battery Charger
INFORMATION 2.5.4 Battery charger 2.5.10 Fuel specification On the engine is an alternator generating 50 Amp 12V. The engine must only be used with diesel fuel oil which This current is rectified to charge the battery. The conforms the standards for use in modern diesel en- voltage is regulated at 14.2V. -
Page 12: Cooling Liquid
16 kW Cooling system indirect cooling by raw water, 20-25 l/min. Cooling water pump pto driven Mastervolt self priming impeller pump, type M16 Fuel lift pump engine mechanical pump, additional12V electric pump available upon request Starting battery (optional) 110 Ah12V... -
Page 13: Wiring Codes And Colours
INFORMATION 2.5.14 Wiring codes and colours Cable code number colour cross section battery > starter motor 35 mm2 starter motor > DCC 6 mm2 starter motor > LCP 2,5 mm2 battery > ground black 35 mm2 ground > LCP ground (GND) black 4 mm2 DDC >... -
Page 14: Lay Out Control Pcb
INFORMATION 2.5.15 Lay out control PCB PUMP REGULATOR START/STOP WHITE (PULL) BLACK (COMM.) RED (HOLD) Fig. 7: Lay out control PCB. July 2004 / WHISPER 16 ULTRA / EN... -
Page 15: Electrical Diagram 230V 50Hz
INFORMATION 2.5.16 Electrical diagram 230V 50Hz STATOR GREEN (1) EXCITATION CAPACITOR WINDING GREEN (2) CURRENT TRANSFORMER RED (3) EARTH AND NEUTRAL NOT CONNECTED BLACK (11) (11) 230V 50Hz DCC/ct-1 MAIN WINDING ROTOR BROWN BLACK (4) YELLOW/GREEN RED (3) BLUE MAIN WINDING DCC/AC-1 BLACK (4) YELLOW/GREEN... -
Page 16: Diagram Electronic Governor (Optional)
INFORMATION 2.5.17 Diagram electronic governor (optional) July 2004 / WHISPER 16 ULTRA / EN... -
Page 17: Operation
OPERATION OPERATION GENERAL The generating set is operational after full installation and In operation checks: filling up with: fuel, engine lubricating oil and cooling li- 1 Check for abnormal noise or vibration quid, filling the starter battery with acid, and connecting 2 Check the voltage the battery to earth and connecting the remote control 3 Check sea water flow at exhaust outlet... - Page 18 OPERATION Routine "pre-start" checks: for engine damage in pleasure craft. 1 Check engine oil level. Checks once the generator is in operation: The generator switches off in case of insufficient oil- pressure. Even when the oil level is too low the oil 1 Check for abnormal noise or vibration.
- Page 19 OPERATION Nevertheless, the Whisper is designed so as not to overheat, even under extreme conditions. Do not run the generator for very long periods at no load or at very low load. When this is necessary do load the generator at least one hour in 10 hours for minimum 570%.
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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 xCHECK DAILY: • Level cooling liquid. • Hoses for loose connections or deterioration. • Water inlet filter. AFTER FIRST 50 HOURS: Fig. 13. • Change oil and replace the oil filter. Have the engine run until it is on temperature and 4.2.6 stop it. -
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 cylinderhead bolts , 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 EN / WHISPER 16 ULTRA / July 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 enters the cylinders through the valves this 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 stop 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- 5.3.2 Testing rotary rectifier diode function table, contact your Mastervolt Service Centre or The diode in the rotor can be checked with a multimeter. Mastervolt Amsterdam for an extended service list, tel: When the diode is faulty, the alternator will not generate INT +31-20-3422100. -
Page 28: Windings Resistance Values
TROUBLE SHOOTING 5.3.3 Winding resistant values Under no circumstances the RPM under full load should If after establishing and correcting any fault on the be below 1470 RPM = 49 Hz. When no cause can be capacitor and diodes output is still low when separately found for a wrong speed, the setting can be adjusted: excited, then the main rotor, stator and exciter stator It is very important to identify the correct setting assem-... -
Page 29: Measuring Exhaust By Backpressure
TROUBLE SHOOTING If the rocker arms move piston no.1 is on the T.D.C. of possible to do most repairs on the spot. The the intake or exhaust stroke. In such case turn the heatexchanger is accessible and can be removed. crankshaft 360°... -
Page 30: Spare Parts List
Fuel filter (*) 50206120 V-belt (*) 50206121 Oilfilter (*) 50201350 Raw water pump complete Mastervolt type M16 (***) (refer to fig. 22) 50206254 Impeller + gasket (*) (8+14) 50206255 Cover type M16 (**) (10) 50209018 Bolts cover (**) (1) (6 pcs.) - Page 31 SPARES Fig. 21: Water pump type M16 Spare parts Raw water pump M16, article no 50201350: description article no Pump housing M16 50206261 Screw cam pump M16 50206265 Gasket washer pump M16 50206274 Cam pump M16 50206269 Seal pump M16 50206262 Shaft pump M16 50206267...
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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: July 2004 / WHISPER 16 ULTRA / EN... - Page 33 NOTES EN / WHISPER 16 ULTRA / July 2004...
- Page 34 NOTES July 2004 / WHISPER 16 ULTRA / EN...
- Page 35 NOTES EN / WHISPER 16 ULTRA / July 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 July 2004 / WHISPER 16 ULTRA / EN...
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