Mastervolt WHISPER 6 ULTRA Installation Manual
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Mastervolt WHISPER 6 ULTRA Installation Manual

Mastervolt WHISPER 6 ULTRA Installation Manual

Mobile diesel generating set 230v / 50hz
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INSTALLATION MANUAL FOR MOBILE APPLICATIONS
WHISPER
6 / 8 / 12 / 16 ULTRA
- 1500 RPM -
Mobile diesel generating set 230V / 50Hz
Digital Diesel Control
MASTERVOLT
Snijdersbergweg 93,
1105 AN Amsterdam
The Netherlands
Tel.: +31-20-3422100
Fax.: +31-20-6971006
V5. May 2009
www.mastervolt.com

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  • Page 1 INSTALLATION MANUAL FOR MOBILE APPLICATIONS WHISPER 6 / 8 / 12 / 16 ULTRA - 1500 RPM - Mobile diesel generating set 230V / 50Hz Digital Diesel Control MASTERVOLT Snijdersbergweg 93, 1105 AN Amsterdam The Netherlands Tel.: +31-20-3422100 Fax.: +31-20-6971006 V5.

  • Page 2: Table Of Contents

    Dimensions Whisper 6 Ultra ..........................44 4.13 Dimensions Whisper 8 Ultra ..........................45 4.14 Dimensions Whisper 12 Ultra ........................... 46 4.15 Dimensions Whisper 16 Ultra ........................... 47 Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...

  • Page 3: Introduction

    WARNING! Before working (installation) on the system read the section safety instructions in the user’s manual Figure 1: Typical vehicle application radiator side mounted EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 4: Why Two Radiators

    Therefore aircooled alternators are rarely used in vehicles Figure 3: Typical vehicle application radiator bottom mounted Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...

  • Page 5: Installation

    Please also note that in spite of the automatic oil pressure sensor it is still essential that the oil level is checked regularly. EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 6: Instructions For Optimal Sound And Vibration Insulation

    Never connect the base of the generating set directly to walls or tanks. Figure 5: Mounting of the Whisper generating set. X = wrong, V = OK Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...

  • Page 7: Air Strainer Element

    ATTENTION! Before working (installation) on the system In any case it is necessary to open a hole for read the section safety instructions air inlet! EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...
  • Page 8 Coolant engine in Coolant generator out Expansion tank Exhaust 1½” AC power output Remote control Fig. 7 Connections Whisper 6 Ultra for mobile application Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...
  • Page 9 Battery negative (–) 25mm2 Fuel out Ø8mm Fuel in Ø8mm Battery positive (+) 25mm2 Coolant generator in Coolant engine in Fig. 8b Connections Whisper 8 Ultra EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...
  • Page 10 Fuel out Ø8mm Fuel in Ø8mm Battery negative (–) 25mm2 Battery positive (+) 25mm2 Coolant generator in Coolant engine in Fig. 9b Connections Whisper 12 Ultra Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...
  • Page 11 Coolant generator in Coolant engine in Battery positive (+) 35mm2 Battery negative (–) 35mm2 Fuel in Ø8mm Fuel out Ø8mm Fig. 10b Connections Whisper 16 Ultra EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 12: Fuel Supply

    Fig. 11 Fuel supply (fuel tank is above the generating set) 1 Fuel return 2 Fuel supply 3 Prefilter / Water separator (optional) 5 Fuel Tank Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...
  • Page 13 4 Extra fuel lift pump (optional) 5 Fuel tank Figure 13: Fuel line assembly with vertical mounted pump and fuel lift pump mounted in an angle EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 14: Radiator Cooling

    Before starting your generating set for the first time follow the fuel system bleeding procedure in the users manual. Figure 14: Air traps should be avoided Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...
  • Page 15 (refer to figure 16). Figure 17: 7 litres optional expansion tank with low level alarm. Figure 16. Alternator cooling system: open expansion tank with overflow pillar. EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...
  • Page 16 When both radiators are flat mounted on the roof, the expansion tanks should be mounted a little higher. (refer to figure 19 detail B). Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...
  • Page 17 Refer to figure 21 air flow side mounted Figure 21: Bottom mounted radiators with shield Figure 23: Side mounted radiator EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 18: Dry Exhaust System

    Figure 26. Ways to prevent water to get in fan control, in order to keep the system as simple as possible. Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...
  • Page 19 When any doubt an extra safe guard could be constructed from steel wire or chain. Figure 27. Mounting bracket in rubber with safe guard EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 20: Electrical Installation (12 Volt)

    Be aware of polarity as some relays has a diode inside and should be connected plus to plus en minus to minus as indicated. Refer to fig. 29. Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...
  • Page 21 One of these options is to monitor a second battery (not the starter battery of the vehicle engine or other auxiliary being starter battery) start generator EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...
  • Page 22 Volt fan on the radiator is recommended. One should realize that the power for the fan must be decucted from the output power of the generating set. Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...

  • Page 23: Ac Power System (230 Volt)

    Mastervolt Mass Systemswitch. The fuses must be of the slow reacting type. For electrical motors connected to the system, a motor protection switch must be installed EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 24: Installation Specifications

    When there is only a circuit Commissioning form available website: breaker, use it to disconnect the generating set from www.mastervolt.com.. the grid. Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...

  • Page 25: Technical Data

    Battery charger (alternator including regulator): 50 Amps 50 Amps * Note that this value must be reduced by the power to drive the cooling fans of the radiators. EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 26: Installation Materials

    79006005 Batteryswitch ON/OFF with key 250A 6503003508 Cable lug 35mm² / M8 6503003510 Cable lug 35mm² / M10 TOTAL 50230220 BATTERY INSTALLATION KIT 160Ah Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...
  • Page 27 Hose clamp stainless 10-16 50222020 Copper fuel pipe per meter 50220063 Fuel hose per meter • Spare parts pos. article no description 50230092 Filter for strainer fuel/water separator EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...
  • Page 28 INSTALLATION SPECIFICATIONS Generator Dry exhaust Figure 34: Dry exhaust kit 1½” for Whisper 6 Ultra, 8 Ultra, 12 Ultra and 16 Ultra DRY EXHAUST KIT 1½” for Whisper 6 Ultra, 8 Ultra, 12 Ultra and 16 Ultra article no description 50220043 Exhaust hose SS 1½"...
  • Page 29 Hose clamp stainless mini 9-11 TOTAL 50201878 Radiator cooling kit alternator 19mm 230VAC for Whisper 6, 8 and 12 Ultra RADIATOR COOLING KIT ALTERNATOR ¾” 12VDC for Whisper 6 Ultra. Same as article no. 50201878, except: article no description 50230302...
  • Page 30 Washer mudguard SP 8x30x1,5 50220081 Hose polyurethane 8x11mm 50221532 Hose clamp stainless mini 9-11 TOTAL 50201888 Radiator cooling kit alternator 230VAC Whisper 16 Ultra Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...
  • Page 31 Hose clamp stainless 10-16 TOTAL 50201879 Radiator cooling kit engine 1” - 230VAC Whisper 6 Ultra RADIATOR COOLING KIT ENGINE 1” - 12VDC FOR Whisper 6 Ultra. Same as article no. 50201879, except: article no description 50230302 Radiator cooler AP 300/2 E 12VDC...
  • Page 32 TOTAL 50201877 Radiator cooling kit engine 1¼” (AP430/2-230V) Optional installation materials pos. article no description 50230535 Expansion tank 7L + low level alarm switch Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...

  • Page 33: Diagrams & Drawings

    LAYOUT GENERATOR CONTROL FOR WHISPER 6, 8 AND 12 ULTRA WITH 230VAC FAN Fig. 39: Layout generator control for Whisper 6 Ultra, 8 Ultra and 12 Ultra with 230VAC radiator fan EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 34: Layout Generator Control For Whisper 6 Ultra With 12Vdc Fan

    DIAGRAMS & DRAWINGS LAYOUT GENERATOR CONTROL FOR WHISPER 6 ULTRA WITH 12VDC FAN Fig. 40: Layout generator control for Whisper 6 Ultra with 12VDC radiator fan Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...

  • Page 35: Layout Generator Control For Whisper 6 Ultra With 24Vdc Fan

    LAYOUT GENERATOR CONTROL FOR WHISPER 6 ULTRA WITH 24VDC FAN Optional control for two speeds fans. See chapter 4.9 Fig. 41: Layout generator control for Whisper 6 Ultra with 24VDC radiator fan EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 36: Layout Generator Control For Whisper 16 Ultra With 230Vac Fan

    DIAGRAMS & DRAWINGS LAYOUT GENERATOR CONTROL FOR WHISPER 16 ULTRA WITH 230VAC FAN Fig. 42: Layout generator control for Whisper 16 Ultra with 230VAC radiator fan Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...

  • Page 37: Wiring Colours Whisper 6 Ultra, 8 Ultra And 12 Ultra

    DDC > LCP 1,5 mm2 DDC > LCP red/green 1,5 mm2 DDC > generator AC output brown 1 mm2 DDC > generator AC output blue 1 mm2 EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 38: Wiring Colours Whisper 16 Ultra

    1,5 mm2 DDC > generator AC output brown 1 mm2 DDC > generator AC output blue 1 mm2 DDC=Digital Diesel Control Unit LCP=Local Control Panel Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...

  • Page 39: Ac Wiring Diagram 230V / 50Hz

    DIAGRAMS & DRAWINGS AC WIRING DIAGRAM 230V / 50HZ Fig. 43: AC wiring diagram EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 40: Electrical Diagram Radiator Fan Control 230Vac

    80-70?C 230VAC 230VAC DIMENTION BOX: 270x270x180 MM Fig. 45: Electrical diagram fan control using 230V AC radiator fans – with two speeds fans (optional) Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...

  • Page 41: Electrical Diagram Radiator Fan Control 12 / 24 Vdc

    CU0,75 CU2,5 CU0,75 CU0,75 CU2.5 80-70∞C 45-35∞C DIMENIONS BOX: 160x160x90 MM Fig. 46: Electrical diagram fan control using 12V or 24V DC radiator fans (optional) EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 42: Wiring Diagram Electronic Governor (Standard For Whisper 6, 8 And 12 Ultra)

    RPM of the engine, because the processor uses the 50 Hz of the AC The electronic governor system contains two parts: output voltage as a reference. Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...

  • Page 43: Remote Control Panel Drawings

    4.11 REMOTE CONTROL PANEL DRAWINGS Fig. 48: Whisper remote panel The remote panel comes in a carton that can be used as a template to drill the mounting hole EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 44: Dimensions Whisper 6 Ultra

    POWERCABLES ISO 13297 annex A • 3 x AWG 12 (4 mm2) (not included) REMOTE CONTROL: • 15 meter (45 ft) 8 wire communication cable (included) Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...

  • Page 45: Dimensions Whisper 8 Ultra

    AWG 2 (25 mm2) POWERCABLES ISO 13297 annex A (not included) • 3x6 mm2 (not included) REMOTE CONTROL: • 15 meter 8 wire communication cable (included) EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 46: Dimensions Whisper 12 Ultra

    AWG 2 (25 mm2) POWERCABLES ISO 13297 annex A • 3x10 mm2 (not included) REMOTE CONTROL: • 15 meter 8 wire communication cable (included) Copyright © 2009 Mastervolt / May 2009 / Whisper 6/8/12/16 Ultra for mobile applications / EN...

  • Page 47: Dimensions Whisper 16 Ultra

    POWERCABLES ISO 13297 annex A Ultra is included in the delivery. • 3x16 mm2 (not included) REMOTE CONTROL: • 15 meter 8 wire communication cable (included) EN/ Whisper 6/8/12/16 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...
  • Page 48 Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands Tel : + 31-20-3422100 / Fax : + 31-20-6971006 www.mastervolt.com / info@mastervolt.com...

This manual is also suitable for:

Whisper 8 ultraWhisper 12 ultraWhisper 16 ultra

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