Mastervolt WHISPER 12 ULTRA User Manual Download Page 1

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USERS MANUAL FOR MOBILE APPLICATIONS

WHISPER 12 ULTRA

- Three phase - 1500 RPM -

Mobile diesel generating set 230/400V-50 Hz

Digital Diesel Control

MASTERVOLT
Snijdersbergweg 93,
1105 AN Amsterdam
The Netherlands
Tel.: +31-20-3422100
Fax.: +31-20-6971006
www.mastervolt.com

V2 December 2008

Art.nr. 50200541

Summary of Contents for WHISPER 12 ULTRA

Page 1: ...2 ULTRA Three phase 1500 RPM Mobile diesel generating set 230 400V 50 Hz Digital Diesel Control MASTERVOLT Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel 31 20 3422100 Fax 31 20 6971006 www mastervolt com V2 December 2008 Art nr 50200541 ...

Page 2: ... explosion 8 2 1 7 Chemicals 8 2 2 Transport lifting and storage 9 2 3 The Whisper 12 ULTRA 9 2 3 1 Features 9 2 3 2 Remote control 9 2 3 3 Documentation 9 2 4 Components 10 2 4 1 Main components to identify 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 charg...

Page 3: ...7 Air filter element 27 4 2 8 Air strainer element 27 4 3 Regular maintenance 28 4 3 1 Maintenance schedule 29 4 3 2 Putting out of service 29 5 TROUBLE SHOOTING 30 5 1 Alternator electrical faults 30 5 1 1 General 30 5 1 2 Trouble shooting table alternator 31 5 2 Engine faults 32 5 2 1 General 32 5 2 2 Trouble shooting table engine 33 5 2 3 Warnings 35 5 2 4 Service address 35 5 3 Special procedu...

Page 4: ...e 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 DANGER This danger symbol refers to electric danger and draws attention to special warnings instructions or procedures which if not strictly obs...

Page 5: ...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 water guarantee will be refused Freight costs to deliver s...

Page 6: ...balanced load The Whisper 12 ULTRA Three Phase can be connected as 3 phase 230 400Volt STAR or as 3 phase 230Volt DELTA The alternator is not designed and rated for single phase applications For single phase applications Mastervolt offers another model that has dedicated windings The nameplate indicates the connection as made in the factory BE AWARE THAT THE CONNECTIONS COULD BE RECONNECTED BY FOR...

Page 7: ...ed out by qualified electricians Connection and protection must be done in accordance with local standards 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 Warning signs indicate parts which could be live 2 1 3 Earth ins...

Page 8: ...for proper ventilation Do not smoke or allow sparks flames or other sources of ignition around batteries Keep a fire extinguisher on hand INCASEOFFIRE DONOTOPENSOUNDSHIELD TOAVOIDSERIOUSINJURYORDEATHFROM FIRE IMMEDIATELYDISCHARGEENTIRECONTENTSOFGASEOUS SHUTDOWNENGINES GENERATORSETSANDBLOWERS PORTABLEFIREEXTINGUISHERTHROUGHTHISPORT THROUGH HERE FIREEXTINGUISHERPORT BREAK Fig 2 Fire extinguisher por...

Page 9: ...ures This generating set includes a diesel engine which is connected by close coupling to an alternator in a sound attenuated capsule The set is mounted on a steel base frame and mounted securely on anti vibration mounting pads to the capsule base All cables and hoses are guided through the capsule s sides The set is not self contained and is only operable after proper installation using additiona...

Page 10: ...ine speed adjusting screw 21 Injection pump air bleeding screw 22 Engine serial number 23 Coolant engine out 24 Fuel out Ø8mm 25 Fuel in Ø8mm 26 Battery negative 27 Battery positive 28 Coolant engine in 29 Fuel lift pump 30 Hoist eye front 31 Engine oil dipstick 32 Engine oil pressure switch 33 Coolant drain plug 34 Fuel filter 35 Oil sump handpump 01 Identification plate 02 Digital Diesel Control...

Page 11: ...12Ultra three phase mobile 50 56 54 55 52 53 51 51 46 47 48 40 41 42 43 44 45 40 Exhaust 41 Filler cap engine coolant 42 Rocker cover 43 Filler cap engine oil 44 Temperature switch coolant 45 Thermostat housing 46 Failsafe 47 Air cleaner element 48 Hoist eye rear 50 Exhaust manifold water cooled 51 Rubber engine mounting 52 Starter motor solenoid 53 Starter motor 54 V belt 55 Engine coolant pump 5...

Page 12: ...ig 10 Automatic Voltage Regulator AVR 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 tri...

Page 13: ...ry The voltage is regulated at 14 4V 2 5 5 Alarms and shut down In the event of malfunctioning this will be indicated by the failure LED details will be shown on the display and the engine will be shut down There are three functions guarded oil pressure coolant temperature and alternator temperature Too high alternator temperature indicates lack of fresh air or too high environmental temperatures ...

Page 14: ...is system depends on the size of the radiator piping and other parts in the cooling system 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 th...

Page 15: ...l including automatic start stop ELECTRICAL SPECIFICATIONS Output voltage 230 400V 50 Hz alternating current AC three phase re connectable to three phase 230V Output rating 12 kVA 12kW at power factor cos phi 1 Voltage tolerance 2 balanced load Frequency tolerance 1 electronic governor Alternator Air cooled brushless four pole 6 or 12 wire synchronous Voltage regulation AVR MECHANICAL SPECIFICATIO...

Page 16: ...nk 1 mm2 DDC fuel solenoid hold 9 green 1 5 mm2 DDC fuel solenoid pull 20 pink 2 5 mm2 DDC fuel solenoid com 17 black 2 5 mm2 B terminal alternator starter motor 21 red 6 mm2 DDC R terminal alternator 18 white 1 5 mm2 DDC L terminal alternator 19 orange 1 5 mm2 DDC current measuring transformer AC1 66 black 1 mm2 DDC current measuring transformer AC1 66 red 1 mm2 DDC current measuring transformer ...

Page 17: ...phase for mobile applications December 2008 Copyright 2008 Mastervolt 17 2 5 16 Lay out control wiring Fig 12 Electrical Diagram control wiring Whisper 12Ultra three phase mobile applications See figure 15 for connection of the radiator fan ...

Page 18: ...08 Whisper 12 Ultra Three phase for mobile applications EN 2 5 17 Electrical diagrams AC connections alternator models with 6 wires Only valid for alternator models with 6 wires Fig 13a Electrical Diagram 230 400 V AC 50 Hz three phase Star configuration ...

Page 19: ... WHISPER 12 Ultra Three phase for mobile applications December 2008 Copyright 2008 Mastervolt 19 Only valid for alternator models with 6 wires Fig 13b Electrical Diagram 230 V AC 50 Hz three phase Delta configuration ...

Page 20: ...8 Whisper 12 Ultra Three phase for mobile applications EN 2 5 18 Electrical diagrams AC connections alternator models with 12 wires Only valid for alternator models with 12 wires Fig 14a Electrical Diagram 230 400 V AC 50 Hz three phase Star configuration ...

Page 21: ...12 Ultra Three phase for mobile applications December 2008 Copyright 2008 Mastervolt 21 Only valid for alternator models with 12 wires Fig 14b Optional configuration modes of the AC wiring for alternator models with 12 wires ...

Page 22: ...ght 2008 Mastervolt December 2008 Whisper 12 Ultra Three phase for mobile applications EN 2 5 19 Electrical diagram radiator fan connection Fig 15 Electrical diagram for standard fan control using a 230 Volt AC radiator fan ...

Page 23: ... governor will bring more power So the electronic governor offers three advantages a more stable frequency and voltage and more power The electronic governor system contains two parts 1 The actuator controls the engine speed This actuator replaces the standard hold solenoid that is on all other mechanical controlled Whisper engines The actuator controls the RPM directly on the fuel rack inside the...

Page 24: ... 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 Switch to an other AC power source if available If a Mass Syste...

Page 25: ...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 Wh...

Page 26: ... 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 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 The system is self bleedi...

Page 27: ...ter A smeer of oil has to be put on the seal of the filter before fitting the filter The filter should be fastened manually when the rubber touches the metal turn 3 4 further 4 2 6 Readjustment V beltplacing oil filter The alternator bracket allows for readjust of the V belt Deflections should be 10 mm refer to fig 21 4 2 7 Air filter element The interval for cleaning of the air filter element fig...

Page 28: ...n expensive breakdown Check and readjust V belt Check the electrical connections EVERY 150 HOURS Change oil Check the battery acid level not applicable when Mastervolt batteries are used Check battery terminals for corrosion Check and readjust V belt EVERY 300 HOURS Replace the oil filter Replace the fuel filter Replacement depends or the condition of the fuel We recommend replacement every 300 ho...

Page 29: ...s Check and clean radiators 1000 hours Check lubricating oil pressure 2000 hours Check injector and injection pressure 2000 hours Replace or clean the air filter element 2000 hours 4 3 2 Putting 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 ...

Page 30: ...e 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 you the possibility to carry out measurements to investigate the cause of the failure If the bottom speed is set at too low a frequency the generator may be damaged On the o...

Page 31: ...r phases is not too high Engine is not reaching the rated RPM Possibly too much load or engine problems lack of fuel Switch off a load part off consumers See to engine RPM problems Generator output voltage too low under load less than 225V between phase and neutral In no load condition it is OK Faulty AVR or readjustment necessary Try to readjust the voltage Check by independent excitation if the ...

Page 32: ...most always originate from battery problems or poor battery cable connections 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 Failure code Problem COMMUNICATION Communication error between the panel end the generator LOW START BAT Starter ba...

Page 33: ...not working Fuel filter is blocked Air in fuel lines Check fuel filter and fuel lift pump clean or replace if necessary Bleed air from fuel system refer to maintenance section Wrong valve clearance Adjust valve clearance Low compression because of dirty valves Clean valves Take off the injection bent and inspect the outlet port When little rust in the port clean the valve by taking off the valve s...

Page 34: ... lack of cooling water Overload loose wire or faulty alarm switch Digital Diesel Control will help to indicate failure Refer to paragraph 2 5 5 and 3 2 2 for information on the alarm system Bypassing the switches can help to confirm the failure Overload or short circuit Switch off the consumers and test for short circuit Lack of fuel Check fuel supply system fuel lines pump filter valves tank leve...

Page 35: ... replace if nescessary Injector blocked Have the injector checked Loss of compression sticking or damaged piston ring Have the compression measured Clean or replace the rings Loss of power Wear out of cylinder Have the compression measured and have the engine overhauled Overload Take away the overload Low level of coolant or air in the cooling system Fill up with coolant and release air bubbles Ch...

Page 36: ...g set to its nominal speed and turn until the required voltage is obtained Fig 25 Automatic Voltage Regulator AVR 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 t...

Page 37: ...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 Alternator models with 6 wires Resistance main stator windings 0 39 Ohm Resistance rotor windings 2 4 Ohm Resistance auxiliary winding 7 5 Ohm Resistance exciter st...

Page 38: ...torque 14 7 2 Nm Fig 28 Cylinder head bolts 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 notch on the crankshaft pulley with the mark on the gear case ref to fig 29 First align the T D C mar...

Page 39: ... the safeguards The easiest way to get the generator out of its capsule is by lifting the set using the lifting eyes 4 One can take off the complete alternator housing Before the alternator can be taken off all cables and wiring have to be loosened first 5 The rotor can be taken off by removing the bolt which goes through the shaft normal clockwise threaded The end of the shaft is specially thread...

Page 40: ... 50205120 V belt 50203121 Oil filter 50209132 Measuring coil 3 pieces 50212902 Rotary diode assembly three phase 50212901 Voltage regulator 50209104 Local control panel 50209099 Digital Diesel Control Unit three phases 50212154 Fuse blade type 3 Amp 32V violet 50212170 Fuse blade type 10 Amp 32V red 50212198 Fuses 20 x 5 3 15 Amps 50201366 Wiring loom complete 50209102 Digital Diesel Remote contro...

Page 41: ...E LOG EN WHISPER 12 Ultra Three phase for mobile applications December 2008 Copyright 2008 Mastervolt 41 MAINTENANCE LOG first service after 50 hours hour counter remarks next service every 150 hours hour counter ...

Page 44: ...Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel 31 20 3422100 Fax 31 20 6971006 Email info mastervolt com ...

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