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July 2005 / MOBILE WHISPER 3,5 / EN

3

1

INTRODUCTION

1.1 GENERAL

This manual applies to the installation of Mastervolt

Whisper 3,5 generating set in vehicles.

Special attention has to be given to the

chapter on safety that is in the users

manual.

A warning symbol draws attention to

warnings and instructions or procedures

which, if not strictly observed, may result in

damage or destruction of equipment,

severe personal injury or loss of life.

This warning 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.

1.2 

GENERATING SETS FOR VEHICLES

1.2.1

Marine and mobile generators

Whisper Generators originate from the marine sector. But

there are also specially designed Whispers available for

mobile applications, suitable for supplying power on

board of vehicles to use professional apparatus and

equipment, strong lightning and air conditioning etc.

The cooling system and exhaust system on vehicles is

completely different from standard marine systems.

Standard marine generators are cooled by seawater that

nowhere exceeds 30° Celsius and is seldom warmer

than 20° Celsius in the northern territories. Cold

seawater is pumped through the alternator, through the

heat exchanger and is injected in the exhaust. The

exhaust gasses are therefore cooled and rubber exhaust

hose can be used.

On vehicles the engine and alternator are individually

cooled by radiator with an electric (12V/24V or 230V)

driven fan. The radiators can be fitted below, on top or in

the side of the vehicle.

The exhaust is of the dry type and includes a stainless

flexible bellow and high quality mufflers.

Never use rubber exhaust hose, neither

fibreglass nor plastic exhaust parts in a dry

exhaust system as applied on vehicles.

1.2.2

Why two radiators:

The Whisper 3,5 engine is cooled by oil. The optimal

engine operating temperature is 87° up to 92° Celsius.

The radiator cools the temperature of the oil in the engine

only 5° to 12° down. The returning “cold” oil therefore has

a minimum temperature of 75° Celsius.

INTRODUCTION

Figure 1. Typical vehicle application radiator side mounted.

Figure 3. Typical vehicle application radiator bottom mounted.

Figure 2.     Typical vehicle application radiator top mounted.

Содержание WHISPER 3

Страница 1: ...sterdam The Netherlands Tel 31 20 3422100 Fax 31 20 6971006 http www mastervolt com INSTALLATION MANUAL FOR MOBILE APPLICATIONS V2 July 2005 WHISPER 3 5 3000 RPM Mobile diesel generating set 230V 50Hz...

Страница 2: ...tions 5 2 4 1 Fuel supply 6 2 4 2 Radiator cooling 8 2 4 3 Dry exhaust system 10 2 4 4 Electric installation 12 Volt 12 2 4 5 AC power system 230 Volt 13 3 INSTALLATION SPECIFICATIONS 15 3 1 Technical...

Страница 3: ...s completely different from standard marine systems Standard marine generators are cooled by seawater that nowhere exceeds 30 Celsius and is seldom warmer than 20 Celsius in the northern territories C...

Страница 4: ...tional weight is no objection To keep resonant vibrations at a minimum it is possible to mount the generating set on a solid steel base plate approx 40 mm 4 July 2005 MOBILE WHISPER 3 5 EN INSTALLATIO...

Страница 5: ...rating set directly to bulkheads walls or tanks 2 3 VENTILATION The generating set normally draws combustion air from the engine room A full enclosure with natural ventilation must have ventilation op...

Страница 6: ...han one meter an extra fuel lift pump must be installed The control board is already prepared to connect an extra fuel pump It is recommended to mount the loose supplied pump close to the tank and mou...

Страница 7: ...ur generating set for the first time follow the fuel system bleeding procedure in the users manual July 2005 MOBILE WHISPER 3 5 EN 7 INSTALLATION 1 2 3 5 6 7 Fig 7 The fuel tank above the generator 1...

Страница 8: ...f the system and mounted as high as possible Different from marine seawater cooling installations radiator systems use an open non pressurised system Therefore the 12 mm overflow pillar on the expansi...

Страница 9: ...t installation kits 4 HOW AND WHERE TO MOUNT THE RADIATORS The radiator kit includes rubber mountings to prevent vibrations to be transferred to the body of the vehicle fig 18 Due to the difference be...

Страница 10: ...ally mounted on the roof refer to figure 17 enough space 50 mm should be between the roof and the fan to have a fre flow of air When the radiator is roof mounted there should be protection against the...

Страница 11: ...nd space below the vehicle between the chassis to mount the mufflers The outlet should blow the fumes away from the doors to avoid a nasty smell When the gasses are in the flow of air blowing from the...

Страница 12: ...n the DDC and an up date of the software of the system panel could be necessary When this is the case consult to the Mastervolt service department for advice When using the factory settings installati...

Страница 13: ...he negative return wire should be of the same diameter The return current should never be lead over the chassis The consumption of power by the 12V DC powered fan makes it necessary to install an addi...

Страница 14: ...w reacting type For elec trical motors connected to the system a motor pro tection switch must be installed 2 INSULATION FAILURES The AC alternator windings are not grounded The housing of the alterna...

Страница 15: ...cable indicating Digital Diesel Control system Battery capacity min 12V 55 Ah Fuel consumption 0 7 1 5 l hr load dependent Lift fuel pump electric driven 12 V DC max lift 1 m Cooling radiator cooling...

Страница 16: ...INSTALLATION SPECIFICATIONS 16 July 2005 MOBILE WHISPER 3 5 EN 230V AC FUEL KIT BATTERY INSTALLATION KIT BASE PLATE KIT 3 2 INSTALLATION MATERIALS Fig 24...

Страница 17: ...e no description dimensions 48 1 50222020 copper fuel pipe 6x8 mm 49 1 50220063 fuel hose 8x16 mm BATTERY INSTALLATION KIT 55 Ah no qtt article no description dimensions 51 1 64000550 battery 55Ah 52...

Страница 18: ...RADIATOR COOLER KIT ALTERNATOR Direction of Air 17 15 5 15 5 4 3 2 21 6 2 20 RADIATOR OIL COOLER KIT ENGINE 73 72 66 68 71 70 69 EXHAUST KIT 63 68 66 46 41 64 65 67 75 32 41 45 42 33 32 45 42 33 31 39...

Страница 19: ...1 2 5 2 ST 50221003 Male hose connection 1 2x13 6 1 ST 50221007 Male hose connection 1 2x20 14 6 M 50220057 Cooling water hose warm water 13x21 mm 15 12 ST 50221521 Hose clamp stainless 12 20 16 16 S...

Страница 20: ...RTER CURRENT MESURING TRANSFORMER BLUE 1 7 BLUE GREEN 1 8 BLUE BLACK 1 7 J10 BLACK 1 5 12 J8 BLUE PINK 1 8 J12 PURPLE 1 6 PURPLE BLACK 1 6 J14 GREY 1 5 5 BLACK 11 RED 11 YELLOW 2 5 4 RED GREEN 1 16 RE...

Страница 21: ...TEMP SWITCH GENERATOR TEMP SWITCH OIL PRESS SWITCH MOTOR STARTER CURRENT MESURING TRANSFORMER BLUE 1 7 BLUE GREEN 1 8 BLUE BLACK 1 7 J10 BLACK 1 5 12 J8 BLUE PINK 1 8 J12 PURPLE 1 6 PURPLE BLACK 1 6 J...

Страница 22: ...H GENERATOR TEMP SWITCH OIL PRESS SWITCH MOTOR STARTER CURRENT MESURING TRANSFORMER BLUE 1 7 BLUE GREEN 1 8 BLUE BLACK 1 7 J10 BLACK 1 5 12 J8 BLUE PINK 1 8 J12 PURPLE 1 6 PURPLE BLACK 1 6 J14 GREY 1...

Страница 23: ...July 2005 MOBILE WHISPER 3 5 EN 23 N GENERATOR L1 M AIRFAN MAIN CIRCUIT BREAKER CIRCUIT BREAKER 230Vac 6A 4 2 CONNECTION DIAGRAM RADIATOR FAN 230VAC Fig 29 DIAGRAMS DRAWINGS...

Страница 24: ...1 mm2 LCP oil temperature switch 7 blue black 1 mm2 DDC exhaust temperature switch 8 blue green 1 mm2 LCP exhaust temperature switch 8 blue rose 1 mm2 DDC fuel valve solenoid 9 green 1 5 mm2 DDC stop...

Страница 25: ...N WINDING BLACK 4 BLACK 4 RED 3 MAIN WINDING GREEN 2 RED 3 EXCITATION GREEN 1 WINDING YELLOW GREEN DDC AC 1 YELLOW GREEN BLUE 33 BROWN 33 BLUE DDC ct 1 11 RED CURRENT TRANSFORMER 11 BLACK CAPACITOR BR...

Страница 26: ...26 July 2005 MOBILE WHISPER 3 5 EN DIAGRAMS DRAWINGS 4 5 WHISPER 3 5 DIMENSIONS Fig 31...

Страница 27: ...l lift pump cable 41 2 battery connection positive 3 3 Connectors radiator temperature switch 13 4 oil pipe out 42 5 Cooling water out 10 6 Battery connection negative 4 7 Exhaust connection 26 8 Oil...

Страница 28: ...October 2004 MOBILE WHISPER 3 5 EN MASTERVOLT Snijdersbergweg 93 1105 AN Amsterdam The Netherlands Tel 31 20 3422100 Fax 31 20 6971006 www mastervolt com info mastervolt com...

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