Mastervolt whisper 7 ultra Installation Manual
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Mastervolt whisper 7 ultra Installation Manual

Mastervolt whisper 7 ultra Installation Manual

Mobile diesel generating set 120/240v / 60hz
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INSTALLATION MANUAL FOR MOBILE APPLICATIONS
U.S.A EDITION
WHISPER
7 / 9.5 / 15 / 20 ULTRA
- 1800 RPM -
Mobile diesel generating set 120/240V / 60Hz
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 U.S.A EDITION WHISPER 7 / 9.5 / 15 / 20 ULTRA - 1800 RPM - Mobile diesel generating set 120/240V / 60Hz Digital Diesel Control MASTERVOLT Snijdersbergweg 93, 1105 AN Amsterdam The Netherlands Tel.: +31-20-3422100 Fax.: +31-20-6971006 V5. May 2009...

  • Page 2: Table Of Contents

    Dimensions Whisper 7 Ultra ..........................44 4.13 Dimensions Whisper 9.5 Ultra .......................... 45 4.14 Dimensions Whisper 15 Ultra ........................... 46 4.15 Dimensions Whisper 20 Ultra ........................... 47 Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US...

  • 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 US / Whisper 7/9.5/15/20 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 7/9.5/15/20 Ultra for mobile applications / US...

  • 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. US / Whisper 7/9.5/15/20 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 7/9.5/15/20 Ultra for mobile applications / US...

  • Page 7: Air Strainer Element

    In any case it is necessary to open a hole for Before working (installation) on the system air inlet! read the section safety instructions US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...
  • Page 8 Coolant engine in Coolant generator out Expansion tank Ø5/16’ (Ø8mm) Exhaust 1½” AC power output Remote control Fig. 7 Connections Whisper 7 Ultra for mobile application Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US...
  • Page 9 Fuel out Ø5/16’ (8mm) Fuel in Ø5/16’ (8mm) Battery + (POS) AWG3 (25mm2) Coolant generator in Coolant engine in Fig. 8b Connections Whisper 9.5 Ultra US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...
  • Page 10 Fuel in Ø5/16’ (8mm) Battery – (NEG) AWG3 (25mm2) Battery + (POS) AWG3 (25mm2) Coolant generator in Coolant engine in Fig. 9b Connections Whisper 15 Ultra Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US...
  • Page 11 Battery + (POS) AWG2 (35mm2) Battery – (NEG) AWG2 (35mm2) Fuel in Ø5/16’ (8mm) Fuel out Ø5/16’ (8mm) Fig. 10b Connections Whisper 20 Ultra US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 12: Fuel Supply

    Figure 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 7/9.5/15/20 Ultra for mobile applications / US...
  • 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 US / Whisper 7/9.5/15/20 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 7/9.5/15/20 Ultra for mobile applications / US...
  • Page 15 (refer to figure 16). Figure 17: Optional 1.8 gallon expansion tank with low level alarm. Figure 16. Alternator cooling system: open expansion tank with overflow pillar. US / Whisper 7/9.5/15/20 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 7/9.5/15/20 Ultra for mobile applications / US...
  • Page 17 Refer to figure 21 air flow side mounted Figure 21: Bottom mounted radiators with shield Figure 23: Side mounted radiator US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 18: Dry Exhaust System

    120V fan control instead of the two speeds 12/24V fan control, in order to keep the system as simple as possible. Figure 26. Ways to prevent water to get in Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US...
  • 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 US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 20: Electrical Installation (12 Volt)

    GREY/PINK GREY BLACK SENSE BAT. 2 WARNING RELAY MAX. 150 mA Whisper Remote Panel Fig. 29 Remote box terminals Fig. 28 Remote control cable Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US...
  • Page 21 (transfer switch, distribution box, etc.) to warn for automatic start) Fig. 31 Starter battery The Mastervolt Digital Diesel Control system offers several options for automatic starting and stopping. US / Whisper 7/9.5/15/20 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 7/9.5/15/20 Ultra for mobile applications / US...

  • Page 23: Ac Power System (120 / 240 Volt)

    (L1 and L2) as must be installed wel as neutral (N). Off course this is the case when using a Mastervolt Masterswitch US / Whisper 7/9.5/15/20 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 7/9.5/15/20 Ultra for mobile applications / US...

  • 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. US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 26: Installation Materials

    Batteryswitch ON/OFF with key 250A 6503003508 Cable lug AWG 2 (35mm²) / M8 6503003510 Cable lug AWG 2 (35mm²) / M10 TOTAL 50230220 BATTERY INSTALLATION KIT 160Ah Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US...
  • Page 27 50222020 Copper fuel pipe per meter 50220063 Fuel hose per meter • Spare parts pos. article no description 50230092 Filter for strainer fuel/water separator US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...
  • Page 28 INSTALLATION SPECIFICATIONS Generator Dry exhaust Figure 34: Dry exhaust kit 1½” for Whisper 7 Ultra, 9.5 Ultra, 15 Ultra and 20 Ultra DRY EXHAUST KIT 1½” for Whisper 7 Ultra, 9.5 Ultra, 15 Ultra and 20 Ultra article no description 50220043 Exhaust hose SS 1½"...
  • Page 29 RADIATOR COOLING KIT ALTERNATOR ¾” 24VDC for Whisper 7 Ultra. Same as above, except: article no description 50230303 Radiator cooler AP 300/2 E 24VDC TOTAL 50201868 Radiator cooling kit alternator 19mm 24VDC for Whisper 7 ULTRA US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...
  • Page 30 Washer mudguard SP 8x30x1,5 50220081 Hose polyurethane 8x11mm 50221532 Hose clamp stainless mini 9-11 TOTAL Upon request Radiator cooling kit alternator 120VAC Whisper 20 Ultra Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US...
  • Page 31 Hose clamp stainless 10-16 TOTAL Radiator cooling kit engine 1” - 120VAC Whisper 7 Ultra Upon request RADIATOR COOLING KIT ENGINE 1” - 12VDC FOR Whisper 7 Ultra. Same as above, except: article no Description 50230302 Radiator cooler AP 300/2 E 12VDC...
  • Page 32 Upon request Radiator cooling kit engine 1¼” (AP430/2-120V) OPTIONAL INSTALLATION MATERIALS pos. article no description 50230535 Expansion tank 7L + low level alarm switch Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US...

  • Page 33: Diagrams & Drawings

    120V AC radiator fans Fig. 39: Layout generator control for Whisper 7 Ultra, 9.5 Ultra and 15 Ultra using a 120VAC radiator fan US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 34: Layout Generator Control For Whisper 7 Ultra With 12Vdc Fan

    LAYOUT GENERATOR CONTROL FOR WHISPER 7 ULTRA WITH 12VDC FAN Fig. 40: Layout generator control for Whisper 7 Ultra, using a 12V DC radiator fan Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US...

  • Page 35: Layout Generator Control For Whisper 7 Ultra With 24Vdc Fan

    LAYOUT GENERATOR CONTROL FOR WHISPER 7 ULTRA WITH 24VDC FAN Fig. 41: Layout generator control for Whisper 7 Ultra using a 24V DC radiator fan US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 36: Layout Generator Control For Whisper 20 Ultra With 120Vac Fan

    LAYOUT GENERATOR CONTROL FOR WHISPER 20 ULTRA WITH 120VAC FAN See section 4.8 for connection of 120V AC radiator fans Fig. 42: Layout generator control for Whisper 20 Ultra with 120VAC radiator fan Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US...

  • Page 37: Wiring Colours Whisper 7 Ultra, 9 Ultra And 15 Ultra

    DDC > generator AC output AC-2 brown 1 mm2 DDC > generator AC output AC-2 blue 1 mm2 DDC=Digital Diesel Control Unit LCP=Local Control Panel US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 38: Wiring Colours Whisper 20 Ultra

    DDC > generator AC output AC-2 brown 1 mm2 DDC > generator AC output AC-2 blue 1 mm2 DDC=Digital Diesel Control Unit LCP=Local Control Panel Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US...

  • Page 39: Ac Wiring Diagram 120-240V / 60Hz

    DIAGRAMS & DRAWINGS AC WIRING DIAGRAM 120-240V / 60HZ Fig. 43: AC wiring diagram US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 40: Electrical Diagram Radiator Fan Control 120Vac

    ELECTRICAL DIAGRAM RADIATOR FAN CONTROL 120VAC MAIN CIRCUIT BREAKER GENERATOR AC LOAD CIRCUIT BREAKER AIR FANS Figure 44: Electrical diagram for standard fan control using 120V AC radiator fans Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US...

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

    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) US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 42: Wiring Diagram Electronic Governor (Standard For Whisper 7, 9.5 And 15 Ultra)

    RPM of the engine, because the processor uses the 60 Hz of the AC The electronic governor system contains two parts: output voltage as a reference. Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US...

  • Page 43: 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 US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 44: Dimensions Whisper 7 Ultra

    POWERCABLES ISO 13297 annex A (not included) Refer to ISO 13297 for details REMOTE CONTROL: • 15 meter (45 ft) 8 wire communication cable (included) Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US...

  • Page 45: Dimensions Whisper 9.5 Ultra

    AWG 3 (25 mm2) POWERCABLES ISO 13297 annex A (not included) Refer to ISO 13297 for details REMOTE CONTROL: • 15 meter 8 wire communication cable (included) US / Whisper 7/9.5/15/20 Ultra for mobile applications / May 2009 / Copyright © 2009 Mastervolt...

  • Page 46: Dimensions Whisper 15 Ultra

    AWG 3 (25 mm2) POWERCABLES ISO 13297 annex A Refer to ISO 13297 for details REMOTE CONTROL: • 15 meter 8 wire communication cable (included) Copyright © 2009 Mastervolt / May 2009 / Whisper 7/9.5/15/20 Ultra for mobile applications / US...

  • Page 47: Dimensions Whisper 20 Ultra

    POWERCABLES ISO 13297 annex A Ultra is included in the delivery. Refer to ISO 13297 for details REMOTE CONTROL: • 15 meter 8 wire communication cable (included) US / Whisper 7/9.5/15/20 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 9.5 ultraWhisper 15 ultraWhisper 20 ultra

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