Mastervolt WHISPER 20 ULTRA User Manual
Marine diesel generating set 120/240v-60 hz
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- Page 1 USERS MANUAL U.S.A. EDITION WHISPER 20 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. April 2004 Fax: +31-20-6971006 www.mastervolt.com...
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Page 2: Table Of Contents
The Whisper 20 ULTRA generating set ........ - Page 3 ..............33 USA / WHISPER 20 ULTRA / May 2003...
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Page 4: Introduction
INTRODUCTION 1 INTRODUCTION The Whisper 20 ULTRA Marine Diesel Generating set is During production and prior to delivery, all of our genera- manufactured and marketed by Mastervolt. ting sets are tested and inspected. It is important to read this manual before installing and operating the generating set. -
Page 5: Liability
1150 x 680 x 750 mm WxDxH LIABILITY WEIGHT 926 lbs 420 kg Mastervolt does not accept responsibility for damage, /EPA injuries or casualties which are the result of operation of Fig. 1: Nameplate. USA / WHISPER 20 ULTRA / May 2003... -
Page 6: Information
Warning signs indicate parts which could or loss of life. be live. May 2003 / WHISPER 20 ULTRA / USA... -
Page 7: Earth Insulation Failures
• Keep a fire extinguisher on hand. External moving parts like fans and V-belts are covered by the canopy and therefore the Whisper 20 ULTRA is • Poor electrical connections or using wiring which very safe, when the canopy is closed is not suited for the rated currents can cause overheating and possibly fire. -
Page 8: Transport Lifting And Storage
Expansion tank, hose and fittings alternator maintenance paragraph for procedures) • Special hoseconnector for measuring exhaust back pressure (Refer to paragraph 5.4.3) • While the battery is stored it should be recharge every 12 weeks. April 2004 / WHISPER 20 ULTRA / USA... -
Page 9: Components
40 Drain plug coolant; 41 Fail safe; 42 Oil filter; 43 V-belt; 44 Rubbervibricationmounting 4x; 45 Boiler connection; 46 PTO hydropump; 47 Digital Diesel Control unit. Fig. 2: Overview Whisper 20 ULTRA. USA / WHISPER 20 ULTRA / April 2004... -
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
2.5.9 Load indicator On the remote control the load will be indicated on the display and by the LEDbar. The load is measured by current transformers on the alternator. USA / WHISPER 20 ULTRA / May 2003... -
Page 12: Cooling Liquid
The engine is cooled by cooling liquid. The capacity of water with anti freeze the right mixture has to be cal- this system of the Whisper 20 ULTRA is 7,6 US qts (7,2 culated according to the information of the supplier of the anti freeze. -
Page 13: Wiring Codes And Colours
1 mm2 DCC > generator AC output blue 1 mm2 DCC > generator AC output brown 1 mm2 DCC > generator AC output blue 1 mm2 DDC=Digital Diesel Control Unit LCP=Local Control Panel USA / WHISPER 20 ULTRA / May 2003... -
Page 14: Lay Out Control
INFORMATION 2.5.15 Lay out control PCB PUMP REGULATOR START/STOP WHITE (PULL) BLACK (COMM.) RED (HOLD) Fig. 7: Lay out control PCB. April 2004 / WHISPER 20 ULTRA / USA... -
Page 15: Electrical Diagram 120/240V 60Hz
YELLOW/GREEN BLACK (22) (22) BLACK (22) (22) DCC/ct-2 DCC/ct-2 EARTH AND NEUTRAL CONNECTED CURRENT 120V 60Hz TRANSFORMER BROWN BLACK (11) (11) DCC/ct-1 YELLOW/GREEN BLUE DCC/AC-1 CURRENT TRANSFORMER YELLOW/GREEN BLACK (22) (22) DCC/ct-2 USA / WHISPER 20 ULTRA / April 2004... -
Page 16: Diagram Electronic Governor (Optional)
INFORMATION 2.5.17 Diagram electronic governor (optional) Fig. 9: April 2004 / WHISPER 20 ULTRA / USA... -
Page 17: 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. USA / WHISPER 20 ULTRA / April 2004... - Page 18 1 Avoid stopping of the generator abruptly after a long be able to recognise the coolant flowing through the period of operation at high load! Doing so, you avoid April 2004 / WHISPER 20 ULTRA / USA...
- Page 19 Masterswitch is installed, this is done automatically. If the engine is not running and failure and charging LED is blinking, reset by stop but- ton, otherwise it will drain the start battery. USA / WHISPER 20 ULTRA / April 2004...
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Page 20: Maintenance And Care
Retighten the bleed screw Fig. 12. when no further air bubbles are expelled. Retighten the cap when ready. April 2004 / WHISPER 20 ULTRA / USA... -
Page 21: Readjusting V-Belt
Install the new impeller and add some grease. Turn the blades in the direction of rotation of the pump. 1 Max. oil level; 2 Min. oil level. Fig. 15. USA / WHISPER 20 ULTRA / April 2004... -
Page 22: Maintenance Schedule
8 Protect the generating set against the influences of bad weather conditions. This way of preservation will be sufficient for 6 months. Repeat step 2, 3, and 4, every 6 months. Change oil before using the engine again. April 2004 / WHISPER 20 ULTRA / USA... -
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 20 ULTRA / April 2004... -
Page 24: Engine Malfunctions
Find out how the water did enter the cylinders (check the air vent). Take precautions to prevent it from happening again. When there is no mechanical malfunction the problem must be an electric malfunction. April 2004 / WHISPER 20 ULTRA / USA... - Page 25 Engine speed drops. • Too much oil. Drain oil to proper level. • Lack of fuel. Check fuel supply system: fuel pump and filter. • Lack of intake air. Check air intake. USA / WHISPER 20 ULTRA / April 2004...
- Page 26 • Insufficient intake air. Check intake air paths and filter, clean and • Choked air filter. replace if necessary. • Fuel injector faulty. Replace injector. • Valve clearance incorrect. Readjust valve clearance. April 2004 / WHISPER 20 ULTRA / USA...
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Page 27: Warnings
The diode in the rotor can be checked with a multimeter. short circuit. This can be solved by charging the capa- When the diode is faulty, the alternator will not generate citor ("flashing") independently by a small 9 Volt battery. any voltage. USA / WHISPER 20 ULTRA / April 2004... -
Page 28: Windings Resistance Values
Therefore a no load setting should be First align the T.D.C. mark for the No. 1 cylinder. Confirm at + 1875 RPM = 62.5 Hz. that the valves do not move up or down when the April 2004 / WHISPER 20 ULTRA / USA... -
Page 29: Measuring Exhaust By Backpressure
9 Test the generating set first outside its capsule and water column should be no more than 27 inches (69 cm.) check very carefully for leakages before putting it of water (1 PSI - 0,07 bar) back in its enclosure. USA / WHISPER 20 ULTRA / April 2004... -
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 Ring pump M16 50206266 Pin shim pump M16 50206270 O-ring pump M16 50206263 Impeller kit pump M16 (8+14) 50206254 Repair kit A pump M16 (6+9+12+7+17+ 5+13+15+4+2+11+10) 50206257 Repair kit B pump M16 (7+17+5) 50206258 USA / WHISPER 20 ULTRA / April 2004...
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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: April 2004 / WHISPER 20 ULTRA / USA... -
Page 33: Notes
NOTES USA / WHISPER 20 ULTRA / April 2004... - Page 34 NOTES April 2004 / WHISPER 20 ULTRA / USA...
- Page 35 NOTES USA / WHISPER 20 ULTRA / May 2003...
- Page 36 MASTERVOLT Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands Tel.: +31-20-3422100 / Fax: +31-20-6971006 www.mastervolt.com / info@mastervolt.com April 2004 / WHISPER 20 ULTRA / USA...
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