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Marine Generator Panda AGT-DC 4000 PMS Icemaster

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1. Gun Fischer Hondo Installation manual Installation maintenance and troubleshooting Marine Generator Panda AGT DC 4000 PMS 12V 24V 4kW Icemaster Fischer Panda since 1977 since 1978 since 1988 since 1988 since 1988 Icemaster GmbH Fischer Marine Conclusion Fischer 100 water cooled Panda Vehicle Generators Icemaster GmbH Panda generators Generators Fischer Panda FISCHER GENERATORS have been manufactured since 1978 and are a well known brand for first class diesel gene rators with especially effective sound insulation Fischer has been one of the leading manufacturers in respect of quality and know how during this period FISCHER as the worldwide manufacturer of modern marine diesel generators developed the Sailor Silent series for example and produced a GFK sound insulated capsule as early as 1979 and the basis for new generator technology The companies Fischer and Icemaster amalgamated under the direction of Icemaster in 1988 in order to concentrate on the development of new products Production was moved to Paderborn The amalgamation of the two qualified companies led to the development of a complete new programme within a short space of time The aggregates developed at that time set new technological standards worldwide The aggregates became more efficient and powerful than other aggregates in the same nominal performance range because of the improved cooling Panda generator demonstrated its superiority in
2. tes 2 A motor fault 2 See Motor running irregularly MOTOR DOES NOT TURN OVER WHEN STARTING zm ms Battery main switch is switched off Check the position of the battery main switch if neces sary switch on Battery voltage not sufficient Check that connection is firm and whether corrosion has occurred Starting current fault The voltage of full batteries fall to a maximum of 11V The wiring is severed if the voltage does not drop The battery is discharged if the voltage drops further Panda PMS AGT DC 4000 Chapter F Tables Page III ES mas sas Tischer Honda MOTOR TURNS OVER BUT DOES NOT START zm ms Check wire connections and circuitry to solenoid valve ref DC wiring diagram Relay K2 Fuse Too much air in fuel lines Test fuel system for leakage Bleed air from fuel system refer to section Air bleeding of the Fuel System Fuel filter blocked Replace fuel filter MOTOR DOES NOT TURN OVER AT THE NORMAL SPEED DURING THE STARTING PROCESS zm mmm Starter battery voltage insufficient Check battery Damaged bearing s piston seized Repairs need to be carried out by Kubota Service refer to Kubota motor manual Cooling water in combustion chamber 1 Turn generator OFF at control panel 2 Remove the glow plug see Kubota manual 3 Rotate the motor by hand carefully 4 Check if there is water in the oil and change both oil and filter if necessary 5 Determine cau
3. JD d e Mu ischer Rondo Installation Instructions _ D 7 4 Installation of the remote control panel eee As standard a 12 core connection cable Acree 7m long is included in the supply Cores aS SJOODBEBBBBEB rola are numbered from 1 to 11 and the 12th core is coloured yellow green The con trol cables are securely connected to the genset On the back of the control panel there are terminals numbered from 1 12 Connect the cores of the control cable in respective order Please ensure that the remote control panel is installed in a protected dry and easily accessible place Made in Germany Page 56 Panda PMS AGT DC 4000 Chapter D Installation Instructions Installation Instructions ng Fischer Panda 4 Control light charge control 5 Control light operating status red glowing Generator is in Stand by mode red blinking Generator is started manually red blinking for more than 20 seconds Generator did not start when activated manu ally green blinking Generator runs in manual mode green glowing Generator runs in automatic mode 6 Switch for Manual Start e Switch pressure in sleeping mode Generator is started and the panel switches to manual mode i e automatic cut off requirements are not carried out Switch pressure in manual mode If the generator starts automatically the generator continues to run and the panel switches to automatic mode e when the last auto
4. 2 Shout Help e Call people who can phone for help 5 Check for Breathing e Look listen and feel for brea thing for 3 to 5 seconds 8 Phone EMS for Help e Send someone to call an ambu lance 1 0 Recheck Pulse Every Minute e Keep head tilted back e Feel for pulse for 5 to 10 seconds e If victim has pulse not breathing continue rescue breathing If no pulse begin CPR
5. JD Tischer Ponda 10 Terminal clamp for external automatic start allocation 15 Battery minus 16 Input for external start demand The potential free contact can be connected to these two terminal The starting sequence occurs automatically if the contact closes 11 Fuse 1 6A slow to blow 12 Switch for the starter motor cut off voltage Switch 1 12V generator Switch 2 24V generator Switch 3 36V generator Switch 4 48V generator Attention Only one switch may remain switched ON all others must be switched OFF otherwise the complete generator could break down An external voltage cut off switch is neccessary for voltages exceeding 48 Volts 13 Compensation potentiometer for 12 Is set at the factory 14 Soldering bridge for choice of pre glow time e Soldering bridge open pre glow time 8 sec e Soldering bridge closed pre glow time 4 sec Attention The panel circuit board voltage is dangerous if the battery voltage exceeds 60 Volts The panel must be mounted that the voltage carrying points can not touched This Is also the case during testing 1 Operating and starting the Generator will works with the Control Panel This implementing the Main Switch 7 is effected for By switching On the Main Switch the Generator will be at first in operaton modus After pressing the button Start 7 the Generator Motor will be aglow and star ting Pay attention the button 7
6. at U UNenn 9 If deviations are determined a new adjustment is necessary C 3 3 Low Generator Output Voltage ATTENTION Before working on the System read the section Safety Instructions on Page iv If the produced alternating voltage is too low switch the load off in order to relieve the generator Mostly the problem already solved If the output voltage is still too low even if all load is switched off the generator runs without load you can assume one or more condensers are defective Panda PMS AGT DC 4000 Chapter C Generator Failure Page 31 CR Ge ene Tischer Honda C 4 Testing Generator Stator Windings ATTENTION Before working on the System read the section Safety Instructions on Page iv C 4 1 Testing Generator Stator Winding for Shorts to Ground The generator stator windings can be tested as follows Ensure that the generator is OFF and cannot be accidentally started Disconnect the battery Remove the cover of the power treminal box All terminal box connections are to be removed See appropriate circuit diagram Remove all cables 0O A OO N A check of the power terminal box is made by means of a multimeter to determine whether there is continuity between the individual windings connections If continuity is detected for any of the combinations the generator must be sent to the factory for inspection and repair If this is not possible the stator can be rewou
7. be on board With the installation of the generator it must be paid attention that the impeller pump is well accessible since the impeller is a wearing part If this place at the location can be reached not well an external pump with electric drive can be used instead of the pump built firmly in the sound cover which should be installed in a well accessible place E E S E E Wasserlinie waterline Hull inlet Heat exchanger Reducer Fresh water pump Water cock Exhaust manifold water cooled Raw water filter Diode block water cooled Raw water pump Cooling water tank Page 10 Panda PMS AGT DC 4000 Chapter A Mode of Operation of the Generator Fischer Panda de of Operation of the Generator Q C ene rischer Ponda B Maintenance Instructions B 1 General maintenance instructions B 1 1 Checks before starting e Oil level e Cooling system leaks e Visual check for any changes leaks oil drain system v belt cable connections hose clips air filter fuel lines Once a month e Lubrication of actuator trapezoid thread spindle Maintenance see Table F 4 Inspection checklist for services on Page IX B 1 2 Hose elements and rubber formed component in the sound cover Check all hoses and hose connections for good condition The rubber hoses are very sensitive to enviromental influences They can season fast with dry air in which environment of muted oil and fuel steams and increased temper
8. filler cap and the cooling water screws and start the generator Start the generator for max 60 seconds Switch the generator off Repeat this procedure several times If no change of the cooling water level can be determined the generator is started for 5 minutes Afterwards repeat the de aeration two three times It is meaningful to repeat the de aeration procedure also after some days again to guarantee that in the system remained bubbles are removed Panda PMS AGT DC 4000 Chapter B Maintenance Instructions Page 17 Vi T Q D Fischer Bondo Kee Instructions B 6 Exchange of the toothed belt for the raw water pump The relative high ambient temperature in the closed sound insulated capsule about 85 C can be a reason for a reduced lifespan of the toothed belts It is possible that the softener in the rubber compound lose their effect after a short operating time because the air in the sound insulated capsule can be relative warm and dry The toothed belt must be controlled in a very short time interval It can be happen to change the toothed belt after some weeks because of unfavorably conditions Therefore the control is nee ded in an interval of 100 operating hours The v belt ia a wearing part It should be enough spare toothed belts on board We suggest to stand by the according service packet Loosen the fixing bolts at the raw water pump Down pull the toothed belt and put a new on Type o
9. if necessary cover them During the installation don t wear a wrist watch or arm jewels you can create under these circumstances a battery short circuit Burning of the skin could be the result Protect every battery contact against unintentional touch Use only cyclical profoundly dischargeable batteries Starter batteries are not appropriate Lead gel batteries are commended They are maintenance free profoundly dischargeable and not produce gas Do not charge a frozen battery Avoid a batterie short curcuit Take care of a good ventilation of the battery to drain off developing gas The battery connection terminals must be checked of a tight contact at least before operating The battery connection cable must be carefully mounted and checked about incorrect heating at operation with load The vibrating devices must be regulary checked about scour points and flaw in the isolation vi Q ischer Ponda Table of Contents Mode of Operation of the Generator ccccceesseessesseeeeeseeesenseeseoneessenseesoessessoensessonseees 5 A 1 Mode of Operation of Operating Surveillance uuusususununnnannnnnnnnnnnnnnnunnnnnnnnnnnnnnnnnnnnn 5 A 1 1 Regulation of the generator voltage by the VC 7 A 1 2 Overloading of engine during longer operation cccooccnccoccnnccnnnnccnnnncnnnnenonnncnnonnnnnononrnnnnnnrnnonanos 8 A 2 Operation of the generator with HTG generator uurssusanunnnnnnunnnnnnnnnnnnnnnnnn
10. in the electrical system also for shore power and inver ter In these cases usually a selector switch is intended which can be determined which voltage supply is switched to the electrical system The voltage conteroller must be installed at the exit of the selector switch thus in the electrical system D 10 1 Adjustment of the rated voltage The voltage controller must be ordered for the appropriate rated voltage 12 24 32 48 42 V DC Other voltage on request Changing between these voltages is not possible D 10 2 Functional decription of the voltage controller The voltage controller has 3 different adjustment possibilities upper switching point lower switching point and time lag of the generator In factory setting the voltage controller is in the following attitude a upper switching point disconnection 13 6V b lower switching point insertion 11 52V Panda PMS AGT DC 4000 Chapter D Installation Instructions Page 67 Q JD Tischer Ponda A upper switching point shut down B lower switching point starting C td time lag of the generators after rea ching the upper switching point Voltage sense plus Voltage sense minus Charging voltage Battery lower voltage not allocated not allocated Output positiv 1 2 3 4 O 6 T 8 Output negative D 10 3 Time lag of the switching points For the upper as well as for the lower switching point a time delay is adj
11. infrared thermometer you can check all the temperatures on the rectifier Check all the cable connections of the DC wiring The easiest is to touch them carefully with your finger If they are getting warm or getting hot these connections are poor and shall be re placed The temperature of the heat sink shall never exceed 95 C The temperature of the copper bars shall never exceed 120 C Panda PMS AGT DC 4000 Chapter B Maintenance Instructions Page 23 ene rischer Honda Ensure that a fuse next to the battery is installed in the battery line for the generator output cable Ensure that a battery switch is installed in the battery line Never leave the generator behind wit hout the cover mounted over the heat sink and capsule not closed Remind the customer e to run the generator only with closed capsule e not to run the generator unattended e to ask for regular service Page 24 Panda PMS AGT DC 4000 Chapter B Maintenance Instructions Q C ene rischer Ponda B 9 Conservation at longer operation interruption B 9 1 Measures on preparation of the winter storage Rinse raw water circuit with an anti freeze solution even if this contains a corrosion protection means The raw water inlet must be removed at the water cock Over a hose connector the anti freeze protection mixture is to be sucked in from a container The leaked cooling water with the exhaust is to be led back into the sucking in contai
12. plate attached on the housing In order to guarantee a long life span the conti nuous load should not exceed 80 of the nominal load By continuous output we understand the continuous operation of the generator over many hours It is harmless for the engine to supply for 2 3 hours the full rated output E IcEMASTER The total conception of the Panda generator guarantees that the continuous load operation does not release superelevated temperatures of the engine also with extreme conditions It is to be considered that the exhaust gas values in the full load operation become more unfavorable soot formation A 2 Operation of the generator with HTG generator A 2 1 Allgemeine Hinweise Beside the alternating current aggregates ICEMASTER supplies also the super compact High tech battery load aggregates from the series of PANDA AGT in sound insulated construction which represent a very interesting alternative solution in a DC AC power technology merged for generation of current within the mobile range The new HTG generators with 280 A charging current offer themselves a alternative for an onboard current generator if a diesel set is not intended These generators differ according to the technology very substantially from all conventional products The size is so compact that you can exchange it also against a generator according to standard This generator can ensure a 230V alternating current supply up to 3 000W power in connection wit
13. preparation of the winter storage 13 The generator housing and the housing of the engine should be sprayed with a corrosion pro tection oil before the winter storage This procedure is recommended also in the season This procedure can avoid that arising and humidity marks on the surface of the aluminum construc tion units be noticed too late 14 Disconnect the starter battery positive and negative pole 15 Lubricate the spindle for the number of revolutions adjustment device with a special lubricant Antiseize grease 16 Use of a air dehumidifier The best way to protect a yacht in the winter storage against damage by humidity is to places a air dehumidifier inside the ship and locks all hatches The devices have a hygrometer which switches the device off if the humidity is under the adjusted value There is no better method in order to protect pads cable electronics wood engines etc optimally against any rotting by humidity B 9 2 Initiation at spring Before the first start turn the engine once with the hand in order to eliminate necessary existing corrosion beginnings in the bushing If necessarily carry out normal engine inspection e Change engine oil and engine oil filters Reintegrate the impeller of the cooling water pump and check pump for leakage e Charge starter battery of the generator connect cables and check battery voltage e Start generator and check the basic adjustments of the generator such as voltage
14. several tests by renowned institutes and magazines during the past years The patented VCS voltage Control System means it can meet all demands including motor speed The start booster ASB means Panda generators meet the highest demands in respect of voltage stability and starting values A Panda generator with the same drive motor produces 15 more effective output than the majority of conventional generators This superiority in efficiency also ensures a fuel saving to the same extent The 100 water cooled Panda Aggregate are currently manufactured in the performance range from 2 to 100 kW in various versions Fast running motors are preferred for performances up to approx 30 kW Nominal speed 3000 rpm The heavier slow runners are preferred for the higher range The fast running aggregates have proved themselves many times for many uses that they meet the demands in quality of yachts and vehicles and offer space and weight saving of 50 compared to slow running generators In addition to the Panda series Icemaster also supply the super compact high tech sound insulated battery charging aggregate from the DC AC Panda AGT series which is a very interesting solution for the production of mobile power The new HTG alternators ensure that a charging rate of 285 amps is achieved that was scarcely thought possible for this compact construction This alternator replaces a separate shipboard generators constant 230 volts AC with up to 3500 kW from t
15. 53 Tischer Ponda Additionally to the standard fine filter a pre filter with water separator must be installed outside of the sound cover in the fuel system line is not included in delivery D 7 Generator DC System Installation D 7 1 Connection of the 12V starter battery only for 24V version The positive battery cable is connected direcly to the solenoid switch of the starter The negative battery cable is connec ted to the engine foot below the raw water pump Page 54 Panda PMS AGT DC 4000 Chapter D Installation Instructions a d o a rischer Honda D 7 2 Terminal block AGT 4000 12V The Panda generators are equipped with various DC relays which can be found under the terminal strip The various relays have the following tasks also see the DC circuit diagram F1 Fuse 15A for DC system F2 Fuse 10A for AC system K1 Starter motor relay K2 Pre glow relay glow plug K3 Fuel pump relay The Panda generators are equipped with various DC relays which can be found under the terminal strip The various lt gt a ke S aka relays have the following tasks also see the DC circuit diagram Ey F1 Fuse 15A for release relay F2 Fuse 15A for DC system F3 Fuse 10A for AC system K1 Starter motor relay K2 Pre glow relay glow plug K3 Fuel pump relay K4 Release relay Panda PMS AGT DC 4000 Chapter D Installation Instructions Page 55 Q
16. 8mV DC ATTENTION The cable for the measuring voltage must be attached directly at the battery and may not attached to the output of the electric rectifier By the voltage drop between generator and battery the accurate voltage can only recieved direct at the battery A false link can lead to damage the battery Panda PMS AGT DC 4000 Chapter D Installation Instructions Page 65 Tischer Ponda VCS 24V C VCS Voltage Control System Ee Elektronische Spannungsreglung f Panda AGT 24 V 01 Voltage sense 24V 06 Battery voltage supply 02 Voltage sense 24V 07 Stop line regulates the actuator back at shut off 03 Actuator the device 04 Actuator 08 Terminal shunt measurement OmV DC 05 Battery voltage supply 09 Terminal shunt measurement 48mV DC ATTENTION The cable for the measuring voltage must be attached directly at the battery and may not attached to the output of the electric rectifier By the voltage drop between generator and battery the accurate voltage can only recieved direct at the battery A false link can lead to damage the battery Page 66 Panda PMS AGT DC 4000 Chapter D Installation Instructions Q CO Tischer Ponda D 10 Voltage controller With a engine operated generator set count always on the fact that through disturbances at the controlling of the diesel engine the control of the number of revolutions monitoring is lost
17. A A A A A 5 Safety steps to follow if someone is the victim of electrical shock Do not try to pull or grab the individual If you cannot turn off the electrical power pull push or lift the person to safety using a wooden pole rope or some nonconductive material If possible turn off the electrical power Send for help as soon as possible After the injured person is free of contact with the source of electrical shock move the per son a short distance away and immediately start necessary first aid procedures XIII WHEN AN ADULT STOPS BREATHING DO NOT attempt to perform the rescue breathing techniques provided on this page unless certified Perfor mance of these techniques by uncertified personnel could result in further injury or death to the victim 1 Does the Person Respond e Tap or gently shake victim e Shout Are you OK 3 Roll Person onto Back e Roll victim toward you by pulling slowly 4 Open Airway e Tilt head back and lift chin e Shout Are you OK 6 Give 2 Full Breaths e Keep head tilted back e Pinch nose shut e Seal your lips tight around victim s mouth e Give 2 full breaths for 1 to 1 secon ds each d Check for Pulse at side of Neck e Feel for pulse for 5 to 10 seconds 9 Begin Rescue Breathing e Keep head tilted back e Lift chin e Pinch nose shut e Give 1 full breath every 5 seconds e Look listen and feel for breathing between breaths
18. CC 9 lerse rita meunings 1 actuatormounting 0 Teiner motor moaning ene screws generator engine 8 a 11 hh eegen an h p h hp p pomme o bp b p b p p emer 0 ja O b b o o m heme SSS a a O b b o m m arent ones z ja O b b far far boesem 81 It O eier m EM IO IO IS IO one LT fuel lines leaks 4 1 4 1 4 6 Panda PMS AGT DC 4000 Chapter F Tables Page IX ES mas sas Tischer Honda F 5 Engine oil Engine oil classification Operating range The operating range of an engine oil is determined by SAE class SAE is for the union of American engineers Society of Automotives Engineers The SAE class of an engine oil only informs over the viscosity of the oil lar ger number more viscous lower number more highly liquidly eg to OW 10W 15W 20 30 40 The first number shows the liquid of cold weather the second number refers to the fluidity with heat Complete yearly oils have usually SAE 10W 40 SAE 15W 40 etc Quality of oil The quality of an engine oil is specified by the API standard American Petroleum Institutes The API designa tion is to be found on each engine oil bundle The first letter is always a C API C for diesel engines The second letter is for the quality of the oil The more highly the letter in the alphabet the better the C f r Diesel motoren Examples for diesel engine oil API CG Engine oil for highe
19. Continuous Nominal charging charging current A current A IM IO CI CI Nominal power Continuous Nominal kW power kW voltage VDC emm w e sm BEE mm nn nm mm mn nn ns mm Panda PMS AGT DC 4000 Chapter F Tables Page I ZE E D Fischer Panda C Tabelle 3 Cable cross section Wiring for vehicle single phase not tin plated PVC isolated nominal wire cross section allowed conrinuous current reference point at 30 C A at 50 C A a DIN VDE 0298 part 4 Page II Panda PMS AGT DC 4000 Chapter F Tables Q CO Tischer Ponda F 1 Trouble shooting GENERATOR OUTPUT VOLTAGE TOO LOW If the generator delivers less than 24V current undervoltage there can be various reasons for this Generator is overloaded Motor is not reaching the rated rpm Refer to motor faults section Actuator is not in maximum position VCS voltage controler defective or wrong adjusted GENERATOR VOLTAGE TOO HIGH MORE THAN 24V The following reasons may be the cause if the generator delivers more than 24V overvoltage The engine is running at the wrong speed Check the speed of the motor with a rev or frequency counter set the correct speed VCS voltage controler defective or wrong adjusted Check resp renew Actuator defective Check resp renew GENERATOR VOLTAGE FLUCTUATES rm mm 1 Fault or defect on the load side 1 Check if the power requirement of the load fluctua
20. E ELE 39 D 1 2 Notice tor optimal sound It ue TR DEE 39 D 2 Generator Connections Scheme cian genen 40 D 2 1 Connections Panda AGT 40004 2 ee are 40 D 2 2 Connections Panda AGT 4000 24 Eeer 41 D 3 Cooling System Installation Raw Water uuuusnnanunnnnnnnnnnnnnunnnnnnunnnnnnnnnnnnunnnnnnnnnnnnnnnnnnnen 42 D 3 1 GeneralBeferenees nee ee ie ae rare 42 D 3 2 Installation of the thru vessel fitting in Yachts nenn nnnnn nenne nenne nenne nenne nennen 42 D 3 3 Quality of the raw water sucking mme 42 D 3 4 installati n above waterline cial dd da ei He 43 D 3 5 Installation below waterline nenne nnnnnn nennen nnnnnenennne nenne nennen 44 DA The Freshwater Coolant Circuit uurssau000 nn00nnnnnnnnnnnunnnnnnunnnnnnnnnnnnunnnnnnunnnnnnnnnnnnnnn 45 D 4 1 De aerating at the first filling of the internal cooling water cru 45 D 4 2 Pressure test for control of cooling water Cru 47 D 4 3 Scheme for freshwater circuit at two circuit cooling system occccooncncccccnccnonccnnnnnnonnannnnnanonos 47 DS Watercooled Exhaust E EE 48 D 5 1 Installation of the standard exhaust system nenne nnennnn nennen nennen nnnnnn nennen 48 D 5 2 Exhaust water separator naeh 49 D 5 3 Installation exhaust water separator nenne nnenne nennen nenne nnennennn 50 D 6 Fuel Syst m Installation zn ee ei ee 52 D 6 1 General ne 52 D 6 2 The elecifical tel PUMA cad 53 D 6 3 Connection of the fuel lines at the tank ooonnncccocccncccnnccnncnnon
21. Failure Page 29 vi ene Tischer Honda Possible disturbances in the area of the rev regulation VCS The spindle of the actuator jams e not regularly lubricated e surface is mechanical damaged e actuator is defect e defect of the VCS control short of winding e signal DC missing e limiting nut jams the spindle Fuse on the printed circuit board of the constant overload of the generator VCS control is melted Steps to check the voltage control by a disturbance 1 Switch off all electrical consumers 2 Disconnect the plug of the actuator 3 Turn the actuator manually to check if the adjusting nut is jamed to the limit stop points 4 Turn the actuator manually to check if the adjusting nut on the spindel runs faultless If there is no result by these steps the actuator is working mechanically correct After this the electrical components must be checked Connect the plug of the actuator Start the generator Turn the actuator by hand and check if the spindle turns back by the motor u E If the motor react on the turn by manual strongly the motor can normally hold with the fingers the drive will be working faultless If there are nevertheless faults in the voltage control there is a fault in the control VCS If the actuator is not moving the following points are necessary 1 The motor turns not strongly rather weak e The actuator has shorts in the winding and must be changed pay atte
22. In this case the diesel engine could wind up without limitation and produce a voltage which becomes substantially larger than the electrical load can process This can destroy very expensive items of equipment It must be take for granted that for the protection of the electrical load a voltage con troller with isolating relays is used for a solid installation The appropriate accessory components are available at Icemaster If it is about a duo combination generator the voltage control for both output parts single phase AC and three phase AC should be planned At different PANDA generators a voltage control is integrated This voltage control affects only the diesel engine If the rated voltage exceed approx 15 this voltage control is activated as the diesel engine is turned off This is only possible with the delay of some seconds load could be damaged in the meantime The only safe method for the protection of the electrical devices is the installation of an external voltage controller with separation contactor We recommend this measure with all reproduction and point out also that the generator manufac turer is not responsible for damage which are caused by overvoltage at external devices Protect your valuable devices by an external voltage controller Position of the external voltage controller Reasonable the external voltage controller is mounted in such a way it works not only for the generator but for all AC voltage supplies
23. Switch the panel ON Press START button The fuel pump runs audible 5 Switch the panel OFF 6 Switch the panel ON 7 Press again the START button This procedure must be repeated several times until fuel nonporously withdraws perfectly at the fuel return pipe 8 Switch the panel OFF 9 Attach the plug at the solenoid of the starter motor Made in Germany Made in Germany Panda PMS AGT DC 4000 Chapter B Maintenance Instructions Tischer Ponda Page 15 A Tischer Honda B 4 2 Exchange the air filter Open the air suctin housing by loosen the six hexagon head screws on the frame cover Change the air filter mat and close the CH cover again Page 16 Panda PMS AGT DC 4000 Chapter B Maintenance Instructions Tischer Ponda B 5 De aerating of the coolant circuit freshwater Special notes for the ventilation of the cooling system If the cooling water is drained or if other air should have arrived into the cooling system it is necessary to de aerate the cooling system This de aerate procedure must be repeated several times Open the ventilation valve over the coo ling water pump Fill in cooling water into the cooling water filler neck If it is to be recognized that the cooling water level does not fall anymore with cold cooling water the cooling water levelmust cover the sheet metal in the exhaust elbow close the
24. a a aaa XI MOS E CC XII Panda PMS AGT DC 4000 Table of Contents Page 3 Q O ene Tischer ondoa Page4 Panda PMS AGT DC 4000 Table of Contents Tischer Ponda A Mode of Operation of the Generator A 1 Mode of Operation of Operating Surveillance Internal monitoring switches The generator is equipped about failure switches which are indicated on the remote control panel and also about failure switch which switch off the generator automatically without indica ting a failure in the remote control panel The remote control panel supervised the following values In the case of a disturbance the gene rator is switched off in order to avoid damage to the aggregate 1 Cooling water temperature at engine and exhaust connection 2 Thermo switches on the Diode block 3 Coil temperature 4 Oil pressure The fault is transmitted if one of these switches measures a value that exceeds the required value all switches are openers The current is switched off by the main relay Fuel magnet valve closes the fuel suction pump is switched off VCS is switched off The combustion engine possesses an oil pressure control switch which switches the engine off if the oil pressure drops under a certain value The additional failure switch in the generator coil it is not indicated at the remote control panel interrupts directly the current supply to the main power relay By this constellation it is guaranteed that the g
25. ature The hoses must be checked regularly for elasticity There are operating situations at which the hoses must be renewed once in the year Additionally to usual tasks of maintenance oil level check oil filter control etc further mainte nance activities are to be accomplished for marine aggregates B 2 Oil circuit maintenance The first oil change is to be accomplished after a period of operation from 35 to 50 hours After wards the oil is to be changed after 100 hours For this the oil SAE30 for temperatures over 20 C and SAE20 for temperatures between 5 C and 20 C is to be used At temperatures under 5 C oil of the viscosity SAE10W or 10W 30 is prescribed Type and amount of required oil see Table F 5 Engine oil on Page X and Table F 2 Technical Data Engine on Page VII Panda PMS AGT DC 4000 Chapter B Maintenance Instructions Page 11 S a CH as Tischer Honda B 3 Execution of an oil change Oil drain hose For the oil change an oil drain hose is lead through the sound cover Oil drain screw The oil can be discharged by opening the oil drain screw For countering use a second wrench Oil drain pump If discharging of the oil is not possible we recommend the employment of a hand pump which can be attached to the oil drain hose Afterwards the oil drain screw is closed again Page 12 Panda PMS AGT DC 4000 Chapter B Maintenance Instructions Tischer Ponda Oil
26. auled completely EN Wasserlinie waterline E E S Ki S E Hull inlet Heat exchanger Reducer Fresh water pump Water cock Exhaust manifold water cooled Raw water filter Diode block water cooled Raw water pump Cooling water tank Panda PMS AGT DC 4000 Chapter D Installation Instructions Page 43 ischer Ponda Installation Instructions _ D 3 5 Installation below waterline If the generator can not be attached at least 600mm over the waterline a vent valve must be installed into the seawater line With location beside the midship line a possible hee ling must be considered The water hose for the external vent valve at the back of the sound cover splits on the pres sure side of the pump and at both ends in each case exten ded with a connecting nipple by a hose end Both hose ends must be led out outside of the sound cover to one point if possible 600mm over the waterlinee in the midship line The valve is connected at the highest place with the two hose ends If the valve is blocked the cooling water pipe cannot be ventilated after the stop of the generator the water column is not interrupted and the water can penetrate into the combustion chamber of the engine This leads to the destruction of the engine The tube bend must be removed Now the two ends are extended in each case with a hose and attached at a value of approx 600mm over the waterline with a ventila tion valve Wasserlinie RN waterl
27. aw water inlet If the generator is installed below the waterline always a vent valve is necessary The vent valve must be checked also during the season regularly In the winter storage the vent valve should always be disassembled checked and greased Hardens or got parts dirty are to be replaced Check water lock If the generator were rinsed with an anti freeze mixture the antifreeze mix ture can leave in the water lock If the generator were rinsed with fresh water the water in the water lock must be drained Otherwise the danger exists that the collector is blown up and destroyed by ice 10 Check the exhaust water separator on leakage and if the hose connectors at the lower surface of the separation unit are in normal condition with extremely sulfureous fuels it is possible that also high grade steel tube ends are attacked 11 Check all construction units at the generator inside the sound cover for leakages If there are traces of humidity in the sound cover the cover must be dried Further the cause for the wet ness must be surched and eliminated 12 During the winter storage the upper section of the sound cover must be taken off in order to avoid condensed moisture formation if traces of humidity remain in the sound cover inside casing by leakages in the raw water circuit Panda PMS AGT DC 4000 Chapter B Maintenance Instructions Page 25 LA Fischer Pando E Maintenance Instructions B 9 1 Measures on
28. e on board Panda PMS AGT DC 4000 Chapter D Installation Instructions Page 63 D Tischer Ponda Installation Instructions _ Electrical fuses lt is absolutely essential that the electrical system installation is inspected by a qualified electrical technician The generator should have its own AC input electrical fuses The fuses should be sized such that the rated current of the generator on each of the individual phases is not excee ded by more than 25 Data for gensets with power output greater than 30kW on request The fuses must be of the slow type A 3 way motor protection switch must be installed to protect the electrical motor Required cable cross sections The following recommended electrical cable dimensions cross sections are the minimum requi red sizes for a safe installation see Cable cross section on Page ll Page 64 Panda PMS AGT DC 4000 Chapter D Installation Instructions Q CH D 9 Voltage Control System The VCS control is used for the adjustment of the number of revolutions of the engine and thus the voltage of the generator It belongs to the accessories and is externally attached VCS 12V 01 Voltage sense 12V 06 Battery voltage supply 02 Voltage sense 12V 07 Stop line regulates the actuator back at shut off 03 Actuator the device 04 Actuator 08 Terminal shunt measurement OmV DC 05 Battery voltage supply 09 Terminal shunt measurement 4
29. each the proper RPM or does not stop pro perly the first item to suspect in most cases is the fuel solenoid valve and should be inspected first A check of the fuel solenoid valve by removing the plug from the fuel solenoid valve for a short period whilst in operation first remove the small retention screw and replace it immediately The motor should react immediately by revving high If the motor does not react sharply to the recon nection of the solenoid wire it is a sign that the solenoid valve could be faulty Fuel solenoid valve C 6 Troubleshooting Table For troubleshooting see Trouble shooting on Page Ill Panda PMS AGT DC 4000 Chapter C Generator Failure Page 37 CR lt ene Tischer Honda Page 38 Panda PMS AGT DC 4000 Chapter C Generator Failure Q CO Tischer Ponda D Installation Instructions D 1 Placement D 1 1 Placement and Basemount Since Panda generators have extremely compact dimensions they can be installed in tight locati ons attempts are sometimes made to install them in almost inaccessible places Please consider that even almost maintenance free machinery must still remain accessible at least at the front drive belt water pump and the service side actuator dipstick Please also note that in spite of the automatic oil pressure sensor it is still essential that the oil level has to be checked regularly The generator should not be installed in the proxi
30. ed Reducer External vent valve Raw water filter 0 Diode block water cooled Raw water pump 1 Heat exchanger Cooling water tank Panda PMS AGT DC 4000 Chapter A Mode of Operation of the Generator Page 9 CR E A 4 1 Control of the vent valve If the valve is blocked the cooling water pipe cannot be ventilated after the stop of the generator the water column is not interrupted and the water can penetrate into the combustion chamber of the engine This lead to destruction of the engine A 5 Operation of the generator with installation over the water line Generator over the waterline If the generator is installed over the waterline a stronger impeller wear is possible the pump can run after the start some seconds dry It is very important that the impeller is exchanged every few months When starting the generator attention should be always paid and heard to it when raw water withdraws from the exhaust neck lf this takes longer than 5 seconds the impeller must exchanged he sucks in air before raw water reaches the impeller see picture below and the impeller then wears strongly In this case the impeller loses his effect and raw water can penetrate into the engine as well as substantially destroy it If the impeller is not exchanged early enough the entire pump must be replaced Otherwise the impeller wings breaks in pieces and it stresses some time to remove these again Replacement impeller should always
31. enerator switches off in each case when an error is present This measure Is if possibly a circuit at the remote control panel failed Thermo switch at engine The thermo switch at the engine serves for monitoring the engine temperature Fig A 1 Thermo switch at engine Panda PMS AGT DC 4000 Chapter A Mode of Operation of the Generator Page 5 ene Tischer Honda Thermo switch exhaust connection If the impeller pump should fail the raw water stream fed here tears off and the exhaust connection heats up immediately extremely fast since the water cooling is missing The thermo switch supervises a functioning raw water cycle Fig A 2 Thermo switch at echaust connection Thermo switch on the connection Thermo switch on the connection bar Fig A 4 Thermo switch on the connection bar Page6 Panda PMS AGT DC 4000 Chapter A Mode of Operation of the Generator Tischer Ponda Coikl thermo switch 1 Thermo switch coil 125 C 2 Generator housing 3 Thermo sensor NTC 981S for measuring Fig A 5 Thermo switch coil Oil pressure switch at diesel engine The combustion engine is equipped with an oil pressure control switch which swit ches the engine off if the oil pressure drops under a certain value J 7 E d ANAM a AT VANA Lip LEFEFFIFFF Fig A 6 Oil pressure switch A 1 1 Regulation of the generator voltage by the VCS The output voltage
32. erator Failure Tischer Ponda 01 Actuator 02 Spiral thread spindle C 3 2 Effects of a overload to the actuator If the generator is overloaded the voltage falls on account of a not adequate motor power under the nominal value The actuator stays at the upper keystroke and tries to rev up the diesel engine An internal regulation limits the current to the actuator nevertheless a longer overload can damage the winding of the actuator short of the winding The motor gets not strictly inoperative but it can happen that the cranking torque of the actuator is getting weak This has the consecu ence that the rev spindle can not be turned to all positions faultless Therefore the voltage of the generator is regulated not good or sometimes not at all If you notice that the spindle of the actuator doesn t run faultless first check if the aggregate was overloaded for a short time and if thereby the winding of the actuator was damaged Then the actuator has to be changed Check the electrical fuse miniature slow to blow fuse 1 6A on the control printed circuit board if the actuator will not turn at all Change this fuse 1 6A slow to blow The generator can t be damaged by an overload because the winding is overload and short cir cuit safety But damages are possible in the periphery Especially connected consumers are endangered because a lower voltage can damage them by order Panda PMS AGT DC 4000 Chapter C Generator
33. f toothed belt Gate power Grip GT MR HTD 410 6 692 M5 Page 18 Panda PMS AGT DC 4000 Chapter B Maintenance Instructions Tischer Ponda Screw on the raw water pump again Fasten the fixing bolts to the raw water pump again B 7 The raw water circuit B 7 1 Clean raw water filter The raw water filter should be released regularly from arrears In each case the water cock must be closed before It is mostly sufficient to beat the filter punnet If water should seep through the cover of the raw water filter this may be sealed in no case with adhesive or sealant Rather must be searched for the cause for the leakage In the simplest case the sealing ring between caps and filter hol ders must be exchanged Panda PMS AGT DC 4000 Chapter B Maintenance Instructions Page 19 Vi 2 lt a rischer Honda B 7 2 Causes with frequent impeller waste The impeller of the cooling water pump must be regarded as wearing part The life span of the impeller can be extremely different and exclusively depends on the operating conditions The cooling water pumps of the PANDA generators are laid out in such a way that the number of revo lutions of the pump lies low compared with other aggregates This is for the life span of the pump a positive effect Unfavorably affects the life span of the impeller if the cooling water sucking in way is relatively long or the supply is handicapped so that the cooling wate
34. fills the same function If the Supersilent exhaust system were installed correctly the generator will not disturb your boat neighbour The exhaust noise should be nearly inaudible The best result is reached if the hose line which derive the cooling water is relocate on a short way falling directly to the outlet and this outlet is under the water line gt 600mm gt 100mm gt 400mm waterline 1 Generator 8 Silencer 2 Water lock 9 Exhaust pipe 3 Exhaust water separator 10 Exhaust pipe 4 Hull outlet exhaust 11 Waterline 5 Hull outlet water 12 Water hose 6 Seacock 13 Exhaust hose 7 Reducer If the thru hull exhaust outlet has to be mounted far from the generator an exhaust water separa tor must definitely be installed The sea water from the separator must then run along the shortest possible path is the thru hull outlet For such long exhaust routes the exhaust hose diameter should also be increased from NW40mm to NW50mm in order to reduce the back pressure The exhaust may have a length of over 10m 32 ft if the exhaust hose diameter is increased to 50mm An additional outlet exhaust muffler close to the hull outlet will help further to reduce noise emissions Page 50 Panda PMS AGT DC 4000 Chapter D Installation Instructions a rischer Honda Example of an unfavorable installation water lock not deeply enough under the hights level of the generator distance water lock to exhaust water
35. h a PANDA HD inverter also in continuous operation A 3 Operation of the generator with automatic start If the generator set were set up far away from the location of the remote control panel that the user cannot hear surely whether the generator starts a automatic starting option accessories should be installed With this option the starter is disengaged automatically if the starting speed is exceeded Page8 Panda PMS AGT DC 4000 Chapter A Mode of Operation of the Generator Tischer Ponda AA Betrieb des Generators bei Einbau unter der Wasserlinie If the generator cannot be installed clearly at least 600mm over the waterline a vent valve must be installed into the raw water line At installation beside the midship s line a possible heeling must be considered The water hose in the sound cover is split on the heat exchanger outlet and extended in each case in the sound cover at both ends with a connecting nipple by a hose end Both hose ends must led out from the sound cover to a point which is at least for 600mm over the waterline if possible in the midship s line The valve is inserted at the highest place at least 600mm over the waterline The tube bend must be removed Now the two ends are extended in each case with a hose and attached at a value of approx 600mm over the waterline with a ventila tion valve Wasserlinie waterline Hull inlet Fresh water pump Water cock Exhaust manifold water cool
36. hat the impeller wearout will be stronger After the start the pump runs dry some seconds The raw water hose should describe a loop as near as possible to the raw water inlet of the gene ator see picture below With it the pump only sucks in air for a short time The impeller will be lubricated by the raw water and its life time will rise By the installation of a check valve in the raw water inlet line which is under the waterline this problem can be limited a little It is very important to change the impeller every few month When starting the generator you should pay attention and listen when raw water comes out from the exhaust lf this lasts longer than 5 seconds the impeller has to be changed because he sucks to much air before raw water reaches the impeller and the impeller wears out strongly In this case the impeller looses its function which leads to an overheating of the engine If the impeller isn t exchanged early enough the impeller wings can break into pieces and clog the cooling circuit Therefore it is very important to change the impeller every few month NOTE Never change the impeller for many years without exchanging the old pump If the sealing ring is defective within the pump seawater runs into the sound cover of the aggregate A repair is then very expensive Replacement impeller and also a spare pump should always be on board The old pump can be sent back to ICEMASTER where it is then economically overh
37. hat the sensor tip is not screwed into the root of the gear rim The screw is subsequently turned anticlockwise by half a turn 0 3 to 0 8mm and held by a counter nut 1 Speed sensor on threaded seat 2 Engine flywheel with gear rim 3 Generator housing 4 Counter nut 1 Speed sensor on threaded seat 2 Engine flywheel with gear rim Panda PMS AGT DC 4000 Chapter D Installation Instructions Page 61 Tischer Ponda D 8 Generator DC System Installation ATTENTION Before the electrical system is installed READ the Safety Instructions on Page iv of this manual FIRST Be sure that all electrical installations including all safety systems comply with all required regulations of the regional authorities This includes lightnening conductor personal protection switch etc D 8 1 Installation Panda AGT 12V sytem 1 Generator 5 Remote control panel 2 Battery bank 12V 6 Voltage control VCS 3 Battery monitor 7 Fuse 4 Fuel pump 8 Battery switch All electrical safety installations have to be made on board Page 62 Panda PMS AGT DC 4000 Chapter D Installation Instructions a mi Tischer Ponda D 8 2 Installation Panda AGT 24V system 1 Generator 6 Voltage control VCS 2 Battery bank 24V 7 Starter battery 12V 3 Battery monitor 8 Fuse 4 Fuel pump 9 Battery switch 5 Remote control panel All electrical safety installations have to be mad
38. he coil have to be measured For this a special measuring instrument is necessary which mea sures the inductance of a coil Inductance is measured in the same way as the ohmic resistance e the coils are compared The value is indicated in mH milli Henry Note These values depends strongly from the measuring method kind of the measuring instru ment An alternative test method to check the stator windings can be performed as follows Ensure that the connection to the circuit system is disconnected All electrical wires in the power terminal box must be disconnected Reconnect the battery connections Start the generator eS Se Measure the voltages between the following terminals and compare for symmetry U1 U2 V1 V2 W1 W2 Page 24 Panda PMS AGT DC 4000 Chapter C Generator Failure C 5 Starting Problems C 5 1 VCS does not work For start problems one chief cause is that the VCS doen not work Check Is the voltage sense connecttion ok Check polatrity Is the shunt connection ok Check pola trity Is the main supply connection ok Check ee polatrity A Does DP VCS ON lie on clamp 6 of the EA plug with 6 pins Panda PMS AGT DC 4000 Chapter C Generator Failure Tischer Ponda Page 35 Q O A Tischer Honda Checking the fuse on the VCS printed cir cuit board C 5 2 De aerating the fuel system Normally the fuel system is designed to bleed out air itself i e as soon as
39. he main machine ICEMASTER GmbH 33104 Paderborn reserves all rights regarding text and graphics Details are given to the best of our knowledge No liability is accepted for correct ness Technical modifications for improving the product without previous notice may be undertaken without notice Before installation it must be ensured that the Pictures diagrams and related material are applicable to the aggregate supplied Enquiries must be made in case o doubt 11 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Attention Important Directions regarding Operation The installation certificate must be completed when taken into use and certified by a signature The installation certificate must be despatched within two weeks of use to ICEMASTER 4 2 3 The official guaranty confirmation will be completed by ICEMASTER after receipt and sent to the customer 4 A guaranty must be shown to make any claims Claims against the guaranty will not be accepted of the above said instructions are not or only partially carried out Manufacturer declaration in terms of the machine guideline 98 37 EG The generator is in such a way developed that all assembly groups correspond to the CE guidelines If machine gui deline 98 37 EG is applicable then it is forbidden to bring the generator into operation
40. id sections Replace if necessary MOTOR STOPS BY ITSELF cr mmm Lack of fuel Check fuel supply system Excess heat in cooling system thermo switch tripped lack of cooling water ls indicated on the remote control panel Lack of oil oil pressure sensor tripped Check cooling water system flow water pump inlet water filter extra heat exchanger coolant flow Check oil level and if necessary top up Check motor s oil pressure and have repaired by Kubota Service if necessary Panda PMS AGT DC 4000 Chapter F Tables Page V ES mas sas Tischer Honda Check electrical load and switch off unnecessary load Check intake air filter clean if necessary Replace injector nozzles Valve clearance incorrect Readjust valve clearance to correct value refer to Kubota manual Poor fuel quality Use better quality diesel recommended 2 D Diesel Poor combustion Incorrect AFR air fuel ratio due to motor timing adjust ment Have motor serviced by Kubota Low compression pressure See Kubota motor manual GENERATOR MUST BE SHUT OFF IMMEDIATELY IF ee mm motor rpm suddenly rises or drops Refer to respective section of manual and if necessary have repaired by Kubota Service or Panda represen unusual noise comes from genset tative exhaust colour suddenly becomes dark motor overheats oll pressure drops oil light suddenly flashes TROUBLESHOOTING VCS SYSTEM rm e Actuator does not m
41. iling at higher speeds more water will be forced into the inlet than what the pump can handle and your generator will overflood D 3 3 Quality of the raw water sucking in line In order to keep the suction resistance in the line at a minimum the raw water intake system i e sea cock thru hull fitting inlet filter etc must have an inner diameter of at least 1 25mm This applies also to installation components such as thru hull fitting sea cock raw water filter etc The intake suction line should be kept as short as possible Install the raw water inlet in close pro ximity to the genset After start up the cooling water quantity must be measured e g by catching at the exhaust The flow rate as well as the necessary cross section of the cooling water pipe take from Table 1 Diameter of conduits on page I Page 42 Panda PMS AGT DC 4000 Chapter D Installation Instructions Installation Instructions ng Fischer Panda D 3 4 Installation above waterline The Panda is equipped with a direct drive water intake pump mounted directly on the motor Since the intake pump is an impeller pump there are wearing parts which will likely require repla cement after some time Ensure that the genset is installed such that the intake pump can be easily accessed If this is not possible an external intake pump could be installed in an easily accessed location If the generator is installed above the waterline it is possible t
42. ine Hull inlet 7 Fresh water pump Water cock 8 Exhaust manifold water cooled Reducer 9 External vent valve Raw water filter 10 Diode block water cooled Raw water pump 11 Heat exchanger Cooling water tank Page 44 Panda PMS AGT DC 4000 Chapter D Installation Instructions Q C mi e Tischer Ponda D 4 The Freshwater Coolant Circuit D 4 1 De aerating at the first filling of the internal cooling water circuit 1 For the preparation of filling the following steps are to be undertaken a Open the cooling water cap on the coo ling water tank b Open the ventilation valve a Fill in the prepared mixture cooling water with anti freeze protection according to the intended mixture at the filler neck at the cooling water tank slowly so long until cooling water leaks at the ventilation valve b Afterwards the cooling water cap must be screwed on firmly Further the ventila tion valve must be closed Panda PMS AGT DC 4000 Chapter D Installation Instructions Page 45 Q JD Tischer Ponda Anti freeze In the interest of safety the freezing point of the closed circuit coolant should be checked on a regular basis Be sure that the coolant antifreeze mixture is good for at least 15 C 5 F and if it is possible that your genset experiences lower temperatures for example during storage or trans portation then the entire cooling system should be drained and purged T
43. k on which the generator is fastened by means of shock mounts Since the aggregate is free downward the combustion air can be sucked in unhindered In addition are void the vibrations which would arise with a closed soil Panda PMS AGT DC 4000 Chapter D Installation Instructions Page 39 Tischer Ponda D 2 Generator Connections Scheme The generator comes supplied with all supply lines i e electric cables fuel lines etc already connected to the motor and generator The supply lines are fed through the capsule s front base panel and are shielded at the capsule inlets with water proof grommets All electrical connections cable types and sizes must comply to the appropriate regulati ons The supplied cables are rated for ambient temperatures up to 70 C 160 F If the cables are required to meet higher temperature requirements they must be run through conduits D 2 1 Connections Panda AGT 4000 12V ATTENTION Before working on the System read the section Safety Instructions on Page iv Passage for battery cable Passage for battery cable Raw water inltake Cable for remote control panel Cable for VCS Cable for fuel pump Page 40 Panda PMS AGT DC 4000 Chapter D Installation Instructions Cable for voltage sense Cable for shunt Connection fuel IN Connection fuel OUT Exhaust OUT Connection external ventilation valvel a mi Tischer Ponda D 2 2 C
44. l tank The electrical con nections are preloaded at the generator with the lead planned e e Suction hight of the pump max 1 2m at 02 bar e Diameter of fuel lines Diameter of conduits on Page D 6 3 Connection of the fuel lines at the tank Lead the return fuel pipe connected to the day tank to the floor The return pipe connected to the tank must be dropped to the same depth as the suction pipe if the generfator is mounted higher than the tank in order to prevent fuel running back into the tank after the motor has been switched off which can lead to enormous problems if the generator is switched off for a long period Non return Valve in the Suction Pipe A non return valve must be fitted to the suction pipe which prevents the fuel flowing back after the generator has been switched off if it is not possible to use the return flow pipe as a submerge pipe be placing it in the tank The instructions Bleeding Air from the Fuel System must be read after initial operation or after it has stood still for a long period in order to preserve the starter bat tery ATTENTION Non return valve for the fuel return pipe If the fuel tank should be installed over the level of the generator e g daily tank then a non return valve must be installed into the fuel return pipe to guaranteed that through the return pipe no fuel is led into the injection pump Panda PMS AGT DC 4000 Chapter D Installation Instructions Page
45. let Water cock Reducer Raw water filter Raw water pump Heat exchanger Fresh water pump Exhaust manifold water cooled Diode block water cooled 7 8 9 External vent valve 10 11 Cooling water tank Panda PMS AGT DC 4000 Chapter D Installation Instructions Page 47 Q JD i5cher Ponda Installation Instructions _ D 5 Watercooled Exhaust System By injecting the outlet raw water into the exhaust manifold the exhaust gases are cooled and the noise emissions from the exhaust system are reduced D 5 1 Installation of the standard exhaust system The generator exhaust system must remain completely independent and separate from the exhaust system of any other unit s on board The exhaust hose has an inner diameter of 40mm 1 6 Panda 14000 and above approx 50mm The water lock must be installed at the lowest point of the exhaust system An optional noise insulated water lock can also be installed The exhaust hose descends from the capsule to the water lock Then the hose rises via the goose neck to the silencer see drawing The goose neck must be vertical and sit preferably along the ship s keel centre line The exhaust system must be installed so that the back pressure inside the exhaust does not exceed 0 4 bar 6 psi and total length does not exceed 6m 20 ft Exhaust diameter see Diameter of conduits on Page I gt 600mm gt 600mm waterline _ 1 Generator 4 Hull inle
46. matic start cuts out the generator stops and the panel goes into sleeping mode If the generator is not started automa tically the generator stops and the panel goes into sleeping mode Switch pressure in automatic mode The generator continues to run and the panel switches to manual mode 7 Main switch If it is already in automatic mode when it is switches on the generator starts and the panel swit ches to automatic mode If it is not in automatic mode the panel switches to sleeping mode If the generator is switched off the generator will stop in every case Panda PMS AGT DC 4000 Chapter D Installation Instructions Page 57 C a e Tischer Ponda EL LL D Main terminal clamp allocation Battery plus Battery minus Input temperature failure Input charge control Input oil pressure failure Input generator voltage 1 Input generator voltage 2 Output pre glow oO 0 N O o A W N Output fuel pump 10 Output starter motor 11 Output VCS ON voltage control for VCS 12 Output operating voltage maximum permissible load 0 2A 9 Terminal clamp for battery monitor allocation 13 Battery minus 14 Input for battery monitor The potential free contact of a battery monitor can be connected to these two terminals the star ting sequence occurs automatically if the contact closes Page 58 Panda PMS AGT DC 4000 Chapter D Installation Instructions Q
47. mity of light walls which can get into resonant vibrations by airborne sound If this is not possible these surfaces should line with 1mm lead foil so the mass and the swinging behavior are changed Avoid to install the generator on a smooth surface with small mass e g plywood plate This affects in the unfavorable case like an amplifier the airborne sound waves An improvement obtains by compound these surfaces by ribs Also break throughs should be sawed which inter rupt the surface Disguising the surrounding walls with a heavy layer e g lead plus foam mate rial improves the conditions additionally The engine draws its inlet combustion air through several holes in the capsule base Therefore the capsule must be fitted with sufficient clearance between the capsule underside and the base plate min 12mm 12 The generator sucks its air from the surrounding engine room Therefore it must be ensured that sufficient ventilation openings are present so that the aggregate cannot overheat High temperature of the intake air decline the power of the aggregate and increases the coolant temperature Air temperatures of more than 40 C reduce the power by 2 per temperature rise of 5 C In order to keep these effects as small as possible the temperature in the engine room should not be higher than 15 C in relation to the outside temperature D 1 2 Notice for optimal sound insulation The convenient base consists of a stable fra mewor
48. nd by a qualified tradesper son technician Winding diagrams can be obtained from ICEMASTER GmbH Germany This test unfortunately is carried out at very low voltage 9V when a normal multimeter is used Therefore only positive short circuits will be displayed There is the possibility that a short circuit will occur in spite of a negative test result i e moisture A reliable check can only be carried by using an essentially higher voltage approx 500V This type of measuring instrument is normally only used by experts If in doubt an electrician must check the winding for a short circuit with an isolation meter Diode block at the Panda generator Page 32 Panda PMS AGT DC 4000 Chapter C Generator Failure Q C Tischer Ponda Wiring diagram C 4 2 Coil Resistance Measurements in Stator Windings If the testing set determined no earthing the coil windings of the generator must be controlled with a resistance measuring instrument ohm meter To measure coil resistance a meter capable of measuring low resistances Milli Ohm resolution if possible accurately The measured resi stance values should be close to the same between the following terminals U1 U2 V1 V2 W1 W2 Checking windings e Disconnect all connections from the power terminal box Loose the nuts and deduct the cables e Remove all winding connections from the power terminal box e Switch your meter in resistance range When you put the probe
49. ner The circuit must be kept upright some minutes to guaranteed that the anti freeze protection mixture reaches all ranges of the cooling system The concentration of the anti freeze mixture in the internal cooling circuit must be checked with a suitable measuring instrument The concentration must be furnished according to the lowest temperatures which can be expected Clean raw water filter and check seal 4 Check water cock for practicability And spray with a corrosion protection oil from the inside or lubricate with acidless grease Check all hoses and hose connectors for good condition The rubber hoses are very sensitive to enviromental influences They can age fast with dry air in environment of light oil and fuel steams and increased temperature The hoses must be checked regularly for elasticity There are operating situations which the hoses must be renewed once in the year Check the hose connectors at all raw water valves doubly and if possible protect them with double hose clamps Dismount the impeller of the cooling water pump and check for wear The impeller may not remain in the pump lt must be greased with vaseline and be kept at a dark place lt can be reintragrated in the spring again into the pump if it is in good condition The impeller is a wea ring part it is recommended to renew it always in the spring independently how many opera ting hours the aggregate ran Control of the vent valve at the r
50. ng ports only cooling water 4 Again de aerating process in the few days after the first startup Also after the first implementing a small amount of air can be reside in the cooling circuit To ensure an imaculate und actual operating of the cooling system the de aerating process must be repeated casual in the next few days if necessary weaks Small amount of air will be still exit out of the de aerating openings especially if the generator stood still for a long time ATTENTION During the de aerating process it must be checked again and again if the cooling water is indeed circulating If air bubbles established in the internal cooling water pump it could be that the cooling water circuit is not circulate Then the generator would be warming very fast and switched off by overheating Page 46 Panda PMS AGT DC 4000 Chapter D Installation Instructions D 4 2 Pressure test for control of cooling water circuit a rischer Honda Check with the hand if a temperature difference exists whether between cooling water in flow and cooling water return Feel the cooling water in flow line at the internal cooling water pump Feel the cooling water return pipe either at the outlet of the water cooled exhaust elbow union or at the side where this pipe entry at the heat exchanger The temperature difference between in flow and return is approx 10 degrees D 4 3 Scheme for freshwater circuit at two circuit cooling system Hull in
51. nnnononnnononnnnennnonnnnnnnnnanennnonannnnnss 53 D 6 4 Position of the pre filter with water separator nenn nenne nn 54 D 7 Generator DC System Installation uusunnsanunnnannnnnnnnnunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnen 54 D 7 1 Connection of the 12V starter battery only for 24V version 54 D 7 2 Terminalblock AGTADOO T2V es ep ae ee 55 D 7 3 Terminal block AGT A OOO EE 55 D 7 4 Installation of the remote control panel nenne nenne nenne nnnnennnnennnnenenn 56 D 7 5 Remote control panel for AC T Generators 56 RE e ue Ee EE 61 D 8 Generator DC System Installation oooccconnncccnnnncccccnncnonancononancnnnannonnnanrrnnnnncrnnnanerennnnnnnaanens 62 D 8 1 Installation Pandas AGT 12V Ssyien unreal 62 D 8 2 Installation Panda AGT 24V sYstemau se seen A 63 D 9 Voltage Control System u une en reed ine 65 D 10 Voltage Controller eege ege EE eg 67 D 10 1 Adjustment of the rated Volta iaa 67 D 10 2 Functional decription of the voltage controller nenn nenn nenne nenne nenne nenne nnenennen 67 D1039 Timelag ofthe Swichng POIS citado lalalala 68 TADOS arrer orton ice ole icieieds Fok Trouble ShoOOlUNd ias II SC SR CONCERT Un E Vil Panda PMS AGT DC 4000 Table of Contents F 3 FA F 5 F 6 F 7 ene Tischer Ponda TEV DOS e EE Vill Inspection Checklist for services uusnauunnanonnnnnnnnunnnnunnunnnnnunnannnnnnnnanennnnennnnnnnnennnnennnnnnnn IX ENGINE TI WE A C00lant speecifications sii at aa a a
52. ntion that the generator is not overloaded anymore 2 The actuator does not move but the spindle can be turned manually e Disconnect the plug of the actuator Connect provisional an external voltage source 12V DC to the motor The actuator don t turns with the external voltage source The actuator is defect and have to be changed Actuator does not turn The actuator is defect and have to be changed the actuator turns und works 1 Check the fuse on the VCS printed circuit board faultless Check if the sense voltage is wired to the VCS printed circuit board Check if the VCS supply voltage is wired to the VCS Check if the VCS outlet signal for the actuator is wired Page 30 Panda PMS AGT DC 4000 Chapter C Generator Failure Cr Fischer Pando Change the VCS printed circiut board if the points above carries no clearance berpr fen der Begrenzung der Generatorspannung The mechanical voltage limitation must be checked regularly The following steps have to be done 1 Disconnect the plug of the actuator Lower suspension point Switch off all load Connect an electrical ammeter Start the generator Turn the actuator manually to the lower suspension point PL 5 9 Ze Charge current must be lt 10 A at U UNenn Upper suspension point 7 Connect the load 8 Turn the actuator by hand gradually the insertable load up to the upper susoension point Charge current must not lay over 140A
53. nunnnnnnnnnnnnnn 8 A 2 1 A A ee 8 A 3 Operation of the generator with automatic start uuusuauuuanunnanunnnnnnnnnnnnnnnnnnnnnnunnnnnnnnen 8 AA Betrieb des Generators bei Einbau unter der Wasserlinie oocconnncconncioncnccncnronnannenannnnnanos 9 A 4 1 erdeelt 10 A 5 Operation of the generator with installation over the waterline oooncccnnciconncionnncconannnas 10 Mamtenance Tu En AAA 11 B 1 General maintenance instructions uuusnaanunnannunnnnnnnnnnunnnnnnnnnnnnnnnnunnnnnnnnnnunnnnnnnnnnnnnnnn 11 B 1 1 Checks before Standar adidas 11 B 1 2 Hose elements and rubber formed component in the sound Cover 11 B 2 OILCIFEUN Maintenance areas 11 B 3 Execution of an Oll CHANGE a 12 BA Checking the water separator in the fuel supply uunuusssnnnnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnn nun 14 B 4 1 De aerating the fuel system au necutdstanscvetel shade dael odiedieiawiineiie Audesbivedecalinndeet 14 B 4 2 Exchange Medal a 16 B 5 De aerating of the coolant circuit freshwater c ocooncconncconncononconorcnanncnannonancnnancnnarenaarenannnnas 17 B 6 Exchange of the toothed belt for the raw water pump ee REENEN KEREN REENEN 18 BL The raw Water Circus E a E E 19 B 7 1 Clean Taw A ln os 19 B 7 2 Causes with frequent impeller waste 20 B 7 3 Exchange Ofte Impeller tapial sis lalalala pcia 20 B S Additional Maintenance eege ENEE 23 B 9 Conservation at longer operation interruption uuausunnannnonnn
54. o purge the cooling system compressed air at about 0 5 bar 7 5 psi is sufficient d Start the generator After filling the generator this must be started During this first phase of start up the generator may not be loaded Switch the generator off after max 2 minutes of operation 3 First de aerating The cooling water circuit of the generator must be de aerated now by multiple repeating of the de aerating procedure During the entire procedure the external cooling water expansion tank remains opened i e the cap must be removed After the first stopping of the the generator wait about one minute until the air in the cooling water can be drop off and raise to the highest point ventilation point Now open all three ventilation points one after another as long as cooling water exit Then the clo sure screw must be closed immediately Turn on only lightly to treat the thread Pay attention that the external cooling water expansion tank is filled with enough cooling water during the de aerating If necessary refill over and over One de aerating step will be last as a rule max 2 minutes and following steps contained The generator runs approx 1 minute Stop the generator Ge Een Hold on one minute for drop of air 4 The collected air is led out over the two de aeration points The ahead described de aerating process must be repeated as long as after the stopping and drop off air none air exit out of the de aerati
55. of the generator is permanently measured by the VCS approx 20 times per second As soon as by a consumer the voltage is affected the speed regulation provides to adapt to the changed power demand by appropriate change of the engine speed Not only by the excitation of the generator it is worked against to the initiating voltage drop but also by the raising of the number of revolutions whereby the drive potential improves Panda PMS AGT DC 4000 Chapter A Mode of Operation of the Generator Page 7 ZE E Fischer Panda de of Operation of the Generator A 1 2 Overloading of engine during longer operation Please ensure that the genset is not overloaded Overloading occurs when the electrical load demand induces a load torque in the generator which is higher than that which the diesel drive motor can provide Overloading causes the engine to run rough burn oil creates excessive exhaust environmentally unfriendly and even to stall Extra caution should be practised with multi power units single and 3 phase current generation to avoid overloading the diesel drive engine rated power for short periods only A high peak Fischer Pando ISETET FONGO ver for current is required to start many electrical IR AGT 4000 devices especially electric motors and compres sors from a still stand state The generator should only be loaded at the peak The height of the rated output P can taken from the identification
56. onnections Panda AGT 4000 24V ATTENTION Before working on the System read the section Safety Instructions on Page iv Passage for battery cable Cable for voltage sense Passage for battery cable Cable for shunt Raw water inltake Connection fuel IN Cable for remote control panel Connection fuel OUT Cable for VCS Exhaust OUT Cable for fuel pump Connection external ventilation valvel 1 Connection starter battery minus cable 2 Connection starter battery plus cable Panda PMS AGT DC 4000 Chapter D Installation Instructions Page 41 Q JD Tischer Ponda D 3 Cooling System Installation Raw water D 3 1 General References The genset should have its own raw water coolant water inlet and should not be connected to any other engine systems Ensure that the following installation instructions are complied with Avoid galvanic corrosion For the avoidance of galvanic corrosion the chapter Service instruction for marine aggre gates corrosion protection is to be considered D 3 2 Installation of the thru vessel fitting in Yachts It is good practice for yachts to use a hull inlet fit Fahrtrichtung gt ting with an integrated strainer The thru vessel fitting raw water intake is often mounted against Borddurchla the sailing direction to induce more water intake EE for cooling For Panda generators the thru vessel inlet should NOT point in the sailing direction When sa
57. ooling of the diode block The diode block is cooled with fresh water A normal cooling of the diode block is therefore only possible as long as the cooling water supply of the generator functions duly The cooling water supply of the generator must be so furnis hed therefore that by a wide dirt deflector it is guaranteed that from outside no dirt can be sucked in into the line system If this is not attainable the supply must be secured by a flow switch or a negative pressure switch The generator must be switched off if the cooling water supply is impair The temperature safety device on the diode block can be regarded only as additional safety device The temperature rise at the diodes is so fast that the diodes can be damaged during a unique interruption of the cooling water supply A safe protection from damage of the diodes is not possible by the temperature monitoring on the diode radiator box Thus this can take place only by means of an appropriate external monitoring of the cooling system ATTENTION Do not connect the minus pole of the starter battery to the ground of the boat because of galvanic reason Warning Never start the generator with the battery disconnected the diodes will be damaged CAUTION Contact of the electrical contacts may be DANGER TO LIVE IN CAUTION The AGT generator is not allowed to be connected to an inverter without batteries A battery must always be connected to the inverter as a capacit
58. ove Check voltage supply and wire connections to actuator Motor connected Check connection to VCS Actuator sets throttle too high or too low Check that the wires to the actuator are connected pro perly Check connection to VCS If the VCS electronics are faulty the generator can still run by over riding the system To override the VCS dis connect the plug and jumper the contacts Loosen the connecting rods motor from the injection pump regulator and turn screw to a max voltage of 33V Page VI Panda PMS AGT DC 4000 Chapter F Tables Ee Je Qe Fischer Ponda F 2 Technical Data Engine Panda AGT DC 4000 PMS Type EA 300 CS Govenour max Power DIN 6270 NB at 3000rpm Valve clearance engine cold 3l Lubrication oil capacity Fuel consumption approx 0 42 1 12 a progressive speed by VCS b 0 351 kW electrical power the randomized values between 30 and 80 of the nominal power lt ne dl D kb gl Panda PMS AGT DC 4000 Chapter F Tables Page VII Tischer Ponda F 3 Types of coil HP3 delta connection HP3 star connection Page VII Panda PMS AGT DC 4000 Chapter F Tables amp ES 2 Fischer Pando F 4 Inspection checklist for services Inspection Category Inspection work DT TOR pee IET Bpr 1 men en IE Inspection Category AAA A ja eB je b e F je o p p p p h a S fot sane tegen TI 3 oo pe
59. r sucking in range develops a negative pressure This can reduce first of all the power of the cooling water pump extremely that the wings of the impeller are exposed to very strong loads This can shorten the life span extremely Further the operation of the impeller pump loaded in waters with a high portion of suspended mat ters The use of the impeller pump is particularly critical in coral waterbodies Cases are well known which a impeller pump had so strongly run after 100 hours already that the lip seal on the wave was ground in In these cases sharp crystal parts of the coral sand assess in the rubber seal and affect like an abrasive the high grade steel shank of the impeller pump If the generator were mounted over the water level it is particularly unfavorable for the impeller pump After the first start some seconds will pass by until the impeller can suck in cooling water This short unlubricated operation time damages the impeller The increased wear can lead after short time to the loss see special notes Effects on the impeller pump if the generator is moun ted over the waterline B 7 3 Exchange of the impeller Close the raw water stop cock Page 20 Panda PMS AGT DC 4000 Chapter B Maintenance Instructions Raw water pump on the front side of the genset Remove the cover of the raw water pump by loosen the wing screws from the hou sing Pull to the impeller with a multigrip pliers of the wave Ma
60. rder to prolong the genset s life expectancy the nominal electrical demand on the system should not be more than 70 of the rated genset peak load Keep PEAK LOADING demand in mind when switching on electrical devices esp fridge com pressors electric motors battery chargers kettles etc which are fed by the generator Careful powering up gradual loading of the electrical demand on the generator will help prolong the life of your genset The genset can be run for several hours at partial load i e 2 3 of rated power however it is not advised that it is run for more than 2 3 hours at full load The Panda is designed so as not to overheat even under extreme conditions Note The exhaust gas will become sooty during peak load operation Effects of Short Circuiting and Overloading on the Generator The generator cannot be damaged by short circuiting or overloading Short circuiting and over loading suppress the magnetic excitation of the generator thus no current is generated and the voltage will collapse This condition is immediately offset once the short circuit has been elimina ted and or the electrical overload removed Panda PMS AGT DC 4000 Chapter C Generator Failure Page 27 Vi E Fischer Panda AAA C 3 Adjusting the nominal charge current ATTENTION Before working on the System read the section Safety Instructions on Page iv These adjustments may not be changed they are sealed The adjustment
61. rk the impeller to make sure that these is used in the correct position at re instal lation Panda PMS AGT DC 4000 Chapter B Maintenance Instructions Tischer Ponda Page 21 23 2 lt Page 22 Panda PMS AGT DC 4000 a Tischer Honda Chapter B Maintenance Instructions Check to the impeller for damage and replace it if necessary Before the reinsertion into the housing the impeller should have been lubricated with glycerin or with a non mineral oil based lubricant e g silicone spray The impeller is attached to the pump wave if the old impeller is used pay attention to the before attached marking Fastening the cover and use a new seal Q CO Z ene rischer Ponda B 8 Additional maintenance Furthermore in addition to the standards checks according to the manual following points of the generator have to be checked e automatic shut down of the generator in case off high heating temperature This shall be done by disconnecting the thermo switch of the heat sink Next to the rectifier you will find a 2 pole connector If you disconnect this connector from the opposite socket the gene rator shall shut down or when the generator is not running you will get a signal on the panel Temperatures of the rectifier and heating e Apply a thermocouple meter to the heat sink and the copper bars and monitor the maximum temperatures of the rectifier With the help of the
62. rminal 13 and 14 on the panel which will start the generator after a adjusted time of one minute if there is the voltage drops down in a adjustable level to reload the batteries On the panel at the terminal 15 and 16 is the allocation for extern switches like thermo time or ambient switches Every switch including the battery monitor will overdrive each other The shut down proce dure will works with the switch that had been switched If there is no extern switch or battery monitor allocated this LED becomes not constant flashing however green blinking If the external battery monitor is inbuilt to monitoring a battery group it will be advisable to switch it with an accessory On Off switch This battery monitor ensures that he will be activ while the voltage of the batteries is on the pre set level Therefore there is a time delay available the genset will run until he reached the upper level More information see battery monitor Page 60 Panda PMS AGT DC 4000 Chapter D Installation Instructions a a rischer Honda D 7 6 The speed sensor Plug for speed sensor Installation of the speed sensor The speed sensor tip must have between 0 3 to 0 8mm of clearance air gap from the gear rim tips In order to achieve this clearance the speed sensor tip should be aligned with the tip of a gear rim and screwed in until it touches the tip of the tooth ATTENTION Ensure that when inserting the sensor t
63. s of you meter together you should get a reading of 0 000hm When you isolate the probes the reading will be Overflow Please do this tests to check your meter e Measure of the resistance within the individual windings The values should be very small It mainly depends on the relation between the values Some measuring instruments operate very inaccurately if the measured values are very small e Resistance measure between different windings If the value is in the Giga ohm area the coil is correct If you find any anormality when doing this test please ask your Fischer Panda dealer If strong deviations are measured in the individual coil windings there is a coil short cut in one coil No voltage is induced The actual values between the coil windings are not determined so exactly lt depends on the fact that the values of all three measurements are as alike as possible Deviations among themselves refer to a coil short cut In this case the generator must be newly wound by a specialist Panda PMS AGT DC 4000 Chapter C Generator Failure Page 33 vi Fischer Panda AAA C 4 3 Measuring the Coil Inductive Resistance Unfortunately the checking of the ohmic resistance permits still no reliable statement about the condition of the coil If the ohmic resistance values arise inequalities between the coils that is a safe indication for the fact that the coil is defective To be exactly sure the inductive resistance of t
64. s should be changed expires the warranty The adjustments of the nominal charging current is made at the actuator By the nuts on the left and on the right at the spindle of the actuator the adjustment is limited The generator must be started and loaaded with the nominal dates The engine adjusts the speed regulator lever after a short time in such a way that the generator supplies appropriate nominal dates The adjusting nuts must be fixed to this point This delimitation serves for the protection of the generator so that it is not overloaded 01 Actuator 02 Spiral thread spindle 04 Spindle nut with speed regulator lever e SC 05 Adjusting nuts for max speed engt A z DE KK ei 02 H VW E I D i p e During any operation at the generator all consumers have to be switched off to avoid damages at the equipments C 3 1 Lubrication of the spiral thread spindle The spiral thread spindle must be lubricated carefully and regularly Please only use a temperatur independence lubricant up to 100 C witch is also equiped with emergency run qualities g Spread also lubricant to the end of the nuts A 1 lt is possible that the spindle could clamp if the spindle is not enough lubricated Then the genera a tor can be switched off by over or undervoltage All screws at the actuator and the spindle must be ensured solveable with a screw safety grease Page28 Panda PMS AGT DC 4000 Chapter C Gen
65. se for excess water in the combustion chamber The excess water can be caused by a defec tive air vent in the cooling water system which should be checked and cleaned or replaced if faulty MOTOR RUNS IRREGULARLY an Faulty centrifugal injector governor Have the centrifugal governor inspected by a Kubota Service technician Too much air in fuel lines Bleed air from fuel system Page IV Panda PMS AGT DC 4000 Chapter F Tables DROP IN THE SPEED OF THE MOTOR Cause Too much oil Lack of fuel Lack of intake air Generator overloaded by too many load Generator overloaded by over energizing Q CO Tischer Ponda Drain oil Check fuel supply system fuel filter renew if necessary check fuel pump check fuel lines bleed if necessary Check air intake paths Check and clean air filter and intake muffler if instal led Reduce the electrical load switch off load Check that the proper capacitor type is installed and that they are connected correctly Defective generator windings bearings or other Generator must be sent to manufacturer for repair of damaged bearings or winding Damaged engine MOTOR SWITCHES ITSELF OFF Fuel solenoid valve or throttle shut solenoid is not swit ching off Repair of bearing damage etc by Kubota Service Check wire connections to solenoid Check valve functions as in the Inlet Fuel Solenoid Valve or in the trottle shut off soleno
66. separator too largely Panda PMS AGT DC 4000 Chapter D Installation Instructions Page 51 Q JD Tischer Ponda D 6 Fuel System Installation D 6 1 General References Additional fuel filters with water seperator must be mounted outside the capsule in easily acces sible places in the fuel lines between the tank intake fuel pump and the diesel motor s fuel pump Generally forward and return fuel flow pipes must be mounted to the diesel tanks Do not connect the generator fuel supply lines with any other fuel lines of other diesel systems The following items need to be installed e Fuel supply pump 12V DC e Pre filter with water separator not part of the delivery e Fine particle fuel filter e Return fuel line to fuel tank unpressurized The fuel supply pump should be mounted as close to the fuel tank as possible The electric cable for the fuel pump is already installed on the generator length 5m o QQ D gt O 1 Generator 5 Condensation water suction pump 2 Fuel stop cock 6 Fuel tank 3 Fuel filter 7 Fuel supply pipe 4 Fuel return pipe 8 Electrical fuel pump 12V DC Page 52 Panda PMS AGT DC 4000 Chapter D Installation Instructions Installation Instructions ng Fischer Panda D 6 2 Theelectricalfuelpump Electrical fuel pump With the Panda generator is usually supp lied an external electrical fuel pump 12V DC The fuel pump must be installed close at the fue
67. speed regu lation etc e Check all switching off devices for function by operational procedures Icemaster does not take over adhesion for possible damages Page 26 Panda PMS AGT DC 4000 Chapter B Maintenance Instructions Q C ene rischer Ponda C Generator Failure C 1 Tools and measuring instruments In order to be able to manage disturbances while driving following tools and measuring instruments should belong to the equipment on board e Multimeter for voltage AC frequency and resistance e Measuring instrument for inductance e Measuring instrument for capacity e Current absorbing clamps e Thermometer ideal is a infrared thermometer e Pressure device pincer f r coolant circuit C 2 Overloading the Generator Please ensure that the genset is not overloaded Overloading occurs when the electrical load demand induces a load torque in the generator which is higher than that which the diesel drive motor can provide Overloading causes the engine to run rough burn oil creates excessive exhaust environmentally unfriendly and even to stall Extra caution should be practised with multi power units single and 3 phase current generation to avoid overloading the diesel drive engine The generator should only be loaded at the peak rated power for short periods only A high peak current is required to start many electrical devices especially electric motors and compressors from a still stand state In o
68. st demands turbo tested Engine oil types above 25 C SAE30 or SAE10W 30 SAE10W 40 0 C to 25 C SAE20 or SAE10W 30 SAE10W 40 below 0 C SAE10W or SAE10W 30 SAE10W 40 Page X Panda PMS AGT DC 4000 Chapter F Tables Q JD F 6 Coolant specifications Tischer Ponda Use a mixture of water and antifreeze The antifreeze needs to be suitable for aluminium The antifreeze concen tration must be regularly checked in the interests of safety ICEMASTER recommend to use the product GLYSANTIN PROTECT PLUS G 48 Engine coolant automotive industry Product description Product name GLYSANTIN PROTECT PLUS G48 Chemical nature Monoethylenglycol with inhibitors Physical form Liquid Chemical and physical properties Reserve alkalinity of 10ml Panda PMS AGT DC 4000 Chapter F Tables Page XI oy eas Tischer Honda F 7 Measurements 595 23 4 595 23 4 650 25 6 50 12 4 270 10 6 ES 399 15 6 395 15 6 z gt i z et rf 2 een gt Ei 270 10 6 60 2 4 270 10 6 Page XII Panda PMS AGT DC 4000 Chapter F Tables
69. strainer The oil strainer must be cleaned every 500 opeatiing hours Open the oil filler neck After opening the cap of the oil filler neck the new oil is refilled Please wait instant before measure the oil level the oil must set off in the sump Oil dipstick With the help of the engine oil dipstick the oil level is to examined The prescribed fil ling level may not exceed the Max mar king We recommend 2 3 oil level Panda PMS AGT DC 4000 Chapter B Maintenance Instructions Page 13 Q O d 5 Fischer Panda Maintenance Instructions B 4 Checking the water separator in the fuel supply The pre filter with water separator has a cock at its lower surface with this cock the downward sunk water can be discharged This is simply possible water is heavier due to its density than the Diesel B 4 1 De aerating the fuel system Normally the fuel system is designed to bleed out air itself i e as soon as the electric starter motor starts operation the fuel pump starts working and the fuel system will be de aerated after some time automatically It is nevertheless essential to bleed the system as follows prior to the first operation as all hoses are empty 1 Put a container under the fuel return pipe to catch running out fuel to catch Page 14 Panda PMS AGT DC 4000 Chapter B Maintenance Instructions 2 Take off the plug at the solenoid of the starter motor 3
70. t exhaust 2 Water lock 5 Silencer 3 Goose neck X Distance as small as possible Page 48 Panda PMS AGT DC 4000 Chapter D Installation Instructions Q CO Tischer Ponda D 5 2 Exhaust water separator The exhaust water separator In order to reduce the noise level of the generator unit to a minimum an optional exhaust outlet muffler mounted next to the thru hull fitting can be installed Additionally there is component at ICEMASTER which exercise both functions of a exhaust goose neck and the water separation With this exhaust water separator the cooling water is derived over a separate pipe Thereby the exhaust noises at the exterior of the yacht are strongly decreased Particularly the water plash allocate The water flow on the exhaust water separator unit has an inner diameter ID of 30mm If the path from the water separator to the sea water outlet is very short the hose can be further redu ced to 1 25mm ID Raw water outlet o 30mm Hose connection 30mm Reducer 30 20mm if required Hose for hull inlet Hose connector Sea cock Hull outlet 1 2 3 4 O 6 T 8 Hose clamps Panda PMS AGT DC 4000 Chapter D Installation Instructions Page 49 u Fischer Panda Installation Instructions _ D 5 3 Installation exhaust water separator If the exhaust water separator was sufficiently highly installed a goose neck is no longer neces sary The exhaust water separator ful
71. the electric starter motor starts operation the fuel pump starts working and the fuel system will be de aerated after some time automatically lt is nevertheless essential to bleed the system as follows prior to the first operation as all hoses are empty Put a container under the fuel return pipe to catch running out fuel to catch Take off the plug at the solenoid of the starter motor Switch the panel ON Press START button The fuel pump runs audible Switch the panel OFF Switch the panel ON Press again the START button me ee Em This procedure must be repeated several times until fuel nonporously withdraws per fectly at the fuel return pipe 8 Switch the panel OFF 9 Attach the plug at the solenoid of the starter motor Page 36 Panda PMS AGT DC 4000 Chapter C Generator Failure Q CO EC ene rischer Ponda C 5 3 Fuel Solenoid Valve For start problems the possibility of an error exists with the solenoid for engine stop or fuel sole noid valve which both effect affect simultaneous on the fuel system The fuel solenoid valve is located in front of the injection pump lt opens automatically if the START button is pressed on the remote control panel The solenoid valve is CLOSED when the generator main power is switched OFF For this reason it requires a few seconds before the motor comes to a full halt If the generator fails to start runs rough does not r
72. until it has been determined that the system into which the generator is to be installed in also corresponds to the regulations of the machine gui deline 98 37 EG This concerns among other things the exhaust system cooling system and the electrical installa tion The evaluation of the protection against contact can only be accomplished in connection with the respective system Likewise among other things responsibility for correct electrical connections a safe ground wire connection foreign body and humidity protection protection against humidity due to excessive condensation as well as the over heating through appropriate and inappropriate use in its installed state on the respective machine lies within the responsibility of those who undertake installation of the generator in the system Use the advantages of the customer registration e Thus you receive to extended product informations which are sometimes safety relevant e you receive if necessarily free Upgrades Far advantages By your full information Fischer Panda technicians can give you fast assistance since 90 of the disturbances result from errors in the periphery Problems due to errors in the installation can be recognized in the apron Technical Support per Internet info fischerpanda de 111 Safety Instructions The electrical Installations may only be carried out be trained and tested personnel The generator may not be taken into use with the cover remo
73. ununnnnnnunnnnnnnnnnnnnnnnnnnn 25 B 9 1 Measures on preparation of the winter storage occcconcccoccnccncnconcnnonnnnnnanononenonncnnonarononenconcnnnns 25 B 9 2 Jegen EE el lo e EE 26 Generator FAUTE usina 27 C 1 Tools and measuring instruments uuurusn ann0nnnnnnnnnnnnnunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 27 C2 Overloading the Generator nennen ieh 27 C 3 Adjusting the nominal charge current s ssssnnnssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn nnmnnn 28 0 3 1 Lubrication of the spiral thread epindle nennen nnnennnnnnnnnnnnnnnnnnnnnnnnennnne nenn 28 0 3 2 Effec1s 01 4 0Vverload TO the e E te EE 29 0 3 3 Low Generator QUtpuUt e e Te anne ds 31 GA Testing Generator Stator Windings ccocnccccnnncccnnnncoconancononancncnnannncnnannrrnnannrrnnnnrrrnnnnrenannnns 32 C 4 1 Testing Generator Stator Winding for Shorts to Groumgd nenne nnenne nen 32 C 4 2 Coil Resistance Measurements in Stator Windings ccccoooncnccccnccnncnonnncnnnnnnnconennnncrnnononacinnnos 33 0 4 3 Measuring the Coil Inductive Resistance occccccocccnncccncconcononnnncononcnnnnonanonnnonanennnnnnanenenonanennnos 34 6 5 Starting Be EE 35 C 5 1 SAO AAA ee A lese 35 Panda PMS AGT DC 4000 Table of Contents Page 1 d Page 2 l d mu o Fischer Honda 0 5 2 De aerating the fuel Sy SM 36 C6 Troubleshooting Tables 37 C 5 3 Fuel Sole VA een de o 37 Installation INSTITUCION SS naci a 39 Dal Placement ee 39 D 1 1 Placement
74. usted That is the voltage must have overstep or fall short of the switching point on the time lag Following values are adjusted a upper switching point 13 6V lag min 20 seconds b lower switching point 11 52V lag 40 seconds Additional notes to the recommendation External electrical voltage controller At Diesel engines count always on the fact that a diesel engine revs up due to special circum stances uncontrolled This is the case if by damage to the system engine oil arrives into the suck ing in way This is possible at many engines by the crank case exhaust A crank damage could cause for example that by overpressure too much oil is pressed into the crank case so that this oil arrives into the sucking in way The engine cannot switch off itself any longer Usually then a damage to the engine is the result It would be fatal even if this damage to the engine were the cause of the destruction of all switched on electrical load because uncontrolled revving up of the Diesel engine leads also to an extreme increase of the voltage Only by an external voltage con troller with separation contactor can be prevented such damage Page 68 Panda PMS AGT DC 4000 Chapter D Installation Instructions ES ZU Fischer Pando F Tables Tabelle 1 Diameter of conduits Y Cooling water pipe Fuelhose Fuel hose Exhaust hose Generator type Fresh water Raw water a mm mm mm mm Tabelle 2 Technical Data
75. ved The rotating parts belt pulley belts etc must be so covered and protected do that there is no danger to life and body If a sound insulation covering must be produced at the place of installation then well placed signs must show that the generator can only be switched on with a closed capsule All servicing maintenance or repair work may only carried out when the motor is not running Electrical voltages above 48 volts battery chargers greater than 36 volts are always dangerous to life The rules of the respective regional authority must be adhered to Only an electrician may carry out installation of the electrical connections for safety reasons General safety references for the enterprise of a AGT generator With all energized systems with which the current is more than 50 Ampere special safety precautions must be made in order to protect the environment of the components against fire It is to be ensured absolutely that at the battery a main switch in well accessible place is accommodated so that with danger of the main switches can be separated immediately The main switch must be however also directly at the battery installed If this place is not well accessible a power relay must be used instead of the main switch which can be served manually which can be served then if necessary from different places The switches for the power relay are to mark accordingly as main switches DC battery with danger switch off C
76. will only be hold down for a second to ignitiate the start proce dure 2 Therefore with the panel it is possible monitoring the operation modus Hereto are beeing pla ced four diodes LED which are connected as a pair each other so they have the possibility to light up in green or red These are 3 for exhaust cooling water temperature 4 Control unit meter oil pressure 5 Control unit meter operating status 6 Control unit meter charge control If 2 3 or 4 is been illuminated red this lights will indicate the precise cause Illuminate con stant green the genset is in operation modus In the starting sequence 2 is been illuminte green 3 4 5 red is there no fault all diodes beco mes green or green flashing when the generator runs Panda PMS AGT DC 4000 Chapter D Installation Instructions Page 59 Q JD Tischer Ponda Discription of the illuminate diode 5 LED all LED s off Generator is off red LED illuminates constant Generator is in Stand by mode red LED blinks up to 20s Generator is in start mode red LED blinks more than 20s Generator had not been started gt failure green LED blinks The genset had been startet on the panel with 6 runs and can only be stopped by this but ton Even if there is a battery monitor instal led green LED illuminates constant The generator had been external startet by an extern switch This could be the battery moni tor te
77. y Recommended capacity at 12V gt 240Ah at 24V gt 120Ah The screws at the electric rectifier may be pulled tight only with a torque wrench Torque 4Nm The battery cable must be secured at the generator and at the batteries with appropriate safety devices The generator is also include into the CO fire extinguishing system Measures to the fire protection All construction units in the environment of energized parts which carry more than 50 Amp must be fire protection moderately secured All junction points at the energized parts must be examined regularly on heating up infrared thermometers Safety Instrictions for the Handling with Batteries These instructions must be noticed additionally to the instructions of the battery manufacturer If the batteries are working someone should be in your near area to help you in a case of emergency Water and soap must be hold ready if battery acid corrode your skin Wear eye protection and protective clothing During working with the batteries don t touch the eyes If you got a acid splash on your skin or clothing grow it with much water and soap out If you got acid in your eyes rinse them immediately with clear water until no cauterization is noticeable Visit imme diate a doctor Don t smoke in the near of the batteries Avoid naked flames or open fires In the area of batteries exists danger of explosions Pay attention that no tools fall on the battery poles

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