Mastervolt whisper 12 ultra User Manual
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Mastervolt whisper 12 ultra User Manual

Mobile diesel generating set 230/400v-50 hz
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USERS MANUAL FOR MOBILE APPLICATIONS
WHISPER 12 ULTRA
- Three phase - 1500 RPM -
Mobile 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
V2 December 2008
www.mastervolt.com

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  • Page 1 USERS MANUAL FOR MOBILE APPLICATIONS WHISPER 12 ULTRA - Three phase - 1500 RPM - Mobile 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 V2 December 2008 www.mastervolt.com...

  • Page 2: Table Of Contents

    Electrical diagrams AC connections (alternator models with 6 wires) ..........18 2.5.18 Electrical diagrams AC connections (alternator models with 12 wires)..........20 Copyright © 2008 Mastervolt / December 2008 / Whisper 12 Ultra - Three phase for mobile applications/ EN...
  • Page 3 Adjusting valve clearance and retightening the cylinder head bolts..........38 5.4.3 Disassembling instructions ......................39 SPARE PARTS LIST ..............................40 MAINTENANCE LOG ................................41 EN / WHISPER 12 Ultra - Three phase for mobile applications / December 2008 / Copyright © 2008 Mastervolt...

  • Page 4: Introduction

    Copyright © 2008 Mastervolt / December 2008 / Whisper 12 Ultra - Three phase for mobile applications/ EN...

  • Page 5: Liability

    Freight costs to deliver spares by normal mail or carriers is covered under guarantee. Special services like express mail, overnight delivery etc. are not covered. Taxes and EN / WHISPER 12 Ultra - Three phase for mobile applications / December 2008 / Copyright © 2008 Mastervolt...

  • Page 6: Identification Plate

    Check the settings (voltage, frequency, rpm) of this load. The power should never exceed the when there is any doubt Copyright © 2008 Mastervolt / December 2008 / Whisper 12 Ultra - Three phase for mobile applications/ EN...

  • Page 7: Information

    • Connection and protection must be done in accordance with local standards. EN / WHISPER 12 Ultra - Three phase for mobile applications / December 2008 / Copyright © 2008 Mastervolt...

  • Page 8: Operation

    • 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 for mobile applications/ EN...

  • Page 9: Transport, Lifting And Storage

    However in this manual there is a list of important parts for maintenance and spare parts as well as a chapter on maintenance and problem solving. EN / WHISPER 12 Ultra - Three phase for mobile applications / December 2008 / Copyright © 2008 Mastervolt...

  • Page 10: Components

    Engine oil pressure switch Coolant drain plug Fuel filter Oil sump handpump Fig. 4: Front right view main components Whisper 12Ultra – three phase, mobile. Copyright © 2008 Mastervolt / December 2008 / Whisper 12 Ultra - Three phase for mobile applications/ EN...
  • Page 11 Starter motor solenoid Starter motor V-belt Engine coolant pump Alternator (12VDC) Fig. 6: Rear view main components Whisper 12Ultra – three phase, mobile EN / WHISPER 12 Ultra - Three phase for mobile applications / December 2008 / Copyright © 2008 Mastervolt...

  • Page 12: Generator 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 for mobile applications/ EN...

  • Page 13: Engine

    Fuel free from water and contaminants is of the This current is rectified to charge the battery. The voltage utmost importance. is regulated at ±14.4V. EN / WHISPER 12 Ultra - Three phase for mobile applications / December 2008 / Copyright © 2008 Mastervolt...

  • Page 14: Oil Information

    The cooling liquid in the engine is pressurised. A high • Normal at ±350kPa (3.5 kgf/cm² - 50 psi) (3.5 pressure hose connects the manifold to the expansion bar). tank.. Copyright © 2008 Mastervolt / December 2008 / Whisper 12 Ultra - Three phase for mobile applications/ EN...

  • Page 15: Technical Data

    Digital remote panel (+15 m cable), fuel filter, fuel lift pump, user and installation manuals Available as option: Installation kits, non earth return (ungrounded), spare part kits EN / WHISPER 12 Ultra - Three phase for mobile applications / 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 for mobile applications/ EN...

  • Page 17: Lay Out Control Wiring

    See figure 15 for connection of the radiator fan Fig 12: Electrical Diagram control wiring Whisper 12Ultra – three phase, mobile applications EN / WHISPER 12 Ultra - Three phase for mobile applications / 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 for mobile applications/ EN...
  • Page 19 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 for mobile applications / 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 for mobile applications/ EN...
  • Page 21 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 for mobile applications / December 2008 / Copyright © 2008 Mastervolt...

  • Page 22: Electrical Diagram Radiator Fan Connection

    INFORMATION 2.5.19 Electrical diagram radiator fan connection Fig. 15: Electrical diagram for standard fan control using a 230 Volt AC radiator fan Copyright © 2008 Mastervolt / December 2008 / Whisper 12 Ultra - Three phase for mobile applications/ EN...

  • Page 23: Diagram Electronic Governor (Standard)

    50 Hz of the AC more stable frequency and voltage and more power. output voltage as a reference. Fig 16: Diagram electronic governer EN / WHISPER 12 Ultra - Three phase for mobile applications / December 2008 / Copyright © 2008 Mastervolt...

  • Page 24: 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. Copyright © 2008 Mastervolt / December 2008 / Whisper 12 Ultra - Three phase for mobile applications/ EN...
  • Page 25 (from a still stand state). EN / WHISPER 12 Ultra - Three phase for mobile applications / December 2008 / Copyright © 2008 Mastervolt...

  • Page 26: 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 / December 2008 / Whisper 12 Ultra - Three phase for mobile applications/ EN...

  • Page 27: Replacing Fuel Filter

    Readjustment V-beltplacing oil filter The alternator bracket allows for readjust of the V-belt. Deflections should be 10 mm (refer to fig. 21) Fig. 23 EN / WHISPER 12 Ultra - Three phase for mobile applications / December 2008 / Copyright © 2008 Mastervolt...

  • Page 28: Regular Maintenance

    Check the battery acid level (not applicable when Mastervolt batteries are used). • Check battery terminals for corrosion • Check and readjust V-belt Copyright © 2008 Mastervolt / December 2008 / Whisper 12 Ultra - Three phase for mobile applications/ EN...

  • Page 29: Maintenance Schedule

    Check lubricating oil pressure 2000 hours Check injector and injection pressure 2000 hours Replace or clean the air filter element 2000 hours EN / WHISPER 12 Ultra - Three phase for mobile applications / December 2008 / Copyright © 2008 Mastervolt...

  • Page 30: Trouble Shooting

    Generator AC output voltage is either too high or too low AC VOLTAGE Generator is in overload HIGH CURRENT Output frequency of the generator is too low FREQUENCY Copyright © 2008 Mastervolt / December 2008 / Whisper 12 Ultra - Three phase for mobile applications/ EN...

  • Page 31: Trouble Shooting Table Alternator

    "soft-start". Inquire at your nearest Mastervolt dealer or directly at the manufacturer, Mastervolt in the Netherlands. EN / WHISPER 12 Ultra - Three phase for mobile applications / December 2008 / Copyright © 2008 Mastervolt...

  • Page 32: Engine Faults

    Generator AC output voltage is either too high or too low AC VOLTAGE Generator is in overload HIGH CURRENT Output frequency of the generator is too low FREQUENCY Copyright © 2008 Mastervolt / December 2008 / Whisper 12 Ultra - Three phase for mobile applications/ EN...

  • Page 33: Trouble Shooting Table Engine

    • Temporarily hunting (this will disappear when engine has run in). • Ongoing hunting caused by faulty Replace faulty parts. electronic governor EN / WHISPER 12 Ultra - Three phase for mobile applications / December 2008 / Copyright © 2008 Mastervolt...
  • Page 34 Check intake air paths and filter, clean and replace if necessary. • Choked air filter element. • Fuel injector faulty. Replace injector. • Valve clearance incorrect. Readjust valve clearance Copyright © 2008 Mastervolt / December 2008 / Whisper 12 Ultra - Three phase for mobile applications/ EN...

  • Page 35: Warnings

    ● Motor RPM suddenly rises or drops. ● Unusual noise comes from generating set. ● Exhaust gases suddenly colour dark. ● Engine failure warning light is on EN / WHISPER 12 Ultra - Three phase for mobile applications / December 2008 / Copyright © 2008 Mastervolt...

  • Page 36: Special Procedures Alternator

    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. Copyright © 2008 Mastervolt / December 2008 / Whisper 12 Ultra - Three phase for mobile applications/ EN...

  • Page 37: Testing Rotary Rectifier Diodes

    Drying out can be carried out by direct warm air (60-80ºC) from a fan heater or similar apparatus into the generator air inlets or outletst EN / WHISPER 12 Ultra - Three phase for mobile applications / December 2008 / Copyright © 2008 Mastervolt...

  • Page 38: Special Procedures Engine

    180 degrees further clockwise to the TDC of cylinder 4 and adjust the valves. And again 180 degrees to Fig 28 Cylinder head bolts adjust cylinder 2. Copyright © 2008 Mastervolt / December 2008 / Whisper 12 Ultra - Three phase for mobile applications/ EN...

  • Page 39: Disassembling Instructions

    Figure 31: exploded view sound shield Whisper 12 Ultra EN / WHISPER 12 Ultra - Three phase for mobile applications / December 2008 / Copyright © 2008 Mastervolt...

  • Page 40: Spare Parts List

    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 for mobile applications/ EN...

  • Page 41: Maintenance Log

    MAINTENANCE LOG MAINTENANCE LOG first service after 50 hours: hour counter: remarks next service (every 150 hours) hour counter: EN / WHISPER 12 Ultra - Three phase for mobile applications / December 2008 / Copyright © 2008 Mastervolt...
  • Page 42 NOTES NOTES Copyright © 2008 Mastervolt / December 2008 / Whisper 12 Ultra - Three phase for mobile applications/ EN...
  • Page 43 NOTES NOTES EN / WHISPER 12 Ultra - Three phase for mobile applications / December 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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