Fuel Supply - Mastervolt whisper 3,5 Installation Manual

INSTALLATION
All electrical connections, cable types and sizes must
comply to the appropriate national regulations. Supplied
electric cables are rated for ambient temperatures up to
70°C. If the cables are required to meet higher
temperature, they must be run through conduits.

2.4.1 Fuel supply

1 FUEL TANK
Fuel tanks should be made of appropriate material
such as (stainless) steel or plastic. Steel tanks should
not be galvanised or painted inside. Condensation can
occur in metal tanks when temperature changes.
Therefore, water accumulates at the bottom of the
tank and provisions should be made for the drainage
of this water.
The tank will need a filling connection, a return con-
nection and an air ventilation connection which will
require protection against water entry.
Some official regulations do not allow connection
points at the base of the fuel tank; connections are to
be made at the top of the tank with internal tubing
down to a few cm above the bottom of the tank. Using
the existing fuel tank of the car-engine the fitting
should be executed with extra care. Both a supply line
and a return line should be installed and go into the
tank from the top. Interference of the two systems (car
engine and generator engine) should be avoided.
Fuel line assembly with vertical mounted
Fig. 6.
pump and fuel lift pump mounted vertical or in
an angle.
6
Do NOT connect the fuel lines to the
lines of the vehicles engine fuel supply.
Driving the tank empty below the level of
the suction pipe of the generator could
makes it necessary to bleed the fuel
system.
2 FUEL LIFT PUMP
In the standard supply of the generating set is a fuel
lift pump; therefore the tank can be installed at a
lower level than the generating set. The maximum
suction height is 1 m. If the pump has to lift the fuel
higher than one meter an extra fuel lift pump must be
installed. The control board is already prepared to
connect an extra fuel pump. It is recommended to
mount the loose supplied pump close to the tank and
mount it in an angle or vertical to prevent air bubbles
to block the system. The pump will become quite hot
and should be mounted out of touch. (Refer to fig. 6)
The pump makes clicking noises and therefore could
be mounted on rubber mountings. When the clicking
noises of the pump are not acceptable an other
noiseless pump is available as an option.
3 FUEL PIPES
When the tank is above the generating set we recom-
mend to end the return line on the top of the tank.
When the return is on the top - in case of a leakage -
the return line cannot overflow because of siphoning.
One will only need a fuel cock in the fuel supply line.
Both supply and return fuel pipe lines should be
appropriate material and 8 mm outer diameter tubing.
The quality of the tubing of fuel pipes could be sub-
mitted to local regulations depending on the applica-
tion of the vehicle.
The fuel pipes can be plumbed to the flexible hoses
which are on the generating set and have a connec-
tion to fit to 8 mm pipe. The fuel lines Mastervolt
supplies are according to ISO 7840 A2.
It is important to avoid bends in the pipes, as they
could trap air bubbles. The return pipe should never
be connected to the suction pipe. The return line
should be of 8 mm diameter and go straight back via
the top to the bottom of the tank. When the return is
too narrow, has too many bents and goes back to the
bottom of the fuel tank, the back-pressure could be to
high. This results in irregular running of the engine.
When the engine runs irregular, one can check if
back-pressure is the problem by disconnecting the
return line just outside the canopy and draining it in a
July 2005 / MOBILE WHISPER 3,5 / EN