Mastervolt WHISPER 20 ULTRA, User Manual

Page 1: ...5 AN Amsterdam The Netherlands Tel 31 20 3422100 Fax 31 20 6971006 www mastervolt com USERS MANUAL U S A EDITION V1 April 2004 WHISPER 20 ULTRA 1800 RPM Marine diesel generating set 120 240V 60 Hz Digital Diesel Control Art nr 50200414 ...

Page 2: ...lures 6 2 1 4 Installation 7 2 1 5 Operation 7 2 1 6 Fire and explosion 7 2 1 7 Chemicals 7 2 2 Transport lifting and storage 8 2 3 The Whisper 20 ULTRA generating set 8 2 3 1 Features 8 2 3 2 Remote control 8 2 3 3 Documentation 8 2 3 4 Accessories included in the delivery 8 2 4 Components 9 2 4 1 Main components 10 2 4 2 Generator control panel 10 2 4 3 Remote control panel 10 2 5 Technical info...

Page 3: ...4 2 6 Readjusting V belt 21 4 3 Regular maintenance 21 4 3 1 Maintenance schedule 22 4 3 2 Putting out of service 22 5 TROUBLE SHOOTING 23 5 1 Alternator malfunctions AC trouble 23 5 1 1 General 23 5 1 2 Trouble shooting check list alternator 23 5 2 Engine malfunctions 24 5 2 1 General 24 5 2 2 Trouble shooting check list engine 24 5 2 3 Warnings 27 5 2 4 Service address 27 5 3 Special procedures ...

Page 4: ...an Community safety regulations During production and prior to delivery all of our genera ting sets are tested and inspected The well functioning of this generating set is subject to guarantee The period and conditions of this guarantee are laid down in the general conditions of delivery as registered with the Chamber of Commerce and Industries in Amsterdam number 33279951 and are available on req...

Page 5: ...rantee certificate unauthorised repairs could lead to furt her damage and violate the guarantee conditions Should work take place which is not in ac cordance with the guidelines instructions and specifications contained in this user s manual and the supplementary installation manual then damage may occur and the generating set may not fulfil its specifica tions In all these cases the guarantee may...

Page 6: ...late gives the nominal maximum load in kVA kW calculated with the indicated power factor one 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 nominal Power in kW as shown on the nameplate Power is rated at an ambient temperature of 104 F 40 C and a sea water temperature of 77 F 25 C For higher temperatures the ge...

Page 7: ... aware of moving parts like V belts The generating set should be operated by authori sed personnel only Be aware of hot parts and specially parts of the exhaust system If the generating set is unsafe fit danger notices and disconnect the battery positive lead so that it cannot be started until the condition is cor rected Do not attempt to operate the generating set with a known unsafe condition Di...

Page 8: ...s 2 3 THE WHISPER 20 ULTRA 2 3 1 Features This generating set includes a diesel engine which is connected by close coupling to an alternator in a sound attenuated capsule The set is mounted on a steel base frame and mounted securely on anti vibration mounting pads to the capsule base All cables and hoses are gui ded through the capsule s sides The set is not self con tained and is only operable af...

Page 9: ...ical fuel lift pump 21 Raw water pump 22 Cooling liquid temperature switch 23 Fuel pressure pump 24 Oil pressure switch 25 Oil sump pump 26 Exhaust connection 27 Fuel vent screw 28 Oil level indicator 29 Control panel 30 Capacitors voltage regulator optional 31 Fuse 1 32 Fuse 2 33 Remote control cable 34 Cooling water injection 35 RPM adjustment screw 36 Thermostat housing 37 Alternator 38 Filling...

Page 10: ...i S4Q2 4 cylinder diesel engine The engine is indirectly injected The engine is water cooled and the cooling liquid is cooled by a heat exchanger and raw water The heat exchanger and all other parts which are in direct contact with the raw sea water are made of seawater resistant material like naval brass and gunmetal The engine has been specially adapted for the Mastervolt application and is very...

Page 11: ...ed cable can be connected if the standard length does not suit the required distance Numerous remote control units can be put in parallel by using the connectors on the back of the units Refer to installation instructions 2 5 8 Hour counter The remote control offers several timer functions and helps to schedule maintenance 2 5 9 Load indicator On the remote control the load will be indicated on th...

Page 12: ... 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 hydraulic pump 2 5 12 Cooling liquid The engine is cooled by cooling liquid The capacity of this system of the Whisper 20 ULTRA is 7 6 US qts 7 2 l We recommend not using water but cooling liquid that is marketed for the use...

Page 13: ...m2 LCP exhaust temperature switch 8 blue rose 17 1 mm2 DCC fuel solenoid hold 9 green 16 1 5 mm2 DCC fuel solenoid pull 20 grey 14 2 5 mm2 DCC fuel solenoid com 17 black 14 2 5 mm2 B terminal alternator starter motor 21 red 10 6 mm2 DCC R terminal alternator 18 wit 16 1 5 mm2 DCC L terminal alternator 19 orange 16 1 5 mm2 DCC current measuring transformer 11 black 17 1 mm2 DCC current measuring tr...

Page 14: ...BLUE 44 BROWN 44 BLUE 33 BROWN 33 TRANSFORMER CURRENT MEASURING BLACK 22 RED 22 SWITCH EXHAUST TEMP WATER TEMP OIL PRESS SWITCH SOLENOID FUEL WHITE PULL BLACK COMM RED HOLD GREY 2 5 20 GREEN 1 5 9 RED GREEN 1 16 PURPLE 1 6 BLUE GREEN 1 8 BLUE 1 7 ORANGE 1 5 19 RED 35 ENGINE BLOCK GROUND TO GLOW PREHEAT PLUGS SWITCH BATTERY OPTIONAL PURPLE BLACK 1 6 J14 BLACK 35 SOLENOID BROWN 6 3 GLOW PREHEAT BROW...

Page 15: ... YELLOW GREEN BLACK YELLOW GREEN 120 240V 60Hz BLUE PE N BROWN L1 DCC ct 1 11 11 CURRENT TRANSFORMER BLACK RED 22 22 DCC ct 2 BLACK RED CURRENT TRANSFORMER TRANSFORMER CURRENT DCC AC 1 BROWN 33 YELLOW GREEN BLUE 33 DCC ct 1 BLUE N YELLOW GREEN PE RED DCC ct 2 22 BLACK 22 RED 11 BLACK 11 TRANSFORMER CURRENT MAIN WINDING 4 MAIN WINDING 4 3 3 EXCITATION WINDING 2 1 YELLOW GREEN DCC AC 1 BROWN 33 BLUE...

Page 16: ...16 April 2004 WHISPER 20 ULTRA USA 2 5 17 Diagram electronic governor optional INFORMATION Fig 9 ...

Page 17: ...ad should be restric ted to 70 of maximum load Stopping generator 1 Switch off all electrical devices consumers If the generating set has been running under full load for a longer period do not shut it down abruptly Reduce the electrical load to about 30 of the rated load and let it run for approx 5 minutes 2 Press the STOP button 3 Close the inlet sea water cock 4 Switch to another AC power sourc...

Page 18: ...ater pump After having become acquainted with the generator you will be able to recognise the coolant flowing through the system by listening for the noise of the water which is expelled Be aware that especially in harbours the coolant water inlet can easily be blocked by floating objects 4 Power source selector switch off shore power gene rator power Switch to power source generator If a MASTERSW...

Page 19: ...t in the engine can trip the high temp alarms In that case a restart of the engine is not possible for some time It is also recommended to switch off electrical users prior to stopping the generator Because of the voltage drop that occurs as the engine comes to a halt Such voltage drops may cause damage to elec tric motors compressors in refrigerators or air condi tioners etc 2 Press the STOP butt...

Page 20: ...l In the first 50 hours the engine should receive special attention Long periods of light or no load running in the first 50 hours may lead to cylinder glazing and high oil consump tion For the same reason it is of the greatest importance to use the right oil specifica tion The first time starting up or after running out of fuel it could be necessary to prime the fuel system 4 2 2 Bleeding fuel li...

Page 21: ...on to the fuel system Retighten the cylinder head bolts and adjust the valve clearance Refer to paragraph 5 4 2 Observe the exhaust at the normal full load The exhaust must be free from soot Do not allow the engine to run with a dirty exhaust without investi gating the cause as this may result in an expensi ve breakdown Check the air vent on a regularly basis When the air vent it not working prope...

Page 22: ...ar the oil should be changed yearly 4 3 1 Maintenance schedule 4 3 2 Putting out of service When not using the generator for a longer period it is re commended to execute an engine preservation procedure 1 Clean the engine 2 Loosen the fuel suction pipe and fuel return and put them in a can with preservation diesel fuel Start the engine and run the engine warm 3 Drain the hot engine oil and refill...

Page 23: ...dual magnetism and flash the alternator refer to special procedures Capacitor loose or broken Check by independent excitation if the problem is in the capacitors or in the windings Rotor diodes broken Check the diode in the rotor refer to special procedures The Whisper 20 ULTRA has one diode in the rotor Generator output voltage too No load at all or very low load Switch on a load and check voltag...

Page 24: ...t from happening again When there is no mechanical malfunction the problem must be an electric malfunction 5 2 ENGINE FAULTS Remove 3 Amp fuse in the control panel while working on the generator to prevent the engine to start 5 2 1 General Most electrical problems relating to Voltage or Frequency are due to wrong engine speed Note that RPM and Hz are basically the same Use the problem solving tabl...

Page 25: ... section Wrong valve clearance Adjust valve clearance Low compression because of dirty valves Clean valves Take off the injection bent and inspect the outlet port When little rust is in the port one can clean the valve by taking of the valve spring and rotate the valve When the outlet port is strongly affected by rust the exhaust system is not properly installed Water has entered the exhaust port ...

Page 26: ...ion system stops the engine Refer to paragraph 2 5 5 and 3 2 2 for after 10 up to 30 seconds this can be caused by oil pressure information on the alarmsystem Bypassing the failure lack of coolingwater switches can help to identify the failure exhaust temperature alarm Loose wire or faulty alarm switch Display will help to identify failures Engine stops by itself Overload or short circuit Switch o...

Page 27: ...ate any voltage F 9V USA WHISPER 20 ULTRA April 2004 27 PROBLEM CAUSE SOLUTION Poor fuel quality Use better quality diesel Poor quality lubricating oil Use better quality oil Continuous running with very low load Increase load and have the engine run for a few hours Loss of power Wrong measurement Check if the load is measured correctly Does the Amp meter show the correct value When calculating th...

Page 28: ...t after running in could occur RPM can be measured by a frequency meter Before readjustment check any other explanation for the wrong speed Engine speed is set at the factory at nominal 1800 RPM 60 Hz A RPM drop of 5 at full load is acceptable Therefore a no load setting should be at 1875 RPM 62 5 Hz Under no circumstances the RPM under full load should be below 1770 RPM 59 Hz When no cause can be...

Page 29: ... the alternator are very accessible as well The same is true for the diode of the rotor 2 To take the generating set out of the canopy all hose and cable connections has to be taken off The set is fixed to its base by four rubber mountings and can be taken loos by removing the four nuts from the bolts of this mountings Moreover the generating set is fixed by 2 fail safes that prevents the generati...

Page 30: ...rings 2 pcs 7 O ring 17 Seal 5 shim 13 Ring 15 Cam 4 screw 2 3 screws 11 cover 10 50206258 Repair kit B 7 17 5 15 50201323 Heat exchanger complete with appendages 50201322 Water hoses with clamps 50201060 Capacitor xx micro farad 2 pcs xx give value when ordering 50209132 Measuring coil 50201890 Rotary diode 50201482 Alternator bearing including O ring 50209140 Voltage regulator optional 50209104 ...

Page 31: ...earing pump M16 2x 50206264 8 Impeller pump M16 50206259 9 Coupling shaft pump M16 50206268 10 Cover pump M16 50206255 11 Screw cover waterpump 50209018 12 Spring pin shaft pump M16 50206272 13 Shim pump M16 50206271 14 Gasket pump M16 50206260 15 Ring pump M16 50206266 16 Pin shim pump M16 50206270 17 O ring pump M16 50206263 Impeller kit pump M16 8 14 50206254 Repair kit A pump M16 6 9 12 7 17 5...

Page 32: ...32 April 2004 WHISPER 20 ULTRA USA MAINTENANCE LOG first service after 50 hours hour counter remarks next service every 150 hours hour counter remarks ...

Page 33: ...USA WHISPER 20 ULTRA April 2004 33 NOTES ...

Page 34: ...34 April 2004 WHISPER 20 ULTRA USA NOTES ...

Page 35: ...USA WHISPER 20 ULTRA May 2003 35 NOTES ...

Page 36: ...36 April 2004 WHISPER 20 ULTRA USA MASTERVOLT Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel 31 20 3422100 Fax 31 20 6971006 www mastervolt com info mastervolt com ...