Table of Contents
Troubleshooting
Related Manuals for Mastervolt Whisper 3.5 3000 RPM
Summary of Contents for Mastervolt Whisper 3.5 3000 RPM
- Page 1 USERS MANUAL WHISPER 3,5 - 3000 RPM - Marine 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 2006 www.mastervolt.com...
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Page 2: Table Of Contents
CONTENTS This manual applies to the Mastervolt Whisper 3,5 marine generating set controlled by Digital Diesel Control. First launched in April 2004. For earlier models refer to other manuals available on our website: www.mastervolt.com CONTENTS: INTRODUCTION................................4 General ................................4 Service and maintenance ........................... - Page 3 CONTENTS OPERATION .................................. 16 General ................................16 Operating Instructions ............................16 3.2.1 Summarised operating instructions (daily use) ................16 3.2.2 Extended operating instructions ...................... 16 MAINTENANCE................................19 Alternator................................19 Engine ................................19 4.2.1 Preliminary instructions ........................19 4.2.2 Bleeding fuel lines ........................... 19 4.2.3 Valve clearance ..........................
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Page 4: Introduction
Whisper generators have an option for an auto start/stop GUARANTEE mode or interval mode. Mastervolt guarantees that this generating set has been Mastervolt cannot be held responsible for damage caused built according to good workmanship, according to the by the unattended running generator. -
Page 5: Liability
Automatic start/stop engineer is covered, but is limited to a reasonable number Mastervolt cannot be held responsible for damage of hours and reasonable rates in relation to the actual caused by the unattended running generator using the repair work that has to be done. -
Page 6: Information
INFORMATION power should never exceed 3 kW. Power is rated at The CE symbol shows that the generating set is build an ambient temperature of 40°C and a seawater according to European Community safety regulations. temperature of 25ºC. For higher temperatures the This includes the regulations regarding the safety of generating set has to be derated. -
Page 7: Installation
L1. Of course this is the case • when using a Mastervolt Masterswitch. Always consult the manual before carrying out Be aware that insulation protection systems can be maintenance. -
Page 8: Transport, Lifting And Storage
INFORMATION • THE WHISPER 3,5 On no account allow any unprotected skin to come into contact with the injector spray as the fuel may enter the blood stream with fatal results. 2.3.1 Features This generating set includes a diesel engine which is •... -
Page 9: Components
INFORMATION COMPONENTS 2.4.1 Main components to identify Air inlet; Starter motor; Battery connection (positive); Battery connection (negative); AC 230 V wiring; AC 230 V output connection box; Fuel filter; Fuel pipe inlet; Fuel pipe return; 10 Bypass hose air vent; 11 Cooling water in;... -
Page 10: Generator Control Panel
(sea) water are made of seawater resistant material like naval brass and gunmetal. Fig... 4: Digital Diesel Control unit The engine has been specially adapted for the Mastervolt application and is very different from the standard engine supplied for industrial applications! 2.5.3... -
Page 11: Battery Charger
INFORMATION 2.5.4 Battery charger 2.5.9 Load indicator There is an extra winding in the alternator generating 6 On the remote control the load will be indicated on the Amp 12 V. This current is rectified on the control PCB to display and by the LED-bar. -
Page 12: Technical Data
3 kW nett. Cooling system Indirect cooling by raw water. Cooling water pump pto driven Mastervolt self priming impeller pump, type K Fuel lift pump engine electric pump (12 V DC), additional pump available upon request Starting battery (optional) 55-90 Ah Fuel consumption 0.7-1.4 litre/hour, load dependent... -
Page 13: Wiring Codes And Colours
INFORMATION 2.5.13 Wiring codes and colours number colour cable code no cross section battery > starter motor 16 mm2 starter motor > DCC 6 mm2 starter motor > LCP 2,5 mm2 battery > ground black 16 mm2 ground > LCP ground (GND) black 2,5 mm2 DDC >... -
Page 14: Lay Out Control Pcb
INFORMATION 2.5.14 Lay out control PCB Fig 7: Lay out control PCB / WHISPER 3,5 / EN May 2006... -
Page 15: Electrical Diagram 230 V Ac / 50 Hz
INFORMATION 2.5.15 Electrical diagram 230 V AC / 50 Hz EARTH AND NEUTRAL CONNECTED Fig 8: Electrical diagram 230V EN / WHISPER 3,5 / May 2006... -
Page 16: Operation
OPERATION In operation checks: 3 OPERATION Check for abnormal noise or vibration Check the voltage Check sea water flow at exhaust outlet GENERAL Power source selector switch (off/shore The generating set is operational after full installation and power/generator power). Switch to power source filling up with: fuel, engine lubricating oil and cooling liquid, generator. - Page 17 OPERATION Check the water strainer. Check for leaks. Regularly check the siphon vent in the cooling water supply. If no MASTERSWITCH is used: Switch main Power Source Selector switch to "OFF" or switch off all devices. Switch on the battery switch. Starting the generator: By pushing the start button briefly the electric system is activated, the fuel lift pump starts pumping and the...
- Page 18 OPERATION The high peak current is meant for the ability to start If the generator is operating in a hot environment and electrical devices that need a high current for starting you do not act as given above, the excessive heat in especially electric motors and compressors (from a still the engine can trip the "high temp"...
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Page 19: Maintenance
MAINTENANCE 4 MAINTENANCE ALTERNATOR needed to bleed, push “start” and hold on the local control panel (so not on the remote panel). Hold as long as The alternator does not require any maintenance. Periodic necessary to bleed the system. inspection and cleaning is recommended, depending on environmental conditions. -
Page 20: Replacing Fuel Filter
MAINTENANCE 4.2.4 Replacing fuel filter AFTER FIRST 50 HOURS: • Filter change depends on contamination of the fuel, but Change oil. should be done however, at least every 1000 running Have the engine run until it is on temperature and hours. -
Page 21: Maintenance Schedule
MAINTENANCE 4.3.1 Maintenance schedule EVERY 1000 HOURS: • Replace the fuel filter Check oil level daily Replacement depends on the condition of the Check water strainer daily fuel. We recommend replacement every 1000 Change oil 150 hours hours. Isolate the fuel supply and change the element. -
Page 22: Trouble Shooting
TROUBLE SHOOTING 5 TROUBLE SHOOTING ALTERNATOR/ ELECTRICAL FAULTS This should only be carried out by an experienced electrician. Check if the engine is running correctly at 3000 (50 Hz) RPM according to its settings and does as well under load. Beware of parts which are live! A RPM drop of 5% at full load is acceptable. -
Page 23: Engine Faults
"soft-start". current during starting Inquire at your nearest Mastervolt dealer or directly at the manufacturer, Mastervolt in the Netherlands. ENGINE FAULTS... - Page 24 When the outlet port is strongly affected by rust, the exhaust system is not properly installed (refer to paragraph 5.4.3). Contact Mastervolt service department for advice. • Wrong valve clearance. Adjust valve clearance, •...
- Page 25 • Water strainer blocked. • Air or water in the fuel. • Blocked air or fuel filter. • Loss of compression by wear out or Repair by Mastervolt service. damage. • Overload or short circuit. Switch off the consumers and test for short circuit.
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Page 26: Warnings
• Engine failure warning light is on 5.2.4 Service address If you cannot correct a problem with the aid of the mal- function table, contact your Mastervolt Service Centre or Mastervolt Amsterdam for an extended service list, tel: INT +31-20-3422100. Fig. 14. SPECIAL PROCEDURES ALTERNATOR 5.3.2 Testing rotary rectifier diodes The diodes in the rotor can be checked with a multimeter. -
Page 27: Winding Resistant Values
TROUBLE SHOOTING Varistor (420V); EMC capacitors (4,7nF - 630V); Diodes (25A - 1200V). Fig15 Fig16: Setting assembly 5.3.3 Winding resistant values RPM be under full load below 2940 RPM = 49 Hz. When If after establishing and correcting any fault on the no cause can be found for a wrong speed, the setting can capacitor and diodes output is still low when separately be adjusted: It is very important to identify the correct... -
Page 28: Disassembling Instructions
TROUBLE SHOOTING The easiest way to get the generator out of its capsule is by lifting the set using the lifting eye and removing the capsule downwards. The cooler elements are welded to the alternator housing with silver and cannot be disassembled. How-ever one can take off the complete alternator housing. -
Page 29: Spare Parts List
Copper washer connection bolt, M10 x 16 (**) 50201035 Copper washer, M12 x 18 (**) 50202048 Stop solenoid (***) 50201250 Raw water pump complete Mastervolt type K (***) (refer to fig. 17) 50209011 Impeller + gasket (3,4,5) (*) 50201012 Cover type K (**) (2) 50209018... - Page 30 SPARE PARTS LIST Fig. 18 Waterpump type K / WHISPER 3,5 / EN May 2006...
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Page 31: Maintenance Log
MAINTENANCE LOG MAINTENANCE LOG first service after 50 hours: hour counter: remarks next service (every 150 hours) hour counter: EN / WHISPER 3,5 / May 2006... - Page 32 Snijdersbergweg 93, 1105 AN Amsterdam, The Netherlands Tel : + 31-20-3422100 / F ax : + 31-20-6971006 www.mastervolt.com / info@mastervolt.com...
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