Mastervolt whisper 16 ultra User Manual

Marine diesel generating set 230/400v-50 hz

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USERS MANUAL

WHISPER 16 ULTRA

- Three phase - 1500 RPM -

Marine 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

V3. November 2008

www.mastervolt.com

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Page 1 USERS MANUAL WHISPER 16 ULTRA - Three phase - 1500 RPM - Marine 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 V3. November 2008 www.mastervolt.com...
Page 2: Table Of Contents
Lay out control wiring........................17 2.5.17 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 / November 2008 / WHISPER 16 ULTRA Three phase / EN...
Page 3 Adjusting valve clearance and retightening the cylinder head bolts..........37 5.4.3 Measuring exhaust backpressure....................38 5.4.4 Disassembling instructions ......................38 SPARE PARTS LIST ..............................40 MAINTENANCE LOG ................................42 EN / WHISPER 16 ULTRA Three phase / November 2008 / Copyright © 2008 Mastervolt...
Page 5: Liability
The cost for returning faulty goods is not covered under guarantee. Additional agreements could be part of the contract of delivery. EN / WHISPER 16 ULTRA Three phase / November 2008 / Copyright © 2008 Mastervolt...
Page 6: Identification Plate
When calculating a load one should always take into account the power factor or cos phi of this load. The power should never exceed the Copyright © 2008 Mastervolt / November 2008 / WHISPER 16 ULTRA Three phase / EN...
Page 8: Operation
When exposed to abnormal high temperatures in • 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 / November 2008 / WHISPER 16 ULTRA Three phase / EN...
Page 9: Transport, Lifting And Storage
Accessories included in the standard delivery • Expansion tank, hose and fittings • Special hose connector for measuring exhaust back pressure (refer to paragraph 5.4.3) EN / WHISPER 16 ULTRA Three phase / November 2008 / Copyright © 2008 Mastervolt...
Page 10: Components
Filler cap engine oil Rocker cover Filler cap engine coolant Temperature switch coolant Engine oil pressure switch Engine serial number Fig. 4: Rear view main components Whisper 16Ultra. Copyright © 2008 Mastervolt / November 2008 / WHISPER 16 ULTRA Three phase / EN...
Page 11 Fuel bleeding screw Starter motor solenoid Starter motor Fuel lift pump for manual priming Fuel injection pump Fig. 6: Front view main components Whisper 16Ultra EN / WHISPER 16 ULTRA Three phase / November 2008 / Copyright © 2008 Mastervolt...
Page 12: Generator Control Panel
Fig. 9: Digital Diesel remote 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 / November 2008 / WHISPER 16 ULTRA Three phase / EN...
Page 14: Fuel Specification
Minimum at idle 98kPa (1 kgf/cm² - 14psi) (1 bar). • Normal at 1500 rpm ±196 to 392 kPa (2-4 kgf/cm² - 28 to 57 psi) (2-4 bar). Copyright © 2008 Mastervolt / November 2008 / WHISPER 16 ULTRA Three phase / EN...
Page 15: Technical Data
Digital remote panel (+15 m cable), fuel filter, fuel lift pump, user and installation manuals Optional: Installation kits, mobile (vehicle) version, non earth return (ungrounded), spare part kits, PTO to drive a hydraulic pump EN / WHISPER 16 ULTRA Three phase / November 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 / November 2008 / WHISPER 16 ULTRA Three phase / EN...
Page 17: Lay Out Control Wiring
INFORMATION 2.5.16 Lay out control wiring Fig 12: Electrical Diagram control wiring Whisper 16Ultra – three phase EN / WHISPER 16 ULTRA Three phase / November 2008 / Copyright © 2008 Mastervolt...
Page 18: Electrical Diagrams Ac Connections (Alternator Models With 6 Wires)
2.5.17 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 / November 2008 / WHISPER 16 ULTRA Three phase / EN...
Page 19 INFORMATION Only valid for alternator models with 6 wires Fig 13b: Electrical Diagram 230 V AC / 50 Hz three phase (Delta configuration) EN / WHISPER 16 ULTRA Three phase / November 2008 / Copyright © 2008 Mastervolt...
Page 20: Electrical Diagrams Ac Connections (Alternator Models With 12 Wires)
2.5.18 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 / November 2008 / WHISPER 16 ULTRA Three phase / EN...
Page 21 INFORMATION 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 16 ULTRA Three phase / November 2008 / Copyright © 2008 Mastervolt...
Page 22: Operation
Switch on battery switch (when installed). Fuel valve: open. Starting: Push the start button to initiate the full automatic starting procedure. You can monitor the procedure on the display. Copyright © 2008 Mastervolt / November 2008 / WHISPER 16 ULTRA Three phase / EN...
Page 23 For instance; a bent piston rod or a cracked cylinder head. In fact water in the cylinder is the main cause for engine damage in pleasure craft. EN / WHISPER 16 ULTRA Three phase / November 2008 / Copyright © 2008 Mastervolt...
Page 24 ‘charging’ LED is blinking, reset by stop stopped and all switches in "OFF" position button, otherwise it will drain the start battery Copyright © 2008 Mastervolt / November 2008 / WHISPER 16 ULTRA Three phase / EN...
Page 25: 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). EN / WHISPER 16 ULTRA Three phase / November 2008 / Copyright © 2008 Mastervolt...
Page 26: Replacing Fuel Filter
A smeer of oil has to be put on the seal of the filter before fitting the filter. The filter should be fastened manually: when the rubber touches the metal turn 3/4 further. Fig. 18 Copyright © 2008 Mastervolt / November 2008 / WHISPER 16 ULTRA Three phase / EN...
Page 27: Regular Maintenance
PTO driven impeller pump through the cooler elements in the generator housing. All parts of the cooling EN / WHISPER 16 ULTRA Three phase / November 2008 / Copyright © 2008 Mastervolt...
Page 28: Maintenance Schedule
1000 hours Check lubricating oil pressure 2000 hours Check injector and injection pressure 2000 hours Check inlet air filter 2000 hours Check cooling system 2000 hours Copyright © 2008 Mastervolt / November 2008 / WHISPER 16 ULTRA Three phase / EN...
Page 29: Trouble Shooting
• Rotor diode(s) broken. Check the diodes in the rotor (refer to special procedures). The Whisper 16 ULTRA Three Phase has six diodes in the rotor. EN / WHISPER 16 ULTRA Three phase / November 2008 / Copyright © 2008 Mastervolt...
Page 30 "soft-start". Inquire at your nearest Mastervolt dealer or directly at the manufacturer, Mastervolt in the Netherlands. Copyright © 2008 Mastervolt / November 2008 / WHISPER 16 ULTRA Three phase / EN...
Page 31: Engine Faults
Inspect battery terminals and cables for a good (battery too weak). electrical connection (inspect against corrosion, tattered wires, etc.) • To thick engine lubricating oil. Change oil for a lower viscosity. EN / WHISPER 16 ULTRA Three phase / November 2008 / Copyright © 2008 Mastervolt...
Page 32 Faulty Digital Diesel Control unit. Stop the command • Loss of control engine manually by the stop handle. Check wire connections to fuel solenoid. Check solenoid function. Replace if necessary Copyright © 2008 Mastervolt / November 2008 / WHISPER 16 ULTRA Three phase / EN...
Page 33 • Injector blocked. Have the injector checked. • Loss of compression, sticking or Have the compression measured. damaged piston ring. Clean or replace the rings. EN / WHISPER 16 ULTRA Three phase / November 2008 / Copyright © 2008 Mastervolt...
Page 34: Warnings
● Motor RPM suddenly rises or drops. ● Unusual noise comes from generating set. ● Exhaust gases suddenly colour dark. ● Engine failure warning light is on Copyright © 2008 Mastervolt / November 2008 / WHISPER 16 ULTRA Three phase / EN...
Page 35: Special Procedures Alternator
Caution: 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 loads. EN / WHISPER 16 ULTRA Three phase / November 2008 / Copyright © 2008 Mastervolt...
Page 36: 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 Copyright © 2008 Mastervolt / November 2008 / WHISPER 16 ULTRA Three phase / EN...
Page 37: Special Procedures Engine
The T.D.C. of compression stroke can be found by aligning the T.D.C. mark (-0-) on the crankshaft pulley with the mark on the gear case (ref. to fig. 26). EN / WHISPER 16 ULTRA Three phase / November 2008 / Copyright © 2008 Mastervolt...
Page 38: Measuring Exhaust Backpressure
The water column should be no more than 27 inches (69 cm.) of water (1 PSI - 0,07 bar) Copyright © 2008 Mastervolt / November 2008 / WHISPER 16 ULTRA Three phase / EN...
Page 40: Spare Parts List
Nozzle injector, 4pcs (**) 50206045 Thermostat (**) 50206038 Gasket thermostat (**) 50206034 Gasket rocker cover (**) More extensive parts list on the internet: MASTERVOLT.COM (fast moving parts) Copyright © 2008 Mastervolt / November 2008 / WHISPER 16 ULTRA Three phase / EN...
Page 42: Maintenance Log
MAINTENANCE LOG MAINTENANCE LOG first service after 50 hours: hour counter: remarks next service (every 150 hours) hour counter: Copyright © 2008 Mastervolt / November 2008 / WHISPER 16 ULTRA Three phase / EN...
Page 44 Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands Tel : + 31-20-3422100 Fax : + 31-20-6971006 Email : info@mastervolt.com...

Mastervolt whisper 16 ultra User Manual

1 Introduction

2 Information

3 Operation

4 Maintenance

5 Trouble Shooting

6 Spare Parts List

Maintenance Log

Quick Links

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for Mastervolt whisper 16 ultra

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