whisper 25 ultra

USERS MANUAL
WHISPER 25 ULTRA
- 1500 RPM -
Marine diesel generating set 230/400V / 50Hz
Digital Diesel Control
Art.nr. . 50200441
MASTERVOLT
Snijdersbergweg 93,
1105 AN Amsterdam
The Netherlands
Tel.: +31-20-3422100
Fax.: +31-20-6971006
www.mastervolt.com
V4. December 2009
TABLE OF CONTENTS
Original instructions
Oorspronkelijke gebruiksaanwijzing
Originalbetriebsanleitung
Notice originale
Manual original
Istruzioni originali
Copyright © 2009 Mastervolt. All rights reserved.
Reproduction, transfer, distribution or storage of part or all of the contents in this document in any form without the prior written
permission of Mastervolt is prohibited.
TABLE OF CONTENTS:
1
INTRODUCTION.............................................................................................................................................................. 4
1.1
General .............................................................................................................................................................. 4
1.2
Service and maintenance ................................................................................................................................... 4
1.3
Guarantee .......................................................................................................................................................... 4
1.4
Liability ............................................................................................................................................................... 5
1.5
Identification ....................................................................................................................................................... 5
1.5.1
General.............................................................................................................................................. 5
1.5.2
Identification plate ............................................................................................................................. 6
2
INFORMATION ................................................................................................................................................................ 7
2.1
Safety ................................................................................................................................................................. 7
2.1.1
General.............................................................................................................................................. 7
2.1.2
Electrical safety ................................................................................................................................. 7
2.1.3
Earth insulation failures ..................................................................................................................... 7
2.1.4
Installation ......................................................................................................................................... 7
2.1.5
Operation........................................................................................................................................... 8
2.1.6
Fire and explosion ............................................................................................................................. 8
2.1.7
Chemicals.......................................................................................................................................... 8
2.2
Transport, lifting and storage.............................................................................................................................. 9
2.3
The Whisper 25 ULTRA ..................................................................................................................................... 9
2.3.1
Features ............................................................................................................................................ 9
2.3.2
Remote control .................................................................................................................................. 9
2.3.3
Documentation .................................................................................................................................. 9
2.3.4
Accessories included in the standard delivery................................................................................... 9
2.4
Components ..................................................................................................................................................... 10
2.4.1
Main components ............................................................................................................................ 10
2.4.2
Generator control panel................................................................................................................... 12
2.4.3
Remote control panel ...................................................................................................................... 12
2.5
Technical Information ....................................................................................................................................... 12
2.5.1
AC alternator ................................................................................................................................... 12
2.5.2
Engine ............................................................................................................................................. 13
2.5.3
Digital Diesel Control system........................................................................................................... 13
2.5.4
Battery charger ................................................................................................................................ 13
2.5.5
Alarms and shut down ..................................................................................................................... 13
2.5.6
Monitoring........................................................................................................................................ 13
2.5.7
Control............................................................................................................................................. 14
2.5.8
Remote control ................................................................................................................................ 14
2.5.9
Hour counter.................................................................................................................................... 14
2.5.10
Load indicator .................................................................................................................................. 14
2.5.11
Fuel specification............................................................................................................................. 14
2.5.12
Oil information ................................................................................................................................. 14
2.5.13
Cooling liquid................................................................................................................................... 14
2.5.14
Technical data ................................................................................................................................. 15
2
Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
TABLE OF CONTENTS
2.5.15
2.5.16
2.5.17
2.5.18
Electrical diagram control wiring Whisper 25 Ultra .......................................................................... 16
Terminal modes 115VAC – 230VAC - 400VAC 50H ....................................................................... 17
Generator Diagram 3 phase with AVR 230V – 400V 50Hz with AVR.............................................. 18
AC Wiring Diagram single phase with AVR 230V Hz (Double Delta) .............................................. 19
3
OPERATION .................................................................................................................................................................. 20
3.1
General ............................................................................................................................................................ 20
3.2
Operating Instructions ...................................................................................................................................... 20
3.2.1
Summarised operating instructions (daily use) ................................................................................ 20
3.2.2
Extended operating instructions ...................................................................................................... 20
4
MAINTENANCE............................................................................................................................................................. 23
4.1
Alternator.......................................................................................................................................................... 23
4.2
Engine .............................................................................................................................................................. 23
4.2.1
Preliminary instructions ................................................................................................................... 23
4.2.2
Bleeding fuel lines ........................................................................................................................... 23
4.2.3
Valve clearance ............................................................................................................................... 23
4.2.4
Replacing fuel filter .......................................................................................................................... 23
4.2.5
Replacing oil filter ............................................................................................................................ 24
4.2.6
Tensioning V-belt............................................................................................................................. 24
4.3
Regular maintenance ....................................................................................................................................... 25
4.3.1
Maintenance schedule..................................................................................................................... 26
4.3.2
Taking out of service ....................................................................................................................... 26
5
TROUBLE SHOOTING .................................................................................................................................................. 27
5.1
Alternator/ electrical faults ................................................................................................................................ 27
5.1.1
General............................................................................................................................................ 27
5.1.2
Trouble shooting table ..................................................................................................................... 27
5.2
Engine faults..................................................................................................................................................... 29
5.2.1
General............................................................................................................................................ 29
5.2.2
Trouble shooting table ..................................................................................................................... 29
5.2.3
Warnings ......................................................................................................................................... 32
5.2.4
Service address............................................................................................................................... 32
5.3
Special procedures alternator........................................................................................................................... 33
5.3.1
Automatic Voltage Regulator (AVR) ................................................................................................ 33
5.3.2
Residual voltage check / excitation procedure (flashing)................................................................. 34
5.3.3
Testing rotary rectifier diodes .......................................................................................................... 34
5.3.4
Winding resistant values.................................................................................................................. 35
5.3.5
Meggering ....................................................................................................................................... 35
5.4
Special procedures engine ............................................................................................................................... 35
5.4.1
Setting the RPM .............................................................................................................................. 35
5.4.2
Adjusting valve clearance and retightening the cylinder head bolts. ............................................... 36
5.4.3
Measuring exhaust backpressure.................................................................................................... 36
5.4.4
Disassembling instructions .............................................................................................................. 37
6
SPARE PARTS.............................................................................................................................................................. 39
MAINTENANCE LOG ............................................................................................................................................................... 42
EN / WHISPER 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
3
INTRODUCTION
1 INTRODUCTION
1.1
General
DANGER
This danger symbol refers to electric danger
and draws attention to special warnings,
instructions or procedures which, if not strictly
observed, may result in electrical shock which
will result in severe personal injury or loss of
life.
This manual applies to the Mastervolt Whisper 25 ULTRA
generating set controlled by Digital Diesel Control first
launched in September 2005. This manual is valid for the
following models:
Part number
51101005
51101006
51101305
51101306
Description
Whisper 25 Ultra 230 Volt Single phase
– 1500rpm / Marine
Whisper 25 Ultra 230 Volt Single phase
– 1500rpm / Marine -ungrounded
Whisper 25 Ultra 230 / 400 Volt 3 phase
– 1500rpm / Marine
Whisper 25 Ultra 230 / 400 Volt 3 phase
– 1500rpm / Marine -ungrounded
1.2
Regular service and maintenance should be carried out
according to the directions in this manual. For service and
maintenance one can appeal to the manufacturer or the
dealers.
1.3
For other models see our website: www.mastervolt.com
The Whisper 25 ULTRA Marine Diesel Generating set is
manufactured and marketed by Mastervolt.
It is important to read this manual before installing and
operating the generating set. Both safety and durability
rely very much on the correct identification, installation and
a good understanding of ratings, features, design,
maintenance and operation procedures.
The
information,
specifications,
illustrations
and
statements contained within this publication are given with
our best intentions and are believed to be correct at the
time of going to press.
Our policy is one of continued development and we reserve the right to amend any technical information without
prior notice.
Whilst every effort is made to ensure the accuracy of the
particulars contained within this publication neither the
manufacturer, distributor, or dealer in any circumstances
shall be held liable for any inaccuracy or the
consequences thereof.
WARNING
A warning symbol draws attention to special
warnings, instructions or procedures which, if
not strictly observed, may result in damage or
destruction of equipment, severe personal
injury or loss of life.
Service and maintenance
Guarantee
Mastervolt guarantees that this generating set has been
built according to good workmanship, according to the
specifications in this manual and according to European
Community safety regulations.
During production and prior to delivery, all of our
generating 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
request. The guarantee period is two years, limited to
1000 running hours. Some aspects of our guarantee
scheme are given here in more detail:
Guarantee does not cover failures that are caused by
misuse, neglect or a faulty installation.
Example 1. Faulty installation:
Seawater entering the engine is the most common cause
of damage to combustion engines in boats. (Both to
propulsion and generator engines.) The entry of water
must be avoided under all conditions. Be aware that the
conditions in blue water sailing can be extreme. See the
installation manual for instructions but remember these are
for guidance only as many factors influence the installation
of a generator. The ultimate responsibility will always be
with the owner to ensure a safe and compliant installation.
WARNING
Damage caused by the ingress of water is
never covered by guarantee
4
Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
INTRODUCTION
Example 2: Misuse:
Long term running with no load or too little load can cause
the exhaust to get choked with soot or carbon. Cleaning
the exhaust is not covered by guarantee.
If any problem arises which could be subject of guarantee,
procedures should be followed as described in the
guarantee conditions, unauthorised repairs could lead to
further damage and violate the guarantee conditions.
Example 3: Neglect
Sometimes the seal of the raw water pump starts leaking.
Mostly this begins with a little drip and slowly gets worse.
Regular visual inspection of the generator is necessary to
prevent damage to occur from a leaking water pump.
When one find serious damage after weeks of neglect
guarantee claims will not be honoured.
Should work take place, which is not in
accordance 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 specifications.
In all these cases the guarantee may become
invalid. Use original spareparts only!
Example 4: Neglect
Whisper generators have an option for an auto start/stop
mode or interval mode.
Mastervolt cannot be held responsible for damage caused
by the unattended running generator.
Guarantee means that faulty parts are repaired or
replaced free of charge. If necessary the whole generator
unit will be exchanged. Labour necessary to complete
repairs on board a vessel executed by an authorized
service engineer is covered, but is limited to a reasonable
number of hours and reasonable rates in relation to the
actual repair work that has to be done.
Travel expenses and travel hours are not covered. Also
not covered is the labour required to take a generator out
of a boat or for reinstallation. There is no cover for labour
needed to get access to the generator, for example to
remove equipment or bulkheads etc.
Goods to be delivered under guarantee will be invoiced.
Only after the faulty goods are returned will the invoice be
credited. Payment in advance may be required or
guaranteed by credit card. If after the faulty goods are
returned, it is indicated that the failure was not covered by
guarantee a credit will not be issued. For example if a
Printed Circuit Board is returned with clear damage
caused by seawater, guarantee will be refused.
Freight costs to deliver spares by normal mail or carriers is
covered under guarantee. Special services like express
mail, overnight delivery etc. are not covered. Taxes and
duties are not covered. For shipments to remote off shore
areas any additional costs incurred over normal carriage
will be invoiced to the customer.
The cost for returning faulty goods is not covered under
guarantee.
1.4
Liability
Mastervolt does not accept responsibility for damage,
injuries or casualties which are the result of operation of
the generating set in specific conditions which brings
dangers which could not be foreseen, or could be avoided
by additional measures. Mastervolt does not accept
liability for damage due to use of the generator, possible
errors in the manuals and the results thereof.
Automatic start/stop
Mastervolt cannot be held responsible for damage
caused by the unattended running generator using the
auto-start/stop mode or interval mode.
1.5
1.5.1
Identification
General
Before using this generating set it is very important to
identify the set correctly. To communicate for service or
ordering parts it is also essential to correctly identify the
generating set. Also for the daily operation of the generating set it is necessary that the operator knows the correct
specifications.
Additional agreements could be part of the contract of
delivery.
EN / WHISPER 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
5
INTRODUCTION
1.5.2
identification plate are also some basic features of the
set:
Identification plate
All required identification data are on the identification
plate.
MODEL
: Whisper 25 ULTRA
ARTICLE NO
: 50901005
SERIAL NO
:
MAX.POWER
: 25kW (kVA) cos = 1
VOLTAGE
: 230V / 230 - 400V
FREQUENCY
: 50Hz
CURRENT
: 108A / 3 x 36A
PHASE
: Single phase / 3 phase
2
POWER
The nameplate gives the nominal maximum continues
load in kVA = kW calculated with 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 as
shown on the nameplate. Power is rated at an
ambient temperature of 40°C and a seawater
temperature of 25ºC. For higher temperatures the
generating set has to be de-rated.
3
VOLTAGE. This shows the nominal voltage.
This voltage should be within the specified tolerance
at the nominal frequency. The Whisper 25 ULTRA
can be connected for different voltages in single
phase or tri phase. The nameplate indicates the
connection as made in the factory; BE AWARE THAT
THE CONNECTIONS COULD BE RECONNECTED
BY FORMER USERS
4
FREQUENCY. This is shown in Hz and is determined
by the speed of the engine (RPM). 50 Hz correlates
with 1500 rpm.
5
CURRENT. This shows the maximum current that is
acceptable at the specified frequency, voltage and
power factor. When connected in tri phase the
indicated current is the current between two phases
that can be taken off three times.
6
WEIGHT shows the net dry weight (approximately) in
kg. This is without fuel, oil, packing and external
installation equipment
7
CE MARKING.. The CE symbol shows that the
generating set is build according to European
Community safety regulations. This includes the
regulations regarding the safety of pleasure craft,
safety of machinery, regarding electric safety and
electric magnetic compatibility (EMC).
DIMENSIONS : 126cm x 68cm x 80cm
WEIGHT
: 480 kg
YEAR OF MANUFACTURING
: 2005
Manufacturer : Mastervolt b.v.
Snijdersbergweg 93, 1105 AN Amsterdam
The Netherlands Tel. + 31 (0)20 3422100
Fig. 1: Identification plate.
Fig. 2: Location identification plate.
1
The identity of the generating set is given by the
SERIAL NUMBER.
Example:
SERIAL NO:
: W822B001
version “B”
When this number is available the manufacturer can
trace the specifications of the generating set. On the
6
Safety also relies on the installation, application and
circumstances. See also the remarks in this manual under
SAFETY
Before changing a factory setting you are advised to
consult the manufacturer. When the generating set you
have to identify is not new you have to take into account
the possibility that former users did change the settings.
Check the settings (voltage, frequency, rpm) when there is
any doubt.
Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
INFORMATION
2 INFORMATION
2.1
Safety
2.1.1
2.1.3
General
When correctly installed and used in normal
circumstances this generating set fulfils EC safety
regulations. This generating set could be part of an
installation or could be used in a way that additional
regulations of the EC or other authorities have to be taken
into account.
DANGER
Warning signs draw attention to special
warnings, instructions or procedures which, if
not strictly observed, may result in electrical
shock which will result in severe personal
injury or loss of life.
Circumstances could make it also necessary
to take additional measures. Be aware of wet
conditions and hazardous environments
caused by explosive gases etc
2.1.2
Electrical safety
This warning sign indicates parts which could
be live. The voltage of 230V or 230V/400V
generated by this generating set is dangerous
and if instructions and procedures are not
strictly observed may result in electrical shock
which will result in severe personal injury or
loss of life.
•
Check all wiring at least once a year. Defects, such as
loose connections, burned cables etc. must be
repaired immediately.
•
Do not work on the electrical system if it is still
connected to a current source. Only allow changes in
your electrical system to be carried out by qualified
electricians.
•
Using the auto-start/stop (interval) mode the generator
can start unexpectedly. When working on the electrical
system, the 3 Amp fuse must be removed from the
control panel and the battery plus cable must be
removed from the battery.
•
Connection and protection must
accordance with local standards.
be
done
Earth insulation failures
According to local regulations and depending on the
application it could be necessary to take measures for
protection against earth insulation failures.
In the standard delivery “neutral” and “ground” are not
connected. To make a connection between “neutral” and
“ground” could be necessary as part of a specific
insulation failure protection system.
Small pleasure craft in Europe is submitted to The
Recreational Craft Directive 94/25/EC. The guidelines of
this directive refer to (ISO 13297).
When the installation complies with this standard the
“neutral” and “ground” should be connected on the
generating set.
Be aware that insulation protection systems can be
different for different applications and even within the ship
there could be different standards for different spaces. We
did refer to the Recreational Craft Directive that applies to
pleasure craft up to 24 m of length. Sometimes one has to
comply with other standards such as the rules of
certification societies like Lloyds Register of Shipping or
Veritas, regulations for the protection of personal, building
legislation, etc. It is of the greatest importance to have
expert advice on this issue.
In all situations the transfer switches between
shore, inverter and generator should switch
both neutral (N) and all phase lines (L1, L2
and L3).
2.1.4
Installation
Whisper generating sets are not self contained and have
to be properly installed in enclosed areas such as a
machine room.
Installation includes measures to be taken to
outlet exhaust fumes which contain carbon
monoxide and are extremely dangerous.
Carbon monoxide (CO) is an invisible odourless gas.
Inhalation produces headache, nausea or death.
Installation includes measures for proper ventilation, safe
electric connections, safe installation of the starting
battery, proper fitting of the cooling system and fuel pipes
etc. See the installation manual.
in
EN / WHISPER 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
7
INFORMATION
2.1.5
Operation
External moving parts like fans and V-belts are covered by
the canopy and therefore the Whisper 25 ULTRA is very
safe when the canopy is closed.
BREAK
THROUGH
HERE
Nevertheless take note of the signs on the
generating set which show symbols in a
triangle indicating danger.
When service has to be carried out while the
engine is running, be aware of moving parts
like V-belts.
•
The generating set should be operated by authorised
personnel only.
•
Be aware of hot parts and especially parts of the
exhaust system and cooling 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 corrected.
FIRE EXTINGUISHER PORT :
IN CASE OF FIRE, DO NOT OPEN SOUNDSHIELD.
TO AVOID SERIOUS INJURY OR DEATH FROM FIRE
SHUT DOWN ENGINES, GENERATOR SETS AND BLOWERS.
IMMEDIATELY DISCHARGE ENTIRE CONTENTS OF GASEOUS
PORTABLE FIRE EXTINGUISHER THROUGH THIS PORT.
Fig. 3 Fire extinguisher port.
•
In case of fire do not open the soundshield. To avoid
serious injury or death from fire, shut down engines,
generator sets and blowers. Break through the label
which is indicated by BREAK THROUGH HERE and
then immediately discharge entire contents of gaseous
portable fire extinguisher through the fire extinguisher
port. On the generating set this fire extinguisher port is
indicated by the label as shown in figure 3.
Poor electrical connections or using wiring which is not
suited for the rated currents can cause overheating
and possibly fire.
•
Do not attempt to operate the generating set with a
known unsafe condition. Disconnect the battery
positive (+) lead prior to attempting any repairs or
cleaning inside the enclosure.
•
Always consult the manual before carrying out
maintenance.
•
Do not change the settings without consulting the
manufacturer. Keep a record of setting changes in this
manual.
2.1.7
•
2.1.6
Fire and explosion
Chemicals
•
Fuels, oils, coolants, and battery electrolyte can be
hazardous to personnel if not treated properly. Do not
swallow or have skin contact with these liquids. Do not
wear clothing that has been contaminated by fuel or
lubricating oil.
Fuels can be flammable. Proper handling
limits the risk of fire and explosion.
•
Avoid refilling the fuel tank while the engine is running.
When oil or fuel is leaking do not use the generating
set.
•
Gaskets may be manufactured from asbestos.
Particles of this material should not be inhaled as this
may result in fatal diseases.
•
Do not run the engine close to explosives or gasses.
•
•
Hydrogen gas generated by charging batteries is
explosive. Take measures for proper ventilation. Do
not smoke or allow sparks, flames, or other sources of
ignition around batteries.
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.
•
Engines may be fitted with seals or O-rings
manufactured from "viton" or similar material. When
exposed to abnormal high temperatures in excess of
400°C an extremely corrosive acid is produced which
cannot be removed from the skin. If signs of
•
8
Keep a fire extinguisher on hand.
Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
INFORMATION
decomposition are evident, or if in doubt, always wear
disposable heavy duty gloves.
2.3
The Whisper 25 ULTRA
2.3.1
2.2
Transport, lifting and storage
When lifting the generating set avoid any risk
of personal injuries, do not stand under the
generating set.
•
Use soft slings to avoid damage
•
On the engine are lifting eyes, which can be used to
take the generator out of the capsule. The lifting eyes
can also be used to lift the entire generator set,
including the capsule
•
After transporting the generating set check for damage
before installation.
•
Long term storage can have detrimental effects on
engine and alternator. The engine should be put
through an engine preservation procedure. (See the
maintenance chapter)
2.3.2
The alternator windings tend to condense. To minimise
condensation, store the generating set in a dry and
warm storage area.
2.3.3
•
•
After removing the generating set from long term
storage perform an insulation check. (See the
alternator maintenance paragraph for procedures)
•
While the battery is stored it should be recharged
every 12 weeks.
Features
This generating set includes a 4 cylinder diesel engine
which is connected by close coupling to a tri phase
synchronous 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. The complete set is again on rubber mountings. All
cables and hoses are guided through the capsule’s sides.
The set is not self contained and is only operable after
proper installation using additional accessories and
installation materials.
Installation accessories are listed in the installation manual
and are available through the supplier of the generating
set. The full automatic Digital Control is based on
microprocessor technology. Several automatic start/stop
functions can be programmed and monitored (see Digital
Diesel Control users manual).
Remote control
The full automatic remote control panel including 15 mtr
cable comes as standard with the Wisper 25 ULTRA.
Documentation
Included in the delivery is
• This users manual (number: 50200441),
• An installation manual (number: 50200451),
• A users manual for DCC (number: 50200461)
• A quick reference guide for the DDC (50200275).
Not included in the standard delivery but available as
options are:
• Parts manual; number: 50200187
• Workshop manual; number: 50200174
However in this manual there is a list of important parts for
maintenance and spare parts as well as a chapter on
maintenance and problem solving.
All manuals are
www.mastervolt.com.
2.3.4
•
•
EN / WHISPER 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
available
on
our
web
site
Accessories included in the standard
delivery
Expansion tank, hose and fittings
Template to mount the generator
9
INFORMATION
2.4
2.4.1
Components
Main components
01
02
03
04
05
06
07
08
09
10
11
12
13
14
Thermostat housing
Boiler connection
Engine coolant pump
V-belt
Exhaust connection
Bypass cooling water out
Bypass cooling water in
Battery +
Battery Fuel out
Fuel in
Raw water inlet
Raw water pump
Rubber engine mounting
15
16
17
18
Filler cap engine oil
Filler cap engine coolant
Rubber engine mounting
Rocker cover
Fig. 4: Left View main components Whisper 25 Ultra
Fig. 5 Top View main components Whisper 25 Ultra
10
Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
INFORMATION
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
Hoist eye rear
Engine speed adjusting
screw
Fuel injector
Glowplug (4x)
Fuel filter
Fuses
Control panel
Air cleaner element
Indentification plate
Oil swump handpump
Coolant drain plug
Engine oil dipstick
Fuel solenoid
Oil filter
Injection pump air bleeding
screw
Fuel lift pump for manual
primimg
Fuel injection pump
Heat exchanger
Fig. 6 Front View main components Whisper 25 Ultra.
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
Temperature switch
Hoist eye front
Alternator
Exhaust manifold
(watercooled)
Hoist eye alternator
Digital Diesel Control (DDC)
Expansion tank
Power take off hydro pump
Remote control
AC power output
Temperature switch exhaust
Cooling water injection bend
Engine oil pressure switch
Starter motor solenoid
Starter motor
Engine serial number (above
starter motor solenoid)
Automatic voltage regulator
(AVR)
Fig. 7: Rear View main components Whisper 25 Ultra.
EN / WHISPER 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
11
INFORMATION
2.4.2
Generator control panel
2.5
2.5.1
Start / Stop
Internal fuel pump Digital Diesel Control
Fuse 3A
Fuse 3A
Remove fuse
before maintenance
Auxiliary
Fuse 10A
External Fuel Pump
Fuse 3A
Whisper Digital Diesel Operation Unit
Observe instructions in the manual
Replace fuses with same type and rating
Technical Information
AC alternator
The tri phase synchronous alternator is directly coupled,
one bearing, brushless, rotating field design, 12 wire, four
pole (1500 RPM) and regulated by an Automatic Voltage
Regulator (AVR).
The exciter stator has a residual magnetism, which
guarantees self-exciting of the generator on start-up (that
thereby generates a residual voltage of about 10%
nominal voltage).
Fig. 8 Control panel.
Fig. 11 Automatic Voltage Regulator (AVR)
Fig. 9 Digital Diesel Control unit
2.4.3
Remote control panel
03
02
01
04
05
06
07
01
Generator load indicator
02
Failure LED
03
Start button
04
Stop button
05
Display
06
Select button
07
Set button
Fig. 10 Digital Diesel remote control panel.
12
The AVR, powered by an auxiliary circuit on the main
stator, acts on the exciter stator indirectly controlling the
field generated by the main rotor by means of the
sequence exciter rotor - diode bridge - main rotor.
The voltage regulator controls and keeps constant the
average voltage of one phase. The voltage setting on the
AVR can be adjusted with the help of a trimmer “V”
between 185 and 290 Volts. (See par. 5.3.1)
A frequency control progressively deactivates the machine
when the drive motor speed drops below a pre-set,
adjustable threshold preventing over-excitement at low
operating speeds and abating the load engage effects on
the engine.
The AVR works only within limits of the set frequency 50
Hz. When operating below the lower limit of 46 Hz ± 1 Hz
the AVR will stop regulating to avoid overloading the
exciter coil (This setting can be changed with trimmer
“UF”). (See par. 5.3.1)
When applying the generator set at 60 Hz the AVR is readjustable as well. To operate at 60 Hz the engine RPM
and Digital Diesel Control settings must also be changed.
For the USA market a dedicated manual (Art. No
50200444) is available for 60 Hz applications. Please refer
to the Mastervolt service centre for specific instructions to
convert the generating set to 60 Hz.
A further option is to readjust the stability of the regulator.
In the event of very irregular (alternating) loads it could be
necessary to change this setting with the help of trimmer
“S” to avoid interference of the regulator and the
Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
INFORMATION
alternating load. In conclusion the regulator reaction time
can be modulated to eliminate any voltage instability that
may arise. (See par. 5.3.1)
Trimmer
Trimmer V
V
TrimmerST
ST
Trimmer
Trimmer UF
Trimmer
UF
Jumper J
2.5.2
2.5.3
Fig. 12 AVR Trimmers (potentiometers).
The power comes from 12 wires that can be connected in
star, delta or combined double / star and double / delta
arrangements to take off different voltages. For tri phase
400V use, the alternator should be connected in star. For
single voltage 230V use the wires should be connected in
double delta. The alternator is specially designed that in
this way one can take off the full power off the generator.
However the use of three groups of 230 V taken from the
three corners of a single delta arrangement is
recommended. Other voltages (115 Volt) can be arranged
as well. Further technical data on the connections of the
alternator can be found in drawings and diagrams in this
manual.
The tri phase synchronous alternator is directly coupled,
one bearing, brushless, rotating field design, 12 wire, four
pole (1500 RPM) and regulated by an Automatic Voltage
Regulator (AVR).
Residual magnetism causes a small voltage over the
stator windings and allows a current to flow in the
windings, which is magnified because of the feed back
effect between rotor and stator. The field windings in the
rotor are short-circuited over a diode to rectify the current.
A capacitor over an additional winding in the stator which
is at an angle with the power-winding keeps the voltage
stable within 5 % at the specified rpm and provides voltage
fall off with speed, preventing over-excitation at low engine
speeds and softening the effect of load switching to relieve
the burden on the engine.
Further technical data on the design of the alternator can
be found in drawings and diagrams in this manual.
EN / WHISPER 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
Engine
The Whisper 25 generating set is based on the Mitsubishi
S4S 4 cylinder 4 stroke diesel engine. The engine is
indirectly injected. The engine is water cooled and the
cooling liquid is cooled by a heat exchanger and raw (sea)
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 copper
nickel.
The engine has been specially adapted for the Mastervolt
application and is very different from the standard engine
supplied for industrial applications!
Digital Diesel Control system
The standard electrical engine control system is 12 Volt
negative earth, non earth return (ungrounded) is available
as optional. Check your identification data to determine
which system is applied. The system is designed
according to the "energise to run" system. The Digital
Diesel Control is a very advanced microprocessor based
full automatic system. Besides automatic start the system
offers many monitoring options. See the separate Digital
Diesel Control users manual (number 50200261).
The microprocessor unit of the Digital Diesel Control is
located in the black box on top of the AC alternator (see
figures 7 and 9).
2.5.4
Battery charger
On the engine is an alternator generating 50 Amp 12V.
This current is rectified to charge the battery. The voltage
is regulated at approx. 14.4V.
2.5.5
Alarms and shut down
In case of malfunctioning this will be indicated by the
failure light, details will be shown on the display and the
engine will be shut down. There are three functions
guarded: oil pressure, oil temperature and exhaust
temperature.
Exhaust temperature too high indicates the cooling water
to be blocked.
All alarm switches are closed when no malfunction occurs.
A contact is cut in the event of an alarm. This means that
the generating set will not work when the alarm switches
are broken or there is a loose wire. The system therefore
is intrinsically safe. The panel will display details about the
alarm.
2.5.6
Monitoring
Refer to the operating of the Digital Diesel Control
13
INFORMATION
2.5.7
Control
The generating set can be operated by push buttons on
the panel on the alternator or by the remote control. By
pushing the START button the control system is activated
and will start the engine automatically. Pushing the STOP
button will stop the engine and the electrical system will be
deactivated. Stopping the engine is executed by the
solenoid that will shut off.
2.5.8
Hour counter
The remote control offers several timer functions that help
to schedule maintenance.
2.5.10 Load indicator
On the remote control the load will be indicated on the
display and by the LED-bar. The load is measured by
current transformers on the alternator. All phases are
monitored and overload of all phases or just one or two
phases will provoke an alarm or even shut down when the
alarm is ignored.
2.5.11 Fuel specification
The engine must only be used with diesel fuel oil which
conforms to the standards for use in modern diesel
engines. Fuel free from water and contaminants is of the
utmost importance.
2.5.12 Oil information
1
Specification:
The oil must be suitable for oil changes as specified in
the maintenance chapter. The Mitsubishi engine must
be run on heavy duty lubricating oil meeting the
requirements of API class CC, CD, CF or CF_4.
It is very important to use the correct oil
specification. Very often local oil suppliers
recommend a higher class, because they
assume that a higher class is allowed. This is
not the case. One should not follow these
recommendations.
Using the wrong specification will cause high
oil consumption.
14
Oil viscosity:
We recommend a multigrade oil 15W40.
3
Oil capacity:
Excluding the oil filter the content of the crankcase is
9 l. Including the oil filter it is 9.3 l. Note that the
engine may contain some residual oil due to testing at
the factory.
While filling, check the lubricating oil level by means
of the engine oil dipstick. Do not overfill with
lubricating oil as this may have a detrimental effect on
engine performance
Remote control
All wiring connections from the remote control to the board
are made by plug in connectors.
An intermediate communication cable is in the standard
supply. If necessary an optional longer 8 wire
communication 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. (See installation
instructions)
2.5.9
2
4
Oil pressure
•
Minimum at idle 98 kPa (1 kgf/cm²/14psi) (1 bar).
•
At 2230 rpm ±300 kPa (3 kgf/cm²/45 psi) (3 bar).
2.5.13 Cooling liquid
The engine is cooled by cooling liquid. The capacity of this
system of the Whisper 25 ULTRA is 9.5 litres.
Always use coolant which is compatible with
aluminum components of the cooling system.
Do not mix coolants with different kinds of
chemical compound, as this may cause
congelation of the coolant. In case of doubt
refresh the content of the entire cooling
system.
We recommend not using water but cooling liquid that is
marketed for the use in combustion engines. Cooling liquid
protects the engine against frost to minus 25° C. Also it
protects the engine block against corrosion. One can fill
the engine via the filling cap on the exhaust manifold. Fill
up till the level is just below the filling cap. When the
engine is on temperature the liquid will expand and the
redundant liquid will be pressed into the expansion tank.
This tank has to be filled up till the mark. When cooling
liquid is not available clean fresh water could be used with
an additive of anti freeze. When using water with anti
freeze the right mixture has to be calculated according to
the information of the supplier of the anti freeze. When the
cooling is based on keel cooling or radiator cooling the
capacity of these coolers and piping has to be taken into
account calculating the right mixture.
The cooling liquid in the engine is pressurised and has a
boiling point above 100° C. The temperature switch in the
thermostat housing switches at 110° C. When keel cooling
is applied the cooling system is not pressurised. There
should be a special cap on the manifold without valves
leaving the connection to the expansion tank open. See
the special manual on keel cooling and radiator cooling.
Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
INFORMATION
2.5.14 Technical data
GENERAL
Model
RPM
Alternator
Engine
Number of cylinders
Displacement
Bore X stroke
Combustion air consumption
Continuous power 50Hz
Cooling system
Cooling water pump
Fuel lift pump engine
Starting battery (optional)
Fuel consumption
Control
Sound level (ISO 3746):
ELECTRICAL SPECIFICATIONS
Output voltage
Output rating 50Hz
Voltage tolerance
Frequency tolerance
Alternator
Voltage regulation:
MECHANICAL SPECIFICATIONS
Supply includes
Dimensions in sound shield hxwxd
Dimensions without sound shield
Color:
Weight with sound shield
Weight without sound shield
Max. operation angle
Standard supplies
Optional
WHISPER 25 ULTRA
1500 rpm
3 phase synchronous (air cooled)
Mitsubishi diesel, model S4S (Japan)
4
3331 cm3
94x120 mm
10 m³/min.
25 kW electric power
indirect cooling by raw water, 20-25 l/min.
PTO driven Mastervolt self priming impeller pump, type M16
Mechanical pump, additional electrical pump available upon request
110 Ah 12V
2-9 litre/hour, load dependent
Digital Diesel Control including automatic start/stop
72.3 dB(A) (distance = 1 meter)
230/400V 50 Hz alternating current (AC) tri phase re-connectable to take off single
phase or dual voltage
Whisper 25kVA at powerfactor cos phi = 1
± 2% (balanced load)
± 3%
Air cooled, brushless, four pole, twelve wire, synchronous
AVR
Sound shield with steel base, mounted on rubber anti vibration mounts. (Genset
without sound shield is optional)
126x68x80 cm
115x60x75 cm
metallic silver / grey
580 kg
480 kg
25 degrees
Remote panel (+15 m cable), fuel filter, fuel lift pump, user and installation
manuals
Installation kits, mobile (vehicle) version, non earth return, spare part kits, PTO to
drive hydraulic pump
EN / WHISPER 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
15
INFORMATION
2.5.15 Electrical diagram control wiring Whisper 25 Ultra
Fig. 13 Electrical Diagram control wiring Whisper 25 Ultra
16
Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
INFORMATION
2.5.16 Terminal modes 115VAC – 230VAC - 400VAC 50H
Fig. 14 Terminal modes
EN / WHISPER 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
17
INFORMATION
2.5.17 Generator Diagram 3 phase with AVR 230V – 400V 50Hz with AVR
* TO CONNECT NEUTRAL TO GROUND
REFER TO 2.1.3 USER MANUAL WHISPER 25U
*
Fig 15. Generator Diagram 3 phase with AVR 230V – 400V 50Hz with AVR
18
Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
INFORMATION
2.5.18 AC Wiring Diagram single phase with AVR 230V Hz (Double Delta)
* TO CONNECT NEUTRAL TO GROUND
REFER TO 2.1.3 USER MANUAL WHISPER 25U
Fig 16. AC Wiring Diagram single phase with AVR 230V Hz (Double Delta)
EN / WHISPER 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
19
OPERATION
3 OPERATION
3.1
General
The generating set is operational after full installation and
filling up with: fuel, engine lubricating oil and cooling liquid,
filling the starter battery with acid (Mastervolt batteries do
not need to be filled up and are sealed), connecting the
remote control panel.
In operation checks:
1 Check for abnormal noise or vibration
2 Check the voltage
3 Check sea water flow at exhaust outlet
4 Power
source
selector
switch
(off/shore
power/generator power). Switch to power source
generator.
5 Before loading the generating set up to maximum,
have it run warm. Continuous load should be
restricted 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 230V/400V power source, if
available.
1
2
1
2
Maximum oil level
Minimum oil level
Fig. 17 Engine Oil Dipstick markings.
3.2
Operating Instructions
3.2.1
Summarised operating instructions (daily
use)
Routine "pre-start" checks:
1
2
3
4
5
Check oil level (see figure 17).
Water inlet (all valves open).
Power
source
selector
switch
(off/shore
power/generator power). Switch to power source
switch "OFF", or switch off all consumers in the usual
way.
Switch on battery switch (when installed).
Fuel valve: open.
3.2.2
Extended operating instructions
Check when starting the first time or after a longer
period of rest:
1
2
3
4
5
6
If there is any damage caused by transport or
installation.
Check if installation conforms to the installation
instructions.
Ensure the generating set is free to turn without
obstruction.
Check all hoses and hose connections for leaks.
Check all cables and cable end terminal connections.
Check the engine and generator mounting bolts.
Starting:
Push the start button to initiate the full automatic
starting procedure. You can monitor the procedure on
the display.
20
Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
OPERATION
Routine "pre-start" checks:
1 Check engine oil level.
The generator switches off in the event of insufficient
oil-pressure. Even when the oil level is too low the oil
pressure can be high enough. Do not run the
generator with the oil below the lowest mark in the,
because a smaller volume of oil will become
contaminated considerably quicker than a larger
volume. Therefore we recommend daily oil-checks.
Check oil level prior to starting the engine or at least 5
minutes after the engine has stopped.
2 Check sea water cocks. Do not forget the valve of the
water outlet in case of a water/exhaust gas separator.
3 Check the water strainer.
4 Check for leakages.
5 Regularly check the siphon vent in the cooling water
supply.
6 Switch main Power Source Selector switch to "OFF"
or switch off all devices.
7 Switch on the battery switch.
Checks once the generator is in operation:
Starting the generator:
By pushing the start button briefly the electric system
is activated and the starting procedure will begin. (By
pushing the stop button the system is deactivated)
The first time starting up or after running out of fuel it
could be necessary to prime the fuel system. (See
bleeding fuel system instructions in the maintenance
chapter).
Before loading the generating set up to maximum, have it
run warm. The first 50 hours of running the continuous
load should be restricted to 70 % of maxi-mum load.
Running for long periods at no load or light load in the first
50 hours can cause cylinder glazing and high oil
consumption.
1
2
3
Check for abnormal noise or vibration.
Check the voltage.
Check coolant flow.
Always check immediately after starting the generator
if cooling water flows at the exhaust outlet. If this is
not the case, check the cooling water 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/generator power). Switch to power source
generator.
A restart protection prevents starting the engine when it is
already running, which could cause damage.
In the event of starting problems (numerous
attempts are made), close the sea-water inlet
cock while cranking to prevent the outlet
system and engine to fill up with water.
During the starting process, the cooling water pump is
driven with the engine. The cooling water is discharged to
the exhaust outlet, because the engine does not run, the
exhaust pressure is not high enough to expel this water.
Open the valve immediately when the engine starts in
order to prevent damaging the impeller.
Water in the cylinders will cause serious damage to the
engine. 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 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
21
OPERATION
Engine load during longer operation:
Please ensure that the generating set is not overloaded.
Overloading occurs when the electrical load (demand) is
so high that the generator cannot be turned around
properly by the diesel engine. Overloading causes the
engine to run rough, while using oil and excessive fuel and
producing soot by the exhaust. The engine can even stop.
Stopping the generating set:
1
Avoid stopping of the generator abruptly after a long
period of operation at high load! Doing so, you avoid
unnecessary thermal load to your generating set!
Act as follows:
Prior to switching off the generating set, decrease the
generator load (i.e. turn off most electrical users) and
let the generator run at low load for approx. 5 minutes
to allow the engine to get properly cool (the influent
sea water must flow through the system in order to
cool the engine).
If the generator is operating in a hot environment and
you do not act as given above, the excessive heat 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
electric motors, compressors (in refrigerators or air
conditioners etc.).
2
Press the STOP button.
3
Close the inlet sea water cock.
4
Switch to an other 230V/400V power source
The generator should therefore only be loaded at the
maximum rated power for short periods (2-3 hours) only!
The high peak current is meant for the ability to start
electrical devices that need a high current for starting
especially electric motors and compressors (from a still
stand state).
In order to prolong the generating set’s life expectancy, the
nominal electrical demand on the system should be about
70% or the rated generating set’s maximum load. Please
note this when switching on your electrical devices!
Nevertheless, the Whisper is designed so as not to
overheat, even under extreme conditions.
Do not run the generator for very long periods at no load
or at very low load. When this is necessary do load the
generator at least one hour in 10 hours for minimum 70%.
Long term running at too low load will cause the exhaust to
be choked by carbon.
Never remove the battery while the engine is
running or any electrical cable while the
battery is connected in the circuit. Only
disconnect the battery with the engine
stopped and all switches in "OFF" position
22
Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
MAINTENANCE
4 MAINTENANCE
4.1
Alternator
The alternator does not require any maintenance. Periodic
inspection and cleaning is recommended, depending on
environmental conditions.
However when the alternator has been idle for a long
period attention to winding condition is recommended.
The condition of windings can be assessed by
measurement of insulation resistance to earth. (See 5.3.5
Meggering)
The alternator bearing is greased for life and is therefore
not regreasable
01
4.2
4.2.1
02
Engine
Preliminary instructions
All regular maintenance can be carried out when the
enclosure is open. When oil and dirt has gathered in the
enclosure measures have to be taken to avoid spilling oil
and polluting the environment.
The first service on the engine should be carried out after
50 hours of its life and after a major overhaul. 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
consumption.
For the same reason it is of the greatest
importance to use the right oil specification
01
Injection pump air bleeding screw
02
Hand operated fuel lift pump
Fig. 18 Bleeding fuel lines.
4.2.3
Valve clearance
When the engine is in cold condition both valves (inlet and
outlet) should have a clearance of 0.25 mm. The
adjustment has to be done at TDC (see 5.4.2).
4.2.4
Replacing fuel filter
Filter change depends on contamination of the fuel, but
should be done however, at least every 300 running hours.
A clogged filter results in a lack of output of the generating
set.
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 lines
Ensure there is sufficient fuel. The Whispers are self
bleeding. To check the well functioning release the bleed
screw on the high pressure fuel pump. Turn loose the cap
of the fuel lift pump, and move the piston up and down to
prime the system. Retighten the bleed screw when no
further air bubbles are expelled. Retighten the cap when
ready.
EN / WHISPER 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
01
01
Fuel filter
Fig. 19 Location fuel filter cartridge
23
MAINTENANCE
4.2.5
Replacing oil filter
Replacement has to be executed according to the
schedule in this manual. Drain the oil using the sump
pump and put some tissues under the filter.
01
02
Fig. 21 Location rubber packing-ring oil filter.
A smear 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.
4.2.6
Tensioning V-belt
The alternator bracket allows for readjust of the V-belt.
Deflections should be 13 mm (see fig. 22)
01
Engine oil filter
02
Engine oil dipstick
Fig. 20 Location engine oil filter and dipstick.
Fig. 22 Tension V-belt.
24
Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
MAINTENANCE
4.3
Regular maintenance
When replacing the impeller the gasket between the pump
case and the cover should be replaced as well. So when
ordering a spare impeller order a gasket as well. Remove
the cover to get access to the impeller. Remove the old
impeller with the help of two screwdrivers. Install the new
impeller and add some grease. Turn the blades in the
direction of rotation of the pump.
CHECK DAILY:
• Oil level (see fig. 23)
Take care the oil level is never
below the mark. Do not add oil
when the level is still above the
mark
1
2
Maximum oil level
Minimum oil level
Fig. 23:
•
•
•
•
1
2
Level cooling liquid
Hoses for loose connections or deterioration.
Water inlet filter.
V-belt tension
AFTER FIRST 50 HOURS:
• Change oil and replace the oil filter.
Have the engine run until it is on temperature and stop
it. Replace the filter. Drain oil by the sump pump into a
suitable retainer and fill up with fresh oil. Start the
engine again and have it run for 5 minutes. Stop the
engine again and pause for a few minutes to let the oil
gather in the crankcase. Check the level again and add
oil when necessary.
• Check and tighten nuts, bolts, and unions, paying
particular attention to the fuel system.
• 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 investigating
the cause as this may result in an expensive
breakdown.
• Check air vent (siphon breaker valve) on a regular
basis. When the air vent it not working properly, the
engine can fill up with water by siphoning. Water in the
combustion chamber causes serious damage to the
engine.
• Check and readjust V-belt.
• Check the electrical connections
EVERY 300 HOURS:
• Replace the impeller of the raw water pump.
• Retighten the cylinder head bolts and adjust the valve
clearance. (See paragraph 5.4.2).
• Check air cleaner element.
• Replace the oil filter.
• Replace the fuel filter
Replacement depends or the condition of the fuel. We
recommend replacement every 300 hours.
EVERY 1000 HOURS:
• Replace the V-belt.
• Retighten cylinder head bolts/adjust + check and
adjust valve clearance.
EVERY 2000 HOURS:
• Check lubricating oil pressure
• Clean and check or replace fuel injector nozzles and
check injection pressure.
• Check the air cleaner element:
• The air is taken from the section between the
alternator and the engine
• Check the cooling system:
The engine cooling liquid is indirectly cooled by raw
water via a heat exchanger. The seawater is pumped
by the PTO driven impeller pump. All parts of the
cooling system are of corrosion free and seawater
resistant materials such as naval brass and
copper/nickel. In case of gathering of dirt in the system
it could be cleaned by compressed air. When
overhauling the engine one could clean the parts
thoroughly or replace.
When the generator set runs less than 150 hours a year
the oil should be changed yearly
EVERY 150 HOURS:
• Change oil.
• Check the battery acid level (not for Mastervolt
batteries).
• Check battery terminals for corrosion
• Check and readjust V-belt
• Check impeller raw water pump (durability depends on
the purity of the sea water. In sandy water and warm
water wear will increase).
EN / WHISPER 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
25
MAINTENANCE
4.3.1
Maintenance schedule
4.3.2
Check oil level
daily
Check water inlet filter
daily
Check the level of the cooling liquid
daily
Check hoses for loose connections or deterioration
daily
Change oil and oil filter
after first 50 hours
Check and tighten nuts, bolts, etc.
after first 50 hours
Check exhaust
after first 50 hours
Check air vent
after first 50 hours
Check and readjust V-belt
after first 50 hours
Check electrical connections
after first 50 hours
Taking out of service
When not using the generating set for a longer period it is
recommended 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 with preservation oil.
4
Stop the engine and take loose the inlet of the raw
water pump. Drain the water from the water lock.
Crank the engine having the raw water inlet sucking
anti freeze from a can until the pump, heat exchanger
and manifold are filled.
5
The coolant can stay in the engine
6
Disconnect the battery and store it in a place free of
frost and dry and charge it regularly.
Change oil
150 hours
Check battery
150 hours
Check air vent
150 hours
Check and readjust V-belt
150 hours
Check impeller water pump
150 hours
Replace impeller water pump
300 hours
Retighten cylinderhead bolts and readjust
valve clearance
Replace oil filter
300 hours
300 hours
Replace fuel filter
300 hours
Check air cleaner element
300 hours
7
Close inlet- and outlet openings with tape.
1000 hours
1000 hours
8
Protect the generating set against the influences of
bad weather conditions.
Retighten cylinderhead bolts , adjust valve
clearance
Replace the V-belt
Check lubricating oil pressure
2000 hours
Check injector and injection pressure
2000 hours
Check inlet air filter
2000 hours
Check cooling system
2000 hours
26
This method of preservation will be sufficient for 6 months.
Change oil before using the engine again.
Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
TROUBLE SHOOTING
5 TROUBLE SHOOTING
5.1
Alternator/ electrical faults
CAUTION!
Remove 3 Amp. Fuse in the control panel
while working on the generator to prevent the
engine to start
DANGER!
Take care for parts which are live!
5.1.1
General
If any problem should occur, check basic conditions and
examine all external wiring, switch gear and circuit
breakers. Also check if measuring instruments give the
correct value. If in doubt, measure directly on the
alternator terminals with an independent instrument. This
should only be carried out by an experienced electrician.
If during these measurements the engine immediately
stops after starting and an error code is displayed at the
remote control panel ( “AC VOLTAGE”), one can start the
generator by means of a “service start” at the service
menu (see paragraph “service start” of the user’s manual
of the Digital Diesel Control). By doing this, the generator
will keep running for 2 minutes before it stops. This offers
Failure code
COMMUNICATION
LOW START BAT
ALTERNATOR
EXHAUST TEMP
WATER TEMP
OIL PRESSURE
LOW VOLTAGE
HIGH CURRENT
FREQUENCY
5.1.2
you the possibility to carry out measurements to
investigate the cause of the failure.
Check if the engine is running correctly at 1500 RPM (50
Hz) according to its settings and does as well under load.
A RPM drop of 3% at full load is acceptable. Therefore a
no load setting should be at 1545 RPM = 51.5 Hz. Under
no circumstances should the RPM under full load be below
1485 RPM = 49.5 Hz.
When the problem is in the RPM refer to the engine fault
finding paragraph.
Digital Diesel Control system will help to indicate failures
and display causes
CAUTION!
If the voltage is set any higher than its
maximum limit, the generator may be
damaged.
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.
A failure code is displayed when a hardware failure at the
generator is detected
Problem
Communication error between the panel end the generator
Starter battery voltage too low
No output battery charging voltage
Exhaust temperature is too high
Coolant temperature is too high
Oil pressure failure
Generator AC output voltage is too low
Generator is in overload
Output frequency of the generator is too low
Trouble shooting table
PROBLEM
No output (Voltage) at all
CAUSE
• Circuit breaker "off" or faulty main fuse
• Faulty fuse of the AVR
• Loss of residual magnetism
• Low engine RPM.
• Faulty RPM.
EN / WHISPER 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
SOLUTION
Check switches and fuses and measure
directly on the alternator to exclude external
causes. Check fuse of the AVR
Check the residual magnetism, temporally
increase RPM with 15%. Try to and flash the
alternator (see special procedures)
Check the engine RPM and adjust (see special
procedures).
Check by independent excitation if the problem
is in the AVR or in the windings and replace if
necessary (see special procedures).
27
TROUBLE SHOOTING
PROBLEM
CAUSE
• Rotor diode broken.
SOLUTION
Check the diode in the rotor (see special
procedures). The Whisper 25 ULTRA has one
diode block/rectifier unit.
Generator output voltage too
low when no load is on it (less
than 225V between phase and
neutral).
• Engine is not reaching the rated RPM.
See special procedures to readjust RPM.
• Faulty AVR. When slightly too low,
adjustment could be necessary
Try to readjust AVR. Check by independent
excitation if the problem is in the AVR or in the
windings and replace AVR if necessary (see
special procedures).
Check the diode in the rotor (see special
procedures). The Whisper 25 ULTRA has one
diode block/rectifier unit.
• Defective diode
Generator output voltage too
low under load (less than 225V).
In no load condition it is OK
• When applying 3 phase: an
unbalanced load; check the voltage of
the other phases. When the voltages
are different this is caused by an
unbalanced load.
• Engine is not reaching the rated RPM.
Possibly too much load or engine
problems (lack of fuel)
• Faulty AVR or readjustment necessary
Bring load in balance. When slightly out of
balance, remove the sense wires to the phase
with the highest load and check if the voltage
on the other phases is not too high.
Switch off a load; (part off) consumers
See to engine RPM problems
Try to readjust the voltage
Check by independent excitation if the problem
is in the AVR or in the windings and replace
AVR if necessary (see special procedures).
Generator output voltage too
high, (more than 235V)
• Over-energising due to defective AVR
or wrong AVR setting
Check AVR, readjust and replace if necessary
capacitor specification and replace AVR if
necessary (see special procedures)..
Generator output voltage too
high, (more than 235V)
In no load condition it is OK
• Unbalanced load
Bring load in balance.
When slightly out of balance, remove the
sense wires to the phase with the highest load
and check if the voltage on the other phases is
not too low.
Generator voltage fluctuates.
• Disturbances on the electrical system/
user side.
• AVR reacts on fluctuating load
Check if electrical load is fluctuating
Generator is not able to start an
electric motor
28
• Engine runs irregularly.
Readjust the stability setting on the AVR
trimmer “ST”
When engine runs irregularly see section:
"Engine runs irregularly" at the “Engine faults”
paragraph.
If the generator is unable to supply
enough power to start an AC electric
motor, this is usually because this motor
draws too much current during starting
As the alternator is very much underrated the problem will appear by the
engine RPM collapsing
Check the electric motor’s current draw
required for starting. This should not exceed
the rated generator output current. This could
be remedied by using a "soft-start". Inquire at
your nearest Mastervolt dealer or directly at
the manufacturer, Mastervolt in the
Netherlands.
Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
TROUBLE SHOOTING
5.2
Engine faults
CAUTION!
Remove 3 Amp. fuse in the control panel
while working on the generator to prevent the
engine from starting.
5.2.1
CAUTION!
When the engine does not start instantly,
prolonged cranking can fill up the exhaust
system with cooling water because of the
water injected exhaust. When the water
enters the cylinder through the valves this will
bring severe damage to the engine. When the
engine does not start and repeated cranking
is necessary shut off the seawater inlet. Open
the valve immediately after the engine has
started.
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 table to find the cause of a wrong
engine speed. When there is no obvious cause one can
adjust the RPM (see special procedures).
When the engine is not cranking well, starting problems
almost always originate from battery problems or poor
battery cable connections.
Failure code
COMMUNICATION
LOW START BAT
ALTERNATOR
EXHAUST TEMP
WATER TEMP
OIL PRESSURE
LOW VOLTAGE
HIGH CURRENT
FREQUENCY
5.2.2
When the engine is cranking, well starting problems
almost always originate from lack of fuel or air bubbles in
the fuel pipes.
A failure code is displayed when a hardware failure at the
generator is detected.
Problem
Communication error between the panel end the generator
Starter battery voltage too low
No output battery charging voltage
Exhaust temperature is too high
Coolant temperature is too high
Oil pressure failure
Generator AC output voltage is too low
generator is in overload
output frequency of the generator is too low
Trouble shooting table
PROBLEM
CAUSE
SOLUTION
Diesel engine fails to crank, it
does not react at all, or the
starter makes clicking noises, or
the engine cranks very slowly
• Almost certainly this is an electrical
problem. One other possibility is that
the engine is locked by water in the
cylinders or there is other severe
damage. Display will indicate “low
battery voltage”.
Check on water in the cylinder and further
damage by cranking. When there is water in
the cylinder, then deactivate the control
system, disconnect the battery, remove the
glow plugs. Crank the engine to remove the
water through the opening of the glow plugs.
Check oil on the presence of water and
change oil. Find out how the water did enter
the cylinder (check the air vent). Take
precautions to prevent it from happening
again. When there is no mechanical
malfunction the problem must be an electric
malfunction.
No reaction at all
• Starter battery switched "OFF".
Check position of the battery switch and switch
"ON".
Replace fuse
• Faulty fuse on control panel
• Starter battery voltage insufficient
(battery too weak).
• To thick engine lubricating oil.
• Starter motor faulty
Check battery voltage. Recharge the battery.
Inspect battery terminals and cables for a good
electrical connection (inspect against
corrosion, tattered wires, etc.)
Change oil for a lower viscosity.
Repair the starter motor
EN / WHISPER 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
29
No reaction or clicking noises,
or slow cranking
TROUBLE SHOOTING
PROBLEM
CAUSE
SOLUTION
Starter is turning engine
smoothly, but engine fails to
start
• Out of fuel or faulty fuel, water in the
fuel.
• Fuel solenoid is not working.
Fill up with fuel or replace with better quality.
• Fuel lift pump is not working.
• Fuel filter is blocked.
• Air in fuel lines.
• Wrong valve clearance.
• Low compression because of dirty
valves.
• Blocked injector.
• Loss of compression by wear out or
damage
• Unsuitable contaminated fuel
• Lack of fuel.
• Choked fuel filter.
Engine runs irregularly.
• Disturbances on the electrical system/
user side.
• Faulty fuel lift pump.
• Choked air cleaner.
• Lack of air.
• Choked exhaust system, exhaust
blocked, rubber exhaust hose kinked.
• Air in the fuel pipes
Check if solenoid comes in; if not check wire
connections and circuitcy to solenoid (see DC
wiring diagram).
Check fuel filter and fuel lift pump: clean or
replace if necessary.
Bleed air from fuel system (see maintenance
section).
Adjust valve clearance,
Clean valves. Take off the injection bent and
inspect the outlet port. When little rust in the
port clean the valve by taking off the valve
spring and rotate until clean. When the outlet
port is strongly affected by rust, the exhaust
system is not properly installed (see paragraph
5.4.3). Contact Mastervolt service department
for advice.
Have the injector tested and cleaned if
necessary.
Repair by Mastervolt service
Fill up with fuel or replace by better quality.
Check fuel filter and fuel lift pump: clean or
replace if necessary.
Check if electrical load is fluctuating.
Try the pump by manual operation. Repair
when faulty or replace
Check the air intake
Check the exhaust hose
Bleed air from fuel system (see maintenance
section).
Have the injector tested and cleaned if
• Blocked injector.
necessary.
Adjust valve clearance.
• Wrong valve clearance.
• Temporarily hunting (this will disappear when engine has run in).
•
•
•
•
Engine speed drops
Engine does
command
not
stop
Engine exhaust smokes
30
on
Too much oil.
Lack of fuel.
Lack of intake air.
Choked exhaust system, exhaust
blocked, rubber exhaust hose kinked.
• Generator overloaded
Drain oil to proper level.
Check fuel supply system: fuel pump and filter.
Check air intake.
Check exhaust system.
• Defective generator (windings,
bearings or other)
• Damaged engine
Generator must be sent to manufacturer for
repair of damaged bearing or winding.
Repair by Mastervolt service
• Fuel solenoid is not switching off •
• Loss of control
Faulty Digital Diesel Control unit. Stop the
engine manually by the stop handle.
Check wire connections to fuel solenoid.
Check solenoid function. Replace if necessary
• Faint blue smoke - generally the result
of light load
• Heavy blue smoke - caused by
lubricating oil: Overfull oil sump or worn
cylinder bore, stuck broken or worn
piston rings.
Increase load.
Reduce the electrical load (switch off some
consumers).
Check the oil level.
Check the compression.
Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
TROUBLE SHOOTING
PROBLEM
CAUSE
• Black smoke –incomplete combustion
caused by: Overload, choked air
cleaner, inlet temperature too high,
unsuitable fuel or water in fuel.
SOLUTION
Check air cleaner
Check the fuel .
Check for overload.
Engine starts, but stops after 10
seconds
• Protection system stops the engine;
this can be caused by oil pressure
failure, lack of cooling water (exhaust
temperature alarm). Overload, loose
wire or faulty alarm switch. Digital
Diesel Control will help to indicate
failure.
See paragraph 2.5.5. and 3.2.2 for information
on the alarm system. Bypassing the switches
can help to confirm the failure. When there is
no real failure, it could be a faulty alarm switch
Engine stops by itself
(Digital Diesel Control will help
to indicate failures)
• Overload or short circuit.
Switch off the consumers and test for short
circuit.
Check fuel supply system: fuel lines, pump,
filter, valves, tank level, etc.
Check oil level.
Check engine’s oil pressure and have it
repaired by Mastervolt.
Check cooling water system flow: water pump,
inlet water filter, coolant flow.
• Lack of fuel.
• Oil pressure low. (oil pressure switch
tripped).
• Excessive heat in cooling system
(thermo-switch tripped).
• Lack of cooling water (exhaust switch
tripped).
• Impeller broken.
• Cooling water blocked.
• Water strainer blocked.
• Air or water in the fuel.
• Blocked air or fuel filter.
• Loss of compression by wear out or
damage.
• V-belt broken or loose.
• Thermostat faulty
Repair by Mastervolt service.
Readjust or replace V-belt
Check thermostat and replace
Sooty, black exhaust.
• Generator is being overloaded. Digital
Diesel Control will indicate “overload”.
• Insufficient intake air.
• Choked air cleaner.
• Fuel injector faulty.
• Valve clearance incorrect.
• Poor fuel quality.
• Poor quality lubricating oil.
• Continuous running with very low load.
Loss of power
● Wrong measurement. Check if the load is measured correctly. Does the Amp meter show
the correct value? When calculating the load by multiplying voltage and amps this should
be done by using the exact values, taking into account the power factor of the consumers.
When any doubt, measure the power directly with an appropriate instrument.
Bring the oil to the correct level
• Overfull oil sump.
Replace the fuel filter.
• Choked fuel filter.
Check air inlet openings; clean air cleaner.
• Choked air cleaner
Check the exhaust system.
• Exhaust blocked.
Have the injector checked.
• Injector blocked.
Have the compression measured.
• Loss of compression, sticking or
damaged piston ring.
Clean or replace the rings.
Have the compression measured and have the
• Wear out of cylinder.
engine overhauled.
Over-temperature
• Overload.
• Low level of cooling oil or air in the
cooling system
EN / WHISPER 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
Check electrical load and switch off some
consumers
Check intake air paths and filter, clean and
replace if necessary.
Replace injector.
Readjust valve clearance
Use better quality diesel.
Use better quality oil.
Increase load and have the engine run for a
few hours
Take away the overload.
Fill up with liquid and release air bubbles.
Check if there are air blocks in the system; see
the installation manual
31
TROUBLE SHOOTING
PROBLEM
5.2.3
CAUSE
• Water inlet system blocked.
• Broken impeller.
• Water strainer choked
• Heat exchanger choked.
SOLUTION
Check the cooling system thoroughly.
• Faulty thermostat
Check the thermostat or replace.
Warnings
CAUTION!
Generator must be shut off immediately if:
•
•
•
•
Motor RPM suddenly rises or drops.
Unusual noise comes from generating set.
Exhaust gases suddenly colour dark.
Engine failure warning light is on
5.2.4
Service address
If you cannot correct a problem with the aid of the malfunction table, contact your Mastervolt Service Centre or
Mastervolt Amsterdam for an extended service list, tel: INT
+31-20-3422100.
32
Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
TROUBLE SHOOTING
5.3
5.3.1
Special procedures alternator
Automatic Voltage Regulator (AVR)
The voltage regulator has a ±2% voltage precision in the
machine working range with distortion free loads.
The phase voltage can be adjusted by trimmer “V” (see
figure 24) from 185 to 290V.
The regulator is equipped with a frequency dependant
excitation limiter; the frequency can be calibrated by
trimmer “UF”, which is factory set at 46Hz (56Hz), ±1Hz.
On reaching this frequency, the machine begins to reduce
its voltage until it deactivates for very low frequencies.
A fuse protects the regulator and generator against
overloads and/or faults; a pocket has been provided on the
edge of the board to hold a spare fuse (rapid type 32x6.3
2A).
Another trimmer “ST” allows to adapt the regulator to the
generator parameters.
The regulator has been built to suppress the voltage
surges on releasing the load that are below 20% at
nominal load.
AVR SETTINGS
To select the AVR settings access the control board after
removing the cover. Most adjustments are factory set to
ensure satisfactory results in the operating tests on
commissioning. Further adjustments may be necessary to
ensure optimum operation under specific working
conditions.
If the alternator has to operate at 50Hz the jumper “J”
across the terminals marked “60Hz” has to be left in place,
if it has to operate at 60Hz this jumper should be removed.
The output voltage can be changed by adjusting
potentiometer “V”. Take the generating set to its nominal
speed and turn until the required voltage is obtained. If a
small variation in speed causes a change in voltage, then
the bottom speed protection should first be calibrated. The
voltage reference (orange wires) should be connected:
• to terminals “0” and “115” for an output voltage
between 100 and 140V (factory setting)
• to terminals “0” and “230” for an output voltage
between 200 and 280V.
EN / WHISPER 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
Trimmer
Trimmer V
V
TrimmerST
ST
Trimmer
Trimmer UF
Trimmer
UF
Jumper J
Fig. 24 Automatic Voltage Regulator (AVR).
To increase the range of available voltages by about 15%
use terminal “Pa” instead of terminal “0”.
CAUTION
If the voltage is set any higher than its
maximum limit the generator may be
damaged.
Setting the bottom speed at 50 (60)Hz: start up rotation of
the generating set adjusting it to obtain a frequency of 46
(56)Hz. Turn trimmer “UF” until the voltage begins to
drop. Restore nominal speed.
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 load.
If on load voltage fluctuations are experienced adjust
potentiometer “ST”, which modulates the reaction time of
the regulator to external inputs, thereby eliminating any
instability in the alternator-load system.
33
TROUBLE SHOOTING
5.3.2
Residual voltage check / excitation
procedure (flashing)
When residual magnetism disappears there is no residual
voltage. Residual magnetism can disappear after the
generating set being out of service for a long period or a
short circuit. This can be solved by exciting the exciter field
coil directly, disconnecting the AVR first. Put 12 Volt
directly over the electronic regulator terminals taking
polarity into account.
5.3.3
Testing rotary rectifier diodes
The diodes in the rotor can be checked with a multimeter.
The diodes are integrated in a rectifier unit. When all
diodes are faulty the alternator will not generate any
voltage. When one or more diodes are faulty the alternator
will produce too low voltage.
The flexible leads connected to the diodes should be
disconnected at the terminal end, and the forward and
reverse resistance checked. A healthy diode will indicate a
very high resistance (infinity) in the reverse direction, and
a low resistance in the forward direction. A faulty diode will
give a full deflection reading in both directions with the test
meter on the 10,000 ohms scale, or an infinity reading in
both directions. In case of faulty diodes replace the
rectifier unit. One can get access to the diode unit by
taking off the backend of the alternator.
Fig.25 Residual voltage check / excitation procedure.
When using the starter battery fuse it and limit the current
with a 30 Ohm resistor. Flashing can be done while the
engine is running and the wiring is connected. When a
variac (variable power supply) is available one should be
able to control the voltage manually.
CAUTION
If the starter set battery is used for exciting
one must take care. A short circuit can cause
heavy sparking, fire and injuries.
When external excitation does not bring back voltage, the
rotating rectifier diodes should be tested and a winding
resistant test should be executed.
Fig. 26. Location rectifier diode block
34
Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
TROUBLE SHOOTING
5.3.4
Winding resistant values
5.4
If after establishing and correcting any fault on the AVR
and diodes, and output is still low when separately excited,
then the main rotor, stator auxiliary and exciter stator
winding resistance should be checked as the fault must be
in one of these windings. The respective leads must be
disconnected before taking the readings.
Resistance values should be within 10% of the values
given in the table below:
Resistance Whisper 25 ULTRA
•
•
•
•
•
Resistance main stator windings
Resistance rotor windings
Resistance auxiliary winding
Resistance exciter stator winding
Resistance exciter rotor winding
5.3.5
0.33 Ohm
1.18 Ohm
3.85 Ohm
18 Ohm
0.18 Ohm
5.4.1
Special procedures engine
Setting the RPM
RPM is set by the manufacturer and should not need
readjustment! However a very slight offset 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
1500 (50 Hz) RPM. A RPM drop of 5% at full load is
acceptable. Therefore a no load setting should be at ±
1575 RPM = 52.5 Hz. Under no circumstances should the
RPM be under full load below 1470 RPM = 49 Hz. When
no cause can be found for a wrong speed, the setting can
be adjusted:
Meggering
One can try to measure resistance between the housing
and the windings with a multimeter which should read
infinity. When readings are infinity but a fault is suspected
one can do a high voltage resistance test (MEGGERING)
This procedure should be carried out by an expert. The
AVR should be disconnected during this test. A 500V
‘Megger’ or similar instrument should be used. The
insulation resistance to earth of all windings should be in
excess of 2 MOhm. Should the insulation resistance be
less than this value, drying out the generator windings is
essential. 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 outlets.
01
01
Engine speed adjusting screw
Fig. 27 Location engine speed adjustment screw.
It is very important to identify the correct setting assembly
(see fig. 27). The screw is to be locked in position with the
lock-nut.
EN / WHISPER 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
35
TROUBLE SHOOTING
5.4.2
Adjusting valve clearance and
retightening the cylinder head bolts.
Both procedures have to be executed with a cold engine.
When both procedures are executed be sure to retighten
the cylinder head bolts before adjusting the valve
clearance. When retightening the cylinder head bolts,
drain the coolant by removing the coolant drain plug (ref.
to fig. 4).
Loosen the bolts slightly, remove the rocker assembly (the
rocker arms, shaft, and stays) and then retighten the bolts
to the specified torque in the numerical order illustrated
(ref. to fig. 28).
Tightening torque cylinder head bolt:
Rocker stay tightening torque:
118 ± 5 Nm
10-20 Nm
360° in the direction of engine rotation again. No. 1 piston
is now at T.D.C. of the compression stroke.
After adjusting the valves of cylinder 1 adjust the valve
clearance of the remaining cylinders in firing order 1-3-4-2
Turn the crankshaft 180º clockwise from the T.D.C of
cylinder 1 to the T.D.C of cylinder 3. Adjusts the valves of
cylinder 3 and turn the crankshaft further clockwise to the
T.D.C of cylinder 4 and finally to 2.
5.4.3
Measuring exhaust backpressure
The exhaust system must be of adequate size -2 1/2”/ 63
mm - and maximal length (see installation manual). When
any doubt, backpressure has to be measured. An easy
way to measure for back-pressure is to use a water
column.
Front
MAXIMUM
69 cm
27 Inches
No. of bolts: 17
Fig. 28. Cilinderhead bolt tension sequence.
A
The clearance of both (intake and exhaust) valves should
be 0.25 mm in cold condition. Set the piston of the first
cylinder to be adjusted to top dead centre (T.D.C.) of
compression stroke.
The T.D.C. of compression stroke can be found by
aligning the T.D.C. mark “O” on the crankshaft pulley with
the mark on the gear case
First align the T.D.C. mark for the No. 1 cylinder. Confirm
that the valves do not move up or down when the
crankshaft is turned about 20 degrees in normal and
reverse direction of rotation.
Fig. 30 Measuring exhaust backpressure.
A water column can be made visible in a plastic tube along
a yardstick and fitting the end to a hose connection to fit in
the adaptor on the injection bent after removing the
exhaust temperature switch.
The bent A hanging down should not be to short helping to
damp the pulsating effect of the gas discharge. The water
column should be no more than 27 inches (69 cm.) of
water (1 PSI - 0,07 bar)
Crankshaft pulley
Fig. 29. Checking valve clearance (turning)
If the rocker arms move piston no.1 is on the T.D.C. of the
intake or exhaust stroke. In such case turn the crankshaft
36
Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
TROUBLE SHOOTING
5.4.4
Disassembling instructions
It could be necessary for repair or checks to disassemble
the generating set.
Following instructions will help:
1
The design of the Whisper 25 makes it possible to do
most repairs on the spot. The heat exchanger is
accessible and can be removed. The connections of
the alternator are very accessible as well.
2
The sound shield canopy can be disassembled
according to exploded view below.
Fig. 31 Exploded view soundshield
EN / WHISPER 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
37
TROUBLE SHOOTING
3
4
To take the generating set out of the canopy all hose
and cable connections have to be taken off. The set is
fixed to its base by four rubber mountings and can be
loosened by removing the four nuts from the bolts of
these mountings. The easiest way to get the
generator out of its capsule is by lifting the set with the
aid of the lifting eyes
5
Reassembling the generating set one should take
care of alignment, cleaning the surfaces between
engine and alternator and tighten the bolts crosswise
and gradually.
6
Test the generating set first outside its capsule and
check very carefully for leakages before putting it
back in its enclosure.
Taking the generator set from its mounting, or to
replace a mounting can be done according to the
drawing below
Fig. 32 Exploded view rubber mountings
38
Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
SPARE PARTS
6 SPARE PARTS
A complete parts manual in English is available as an option number: number: 50200187 (***)
A work shop manual in English is available as an option, number: 50200174 (***).
We recommend the following spares for service and maintenance.
• Kit A: parts for regular maintenance parts marked (*)
• Kit B: parts for maintenance + spare parts: all parts marked (*)+(**)
• Kit C: parts for "world travellers" all parts marked (*)+(**)+(***)
ARTICLE NO
50206122
50208120
50208121
50230007
50201350
50206254
50201812
50209018
50206257
50206258
50201553
50201551
50209145
50208010
50208015
50208020
50209104
50209099
50212170
50212154
50212197
50201559
50209102
130010915
50208033
50208030
50206040
50208050
50206045
50206038
50208034
article no. 50201560
article no. 50201561
article no. 50201562
DESCRIPTION
Fuel filter (*)
V-belt (*)
Oil filter (*)
Air cleaner element (*)
Raw water pump complete Mastervolt type M16 (***) (see next pages)
Impeller + gasket (*) (8+15)
Cover type M16 (**) (10)
Bolts cover (**) (1) (6 pcs.)
Repair kit A. See next pages (**)
Repair kit B. See next pages
Heat exchanger complete with appendages (***)
Water hoses with clamps (**)
Measuring coil Wh 25, 3 pcs (***)
Rotary diode three phase (**)
Alternator bearing including O-ring (**)
Voltage regulator
Local control panel (***)
Digital Diesel Control Unit 3 phase (***)
Fuses 10 Amps(*)
Fuses 3 Amps (*)
Fuses 32 x 6.3 / 2 Amps (*)
Wiring loom complete (***)
Digital Diesel Remote control panel (***)
Cable remote control 15 mtr, including connectors
Overhaul gasket kit / Seal kit (***)
Cylinder head gasket kit
Glow plug, 4 pcs (**)
Nozzle injector, 4 pcs (**)
Thermostat (**)
Gasket thermostat (**)
Gasket rocker cover (**)
More extensive parts list on the internet: MASTERVOLT.COM (fast moving parts)
EN / WHISPER 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
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SPARE PARTS
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Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
SPARE PARTS
EN / WHISPER 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
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SPARE PARTS
MAINTENANCE LOG
first service after 50 hours:
hour counter:
next service (every 150 hours)
hour counter:
42
remarks
Copyright © 2009 Mastervolt / December 2009 / WHISPER 25 ULTRA / EN
NOTES
NOTES
EN / WHISPER 25 ULTRA / December 2009 / Copyright © 2009 Mastervolt
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