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Installation Manual Panda PVMV-N 9.000ND Super silent

1. Installation Manual Installation Maintanance and Troubleshooting Panda PVMV N 9 000ND Super silent technology 230V 50 Hz 7 5kW Icemaster Fischer Panda since 1972 since 1978 since 1988 since 1988 since 1988 Established in the Fischer Marine Conclusion Fischer 100 96 water cooled Pan Panda Vehicle Genera Marine technology Generators Icemaster GmbH da generators tors 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
2. In spite of this attention must be paid that a zone is available at a high point where the air bubbles in the coolant are able to escape to As a rule this is the expansion tank as long as this is connected direct to the tank If the coolant expansion tank is however so integrated in the system that it cannot be reached by circulating water then an air release valve must be fitted in the circulation pipe at a place of your own choice which can then also be connected to the expansion tank see next page In case of doubt you should send a diagram of the required coolant system to ICEMASTER and let this be checked there Installation with special air separator An air separator must be fitted at all critical places in the circulation system in case a perfect automatic ventilation on account of obstacles in the pipe passage cannot be achieved A self actuating ventilation valve must be fitted to each air separator Monitoring the Temperature You are expressively advised to measure the temperature of the circulating coolant after installa tion Two remote thermometers must be used for this A connection must be fitted to the motor coolant inlet the second on the coolant outlet After a short warming up period the generator must have a load of at least 7596 of the nominal capacity placed on it The coolant circulating is to be checked The values must lie within the following limits 1 Coolant inlet max 70 C during constant duty at
3. Installation Instructions 1 Plug for fan control Distance from the radiator to the unit Q rischer Ponda 2 Bores diameter 4mm The coolant water pump mounted on the generator is so laid out that a distance of up to 7 mtrs length from the radiator is possible The hose cross section must be laid out accordingly The minimal internal diameter amounts to 18mm Panda 4500 A hose must be used for both sides forward and back flow which is resilient to pressure and high temperatures at least 120 C Minimum hose diameter for cooling lines Panda 04 10 kW 18mm 34 Panda 12 20 kW 25mm 1 Panda 25 30 KW 32mm 1 4 Panda 40 50 KW 038mm 112 Panda 50 60 KW 44mm 19 Coolant expansion tank It is absolutely essential that a exoansion tank that can be aerated is fitted adjacent to the radia tor The ventilation pipe should if possible be fitted to the radiator s highest position For this a pipe with a maximum diameter of 10mm suffices which must be fed to the expansion tank A fur ther pipe which must be fitted to the floor of the expansion tank can be fitted to the cooling system in any desired place i e T piece Frequently a connection is provied on the radiator its elf The coolant expansion tank is not normally supplied by ICEMASTER For this a standard vehicle expansion tank i
4. The solder bridge J1 is located directly behind the circuit board fuse when viewed from the main connection Fan control 01 Connection Battery 04 Terminal 9 02 Terminal 7 05 Internal fuse 03 Terminal 8 06 Solder bridge J1 Panda 9000ND PVMV N Chapter D Installation Instructions Page 33 Q Tischer Ponda D 4 Cooling system General instructions The PANDA vehicle generator is supplied as standard without a radiator Various radiators are available according to the customer s requirements these can be chosen according to the appro priate operating and installation situation The cooling system can also be assembled together with a normal commercial vehicle radiator Determing the size of the radiator Consideration must be paid to the total heat load when determining the size of the unit This equates to the generator nominal performance without the water cooled pre silencer The heat resistance is 1 8 times the generator nominal capacity when the water cooled pre silencer is used i e Panda 12000 PVMV N has a total heat capacity of approx 18kW The radiator can be serviced by any usual radiator servicing agency It should however be pointed out that the radia tor possesses high safety levels Tthe radiator is often manufactured too small ICEMASTER also has various radiators available for horizontal and vertical installation as standard generator components Radiator position The place
5. 02 Water cooled exhaust elbow 09 Stop valve for coolant 03 Coolant expansion tank 10 Pipe with connection for Thermoswitch 04 External fan control 11 Radiator 05 Dry silencer 12 Fan for radiator 06 Exhaust outlet 13 Bucket with submerged pump 07 Pipe with connection for Thermoswitch Page 44 Panda 9000ND PVMV N Chapter D Installation Instructions Tischer Ponda f A A L 1 Ventilation pipe 4 T piece for Ventilation pipe 2 Radiator horizontal 5 External cooling water pump 3 Coolant expansion tank integrated 6 Bucket with submerged pump Panda 9000ND PVMV N Chapter D Installation Instructions Page 45 is Las Tischer Rondo Installation diagram with special air separator Q pum M errare A MEET E WIN RO S ON A Aa e A N E 4 m N E E N O co N N N N N N N N N N N N N N RS MNA ECCE e 1 Ventilation pipe 5 Exhaust output 2 Coolant expansion tank 6 Special air separartor 3 T piece for coolant expabsion tank 7 Radiator 4 Water cooled pre silencer Page 46 Panda 9000ND PVMV N Chapter D Installation Instructions D 5 Exhaust installation Exhaust connection for roof outlet GO 1 Exhaust oulet 5 External pre silencer 2 Generator 6 Exhaust pipe 3 Dachdurchf hrung mit Winkel 7 External series silencer 4 Vibration damper 8 End pipe E
6. and fitting position of the radiator must be carefully considered It is especially important that the warm air can escape For this reason the best place for the radiator is in a ver tical position on the vehicle roof if one take into account that an obstruction could arise in narrow entrances The manufacturer is only too happy to give suggestions on how to install the radiator It must however be expressively pointed out that all recommendations of this type are not binding It continually occurs that special influencing factors are not recognised from the start The customer or the technician making the installation must always take changes to the position or radiator s place of installation into consideration The manufacturer cannot accept liability for the recom mendations given to the best of his knowledge As a precaution attention should always be paid that the air outlet for escaping warm is as large as possible The vehicle paint sprayer is often not in agreement with this but the person making the installation must make the aim clear The fitter must make his position clear Radiators which are installed vertically and the warm air is blown downwards must be twice the size of such radiators by which the warm air rises through its own thermal energy It must also be considered that a build up of heat results through the emission of warm air in the direction of the ground whereby the warm air is once again forced to rise to the are
7. causing the short beep If there is no beep at all or there is a continuous beep then the capacitor s is faulty and needs to be replaced Check all capacitors in the electrical cabinet The cables L1 Z and N leading from the generator must be clamped see diagram beneath Checking of the terminals must be carried out in the following order 1 L1 N 2 Z N The capacitors must not be removed from the electrical cabinet before a check is made The pro cedure for checking the capacitors is given below The beep must be the same period of time for all three checking processes As long as a measuiring device is available to check the capacity it is naturally better if the capacitors are checked with this measuring device Checking the electrical connections to the Capacitor It must be ensured that the electrical connections to the capacitor are always tight fitting Loose connections with transitional resistance can mean that the contact surfaces will become heated externally This can lead to faster deterioration of the capacitors AC Output Terminal box 230V 50Hz Panda 9000ND PVMV N Chapter C Generator Failure Page 21 a lt as Tischer Rondo Wiring Diagram O O0 O Q9 C 2 Testing Generator Stator Winding for Shorts to Ground If no faults are found with the capacitors and the generator is still not performing correctly the generator stator windings must be tested for shorts to ground as
8. follows 1 Ensure that the generator is OFF and cannot be accidentally started Disconnect the battery leads Remove AC output terminal box lid mounted on generator casing All terminal box connections are to be removed See appropriate circuit diagram Remove all cables also earth lead 0O A O N A check of the generator terminal box is made by means of a multimeter to determine whether there is continuity between the individual windings connections and the casing N 50 Hz System L1 N Z N 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 rewound by a qualified tradesper son technician Winding diagrams can be obtained from ICEMASTER GmbH Germany if neces sary 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 C 3 Coil Resistance Measurements in Stator Windings When there are neither faults with the capacitors nor any low or high volt
9. high ambient temperature in the closed sound insulated capsule about 85 C can be a reason for a reduced lifespan of the v belts It is possible that the softener in the rubber com pound lose their effect after a short operating time because the air in the sound insulated capsule can be relative warm and dry The v belt must be controlled in a very short time interval It can be happen to change the v belt after some weeks because of unfavorably conditions Therefore the control is needed in an inter val of 100 operating hours The v belt ia a wearing part It should be enough spare v belts on board We suggest to stand by the according service packet Loosen the fixing screw above the alter nator Loosen the fixing screw below the alterna tor only a little bit Panda 9000ND PVMV N Chapter B Maintenance Instructions Page 15 Q Las Fischer Ponda Page 16 Panda 9000ND PVMV N Chapter B Maintenance Instructions Press the alternator to the direction of the thermostat housing Now the v belt can be changed type XPZ 850 Stretch the v belt by pulling the alternator back The v belt should be able to be pressing approx 1cm with the thumb Tighten the fixing srews above and below the alternator Q as rischer Ponda C Generator Failure C 1 Overloading the Generator Please ensure that the genset is not overloaded This is especially the case with multi power aggregates Overloadin
10. should be tested at 7096 of its maximum performance The temperature values must be checked at the maximum possible performance The external temperature must be taken into consideration when doing this check The values for T1 see additional installation record for the vehicle version may not exceed 85 C even at high external temperatures and maximum load If necessary the maximum permissible performance must be reduced i e by the use of fuses Connection of the Generator to the Vehicle Cooling System The Panda can in many cases be connected to the original vehicle system vehicle drive motor without a problem The amount of time required to do this is minimal if the vehicle radiator is fit ted with an electric fan Should that not be the case an electric fan is to be additionally placed in front of the radiator which is monitored by a thermostat The coolant pipes are connected directly with the pipes leading from the motor to the radiator This installation is comparable with the installation of an additional hot water heating system as long as this includes the motor cooling system The manufacturer should be consulted in cases of doubt The generator can be fitted to the vehicle cooling system via a heat exchanger should there be any objections Page40 Panda 9000ND PVMV N Chapter D Installation Instructions us rischer Rondo Connection of the Generator to the Vehicle Cooling System 1 Exhaust pipe 5 Vehicle combus
11. the letter in the alphabet the better the C f r Diesel motoren Examples for diesel engine oil API CG Engine oil for highest 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 II Panda 9000ND PVMV N Chapter E Appendix L Fischer Panda U Appendix Q E 3 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 9000ND PVMV N Chapter E Appendix Page III a lt as Tischer Rondo E 4 Troubleshooting GENERATOR OUTPUT VOLTAGE TOO LOW For 50Hz versions less than 200V For 60Hz versions less than 100V te e Generator is overloaded Reduce the electrical load Switch off load Refer to motor faults section Check capacitors and replace if necessary GENERATOR VOLTAGE TOO HIGH MORE THAN 240V 50Hz 135V 60Hz If the generator is providing excessively high voltage the followi
12. the system The ventilation pipe should be laid in the open filler cap of the coolant expansion tank during the starting procedure so that escaping coolant runs back into the tank Decisive for the success of this procedure is that sufficient water enters to internal coolant pump so that the coolant pump can function The coolant pump cannot draw water as long as there Is air in the casing Page 42 Panda 9000ND PVMV N Chapter D Installation Instructions Tischer Ponda Installation diagram for vertical radiator NE EN immo o toyS N Lr Kos i SSN F e E H ea H BE DE DE DE DE DE DE DE DE DE DE DE DE DE DE DE DES a un umuu EERE REESE EEEEE EEE EEEEREEEEEEEEEEESEEEE EEE CC CR CC VITILLLLLLLLLL ELLE ZZZ RA 22 RR 222 RR EEL LLL 01 External fan control 07 Stop valve for coolant 02 Coolant expansion tank 08 Thermoswitch 03 Ventilation pipe 09 Bucket with submerged pump 04 Ventilation screw 10 Water cooled pre silencer 05 Fan for radiator 11 Internal cooling water pump 06 Radiator Panda 9000ND PVMV N Chapter D Installation Instructions Page 43 Tischer Ponda Installation diagram for underneath the vehicle C Q Q 200 lev DC D ESSE ZA NNNNNWWVWAXSIENVNANNN cual A N N N N N N N N N N N N N N N N N N N N N ho 01 Water cooled pre silencer 08 External cooling water pump
13. 4 Maintenance INSTUCUONS usa t 7 B 1 Maintenance Requiem Sii nee 7 B 2 Oil Circuit Maintenance ica 7 B 3 De aerating of the coolant circuit uuueuunanennanennannnnannnnnnnnanunnannnnannnnnnnnanunnannnnannnnnnnnanennnn 10 B 4 Alr bleeding of the Fuel System uccelli diia 12 B 4 1 EXENANgE OF UNG WELT Er ae aaa 13 B 5 ExCnange me alr Mer a E 14 B 6 Exchange of th Y beill ec 15 opem me EL i 17 C 1 Overloading the Generator ea sie 17 C 1 1 Generator Voltage Fluctuations and Monitoring nennen 18 C 1 2 A Automatic Voltage Monitoring and Auto Shut Down enn 18 C 1 3 Low Generator Quiput VOllagenie eek 18 C 1 4 Checking the Generator Voltage nennen nennen nnne nnn nnns 19 C 1 5 Ghieckinglie CAD ACI ONS cn ae 20 C 2 Testing Generator Stator Winding for Shorts to Ground 22 C 3 Coil Resistance Measurements in Stator Windings ee esse 22 C 3 1 Measuring the Coil Inductive Resistance nennen nennen nnns 23 C 3 2 Rotor Magnetism Loss and Re magnetizing 24 CA Staino Problems u nee 25 0 4 1 Fuel Solenoid Valve na nern este menu 25 0 4 2 Failure Bypass deu nea 26 C 5 Troubleshooting Table ea 26 installauon InStrUctONS ur 27 Det Generator Connections ett 27 D 1 1 General InstEB HOP dette nee n
14. A 1 Thermo switch cylinder head Thermo switch at water cooled exhaust elbow Fig A 2 Thermo switch at exhaust manifold Thermo switch at pre silencer Fig A 3 Thermoschalter am Abgasanschluss Panda 9000ND PVMV N Chapter A Generator Operating Instructions Page 5 Tischer Ponda Thermo switch at the front plate Fig A 4 Thermo switch at front plate Thermo switch at coil 01 Thermo switch coil 160 C 02 Generator housing Fig A 5 Thermo switch coil Oil pressure switch Fig A 6 Oil pressure switch Page6 Panda 9000ND PVMV N Chapter A Generator Operating Instructions B Maintenance Instructions B 1 Maintenance Requirements Control before starting Oil level Cooling system leaks Visual check for any changes leaks oil drain system v belt cable connections hose clips air filter fuel lines Once a week Lubrication of actuator trapezoid thread spindle For Maintenance Intervalls see Table E 1 Maintenance intervalls on Page B 2 Oil Circuit Maintenance The laid down intervals must be heeded in order to avoid serious damage to the motor The first oil change should be carried out 35 hours after running time Thereafter every 100 hours SAE 30 is to be used for temperatures over 20 C and SEA 20 for temperatures between 5 C and 20 C Viscosity SAE 10W or 10W 30 is laid down for temperatures below 5 C Type and amount of required oil see Table
15. E 2 Engine oil on Page Il and Table E 5 Technical Data Engine on Page VIII An oil drainage hose is fitted in the sound cover for changing the oil This is fed through the capsule to the outside Open the pass through cover at the sound cover for the oil drain hose Panda 9000ND PVMV N Chapter B Maintenance Instructions Page 7 Q uas Tischer Honda The oil can then be drained by opening the oil drainage screw If the oil cannot be drained we recommend the use of a hand pump which can be connected to the oil drainage hose The oil drainage screw is then closed again and the hose again stored in the sound insulated capsule The oil filter could be loosen by a tool oil filter strap Page8 Panda 9000ND PVMV N Chapter B Maintenance Instructions Q JS ss Tischer Ponda Oil filter seal ring Before reinsert the gasket of the new oil fil ter should be coated with something oil Oil filler neck The new oil is filled here l a pl m C kee ity delay Mme With the help of the engine oil dipstick the oil level is too examined The prescribed filling level may not exceed the Max mar king Panda 9000ND PVMV N Chapter B Maintenance Instructions Page 9 Q Fischer Ponda B 3 De aerating of the coolant circuit Particular hints for the de aerating of the cooling system If the coolant has been drained or if a
16. a of the radiator Freely esca ping warm air cannot be guaranteed in this case Additional ventilators may be necessary should the warm air need to be channelled through pipes It must be ensured that warm air is extracted out of the radiator Page 34 Panda 9000ND PVMV N Chapter D Installation Instructions Q CO Tischer Ponda Permitted coolant temperatures The performance of the radiator must be so measured that the coolant temperature of the Panda generator does not exceed more than 70 C The coolant intake must be fitted direct to the coolant pump There must be a large amount of water circulating to ensure that the difference in temperature when compared to the temperature of the water leaving the generator full load does not exceed 12 C The difference may also amount to 17K if a pre silencer is installed The hoses must be so laid out that knots and other obstructions are avoided If necessary the amount of coolant must be measured As a minimum the following values are necessary Essential coolant amounts Panda 4500 min ca 10 l min Panda 8000 9000 approx 16 to 22 l min Panda 12000 14000 approx 24 to 28 l min Panda 18 24 approx 32 to 38 l min Panda 30 32 approx 40 to 45 l min Panda 42 265 scsi ii approx 50 to 60 l min The greater the amount of coolant circulating the lo
17. age shorts in the win dings to ground the windings should then be tested for the correct coils resistance for shorts bet ween wires within the coils To measure coil resistance a meter capable of measuring low resistances Milli Ohm resolution if possible accurately The measured resistance values should be close to the same between the following terminals L1 N L1 Z Page 22 Panda 9000ND PVMV N Chapter C Generator Failure Q s rischer Ponda Checking windings Disconnect all the cables from the terminals in the AC connection box e Remove the Neutral Ground connection Take all the winding connection cables from the terminal bolts Switch your meter in resistance range When you put the probes of you meter together you should get a reading of 0 00Ohm When you isolate the probes the reading will be Overflow Please do this tests to check your meter Measure the resistance between the separate windings Maybe the readings of your meter do not comply with the values of the table in the appendix In every case the relation between the values should be the same Some meters do not work fine when values are very small Measure the resistance between the different windings When you find a value in the 20 Mega Giga Ohm range the winding is ok Measure the resistance between the different windings and housing of the alternator Here you should also find a value in the Giga Ohm range When the winding is short
18. age and low voltage to the generator The front panel must always be closed since the AC Control box produces 400V during operation 1 Terminal block for excitation cable 2 Capacitors Page 32 Panda9000ND PVMV N Chapter D Installation Instructions a T Tischer Ponda D 3 The fan control Temperature controlled adjustable speed control for one or two stage DC Fan The fan regulator must be mounted an a dry and well aired location Ensure it is assembled verti cally The speed adjustment of the fan is determined by the Running Voltage Pulse Pause modulation The Pulse pause ratio is goverened by the cooling water temperature via an external NTC gauge terminal 7 and 8 A NTC resistor reduce his resistor value if the temperature is rising This NTC gauge has the value 100kOhm at 25 C 57 F and 7kOhm at 70 C 102 F The full running voltage is sent to the fan when the upper temperature has been reached The fan regulator can be switched on or off by the connection ON terminal 9 The fan control is switched on if there is the same voltage to ON as Battery If no current flows to ON the fan control has been switched off If this option is not required the circuit board connection ON can be connected direct to Battery via the solder bridge J1 J1 closed Fan control continually running J1 open Fan control only working if current flows to connection ON
19. ages 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 Protective Conductor The generator is earthed as standard The centre and earth are connected by means of a bridge in the generator terminal box This is a basic safety function which offers basic safety as long as no other component has been installed It is above all conceived for supply and an eventual test run This earth PEN is only effective if all parts of the electrical system is earthed and has a common potential The bridges can be removed if this is required for technical reasons and another protection system has been installed The full voltage is exploited at the AC control box when the generator is run It must therefore be ensured that the control box is closed and cannot be tampered with if the generator is running The battery must always be disconnected if work on the generator or electrical system is to be carried out so that the generator cannot be unintentionally started It is not allowed to disconnect the battery during operation After the generator has stopped the battery can be disconnected Switch off all consumers when working on the generator All consumers must be disconnected in order to avoid damages to the devices In addition the semi c
20. all required regulations of the regional authori ties The electrical installation should be performed by a qualified technician A 1 1Protection Conductor The standard Panda generator is grounded The 3 phase connection delta centre point is brid ged to earth in the AC output terminal box mounted on the generator This is the initial earth safety point and is sufficent to ensure safe operation however only as long as no other system is installed This system is adapted to enable test running of the generator before delivery The bridge to ground PEN is only effective when all components in the electrical system share a common ground The bridge to ground can be removed and reconnected to another ground system if required for other safety standards Full voltage connections are mounted in the electrical cabinet It must be ensured that the electri cal cabinet is secured and closed while the generator is running The starter battery cable should be disconnected when work is being done on either the genera tor or the electrical system in order to prevent accidental starting of the generator A 1 2Instructions for Capacitors The generator s electrical system requires two different groups of capacitors A The booster capacitors B The operating capacitors Both types are mounted in the electrical cabinet Capacitors store an electrical charge It is possible that even after they have been disconnected stored energy is still held T
21. and wire connections to servo motor Motor connected Check 230V connection to VCS Servo motor sets trottle too high or too low Check that the wires to the servo motor are connected properly Check 230V 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 1 Loosen the connecting rods motor from the injection pump regulator and turn screw to a max voltage of 240V or 2 Loosen the connecting plugs of the Motor VCS electronic and turn the motor direct by hand Panda 9000ND PVMV N Chapter E Appendix Page VII a lt as Tischer Fondo E 5 Technical Data Engine Type Kubota D 722 Govenor mechanical Automatic Startbooster No cylinder Bore 67 mm otroke 68 mm Stroke volume 719 ccm max Power DIN 6271 NB at 3000rpm 14 0 kW Rated speed 50Hz 3000 rpm Valve clearance engine cold 0 2 mm Cylinder head nut torque 42 Nm Compression ratio 23 1 Lubrication oil capacity 3 8 Fuel consumption approx 0 8 2 1 Oil consumption max 196 of fuel consumption Permissible max permanent tilt of engine a 25 across the longitudinal axis b 20 in the longitudinal direction a 0 351 KW electrical power the randomized values between 30 and 80 of the power rating E 6 Technical Data Generator Generator Panda 9000 ND PVMV N Power 7 5 kW 3000mtr alt 50 C Voltag
22. ately 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 01 Fuel solenoid valve 02 Fuel injector line 03 Ventilation screw Panda 9000ND PVMV N Chapter C Generator Failure Page 25 23 O Fischer Panda AAA C 4 2Failure Bypass Switch The start failure bypass switch enables an immediate restart facility of the generator should it cut out even if this was caused by over heating There is normally a requirement to wait until the motor has cooled down to the correct temperature This can last for several hours in certain cir cumstances since the generator is enclosed in a sound insulated casing which prevents heat loss Failure bypass switch This period can be reduced by pushing the button on the front of the generator The generator can be started by means of the remote control as long as the button is depressed The switch button bypasses any faults allowing the generator to run Before depressing the button a manual check of the oil dip stick must be carried out to determine whether the generator has sufficient oil as it is possible that the oil pressure switch causes the generator to cut out If it has been ascertained that the reason for the motor cutting out is over heating and not lack of oil the generator can be run for several minutes without load so that the motor is cooled by the circulating coo
23. been elimina ted and or the electrical overload removed Overloading the Generator with Electric Motors Please note that electric motors require six to ten times more power than their rated capacity to start If the supplied generator power is lower than what the electric motor requires the generator voltage will collapse For applications where a high current draw is required to start an electrical device such as an electric motor the motor manufacturer should be consulted for possible solu tions for example stronger capacitors gradual power up switches or a specially designed star ting unit for electric motors System efficiency can be improved by up to 5096 and motor current draw to start reduced by as much as 100 if it is properly designed If the inductive load i e E Motor is more than 20 of the generator nominal power a compensation is necessary See also the information brochure Special information for operation of Panda generators with inductive load Panda 9000ND PVMV N Chapter C Generator Failure Page 17 is Fischer Panda qug C 1 1Generator Voltage Fluctuations and Monitoring ATTENTION Before working installation on the System read the section Safety Instruc tions in this Manual During periods of high electric loading the voltage may drop to 190V 50Hz or 95V 60Hz or even lower Such voltage drops can potentially cause damage to certain electrical devices such as electric motors
24. ches the grid back on once the required voltage level is again reached This ensures no damage is caused to the load and fittings through undervoltage Such a voltage relay can be obtained from wholesale dealers or as a complete unit from PANDA dealers The circuit is always automatically cut off if the generator is stopped C 1 3Low Generator Output Voltage ATTENTION Before working installation on the System read the section Safety Instruc tions in this Manual Panda generators are designed such that even high electrical disruptions will not cause serious damage to the generator If the generator does not produce any voltage while the diesel drive engine is running the suspected cause lies outside the generator capsule electrical load not switched off prior to start short circuit somewhere in electrical system electrical overload Page 18 Panda 9000ND PVMV N Chapter C Generator Failure Tischer Ponda C 1 4Checking the Generator Voltage In order to check the generator for faults stop the generator and disconnect the connection cables between generator and system Remove the cables at the connection terminal of the generator or if installed at the system distribution box Make sure there is no voltage on the cables before disconnecting The capacitors also are to be discharged ATTENTION Never work at the electrical cabinet when the generator is running Do not contact the capacitor Before working
25. compressors and electronic equipment In order to ensure that sufficient voltage is available and to avoid the risk of damage to sensitive electrical devices the supply voltage should be monitored with the voltmeter which is mounted at the operation unit The voltmeter must be respectively checked if additional load is switched on As long as the voltage remains below the critical level the sensitive devices must be switched off during this period Overvoltage can be caused by the generator under certain circumstances This occurs especi ally if the speed of the motor changes increases in speed Adjustment to the normal motor speed rpm should only be done with the use of a rev counter and or a voltmeter A voltage regulated circuit breaker is installed in the electrical system in order to avoid damage if sensitive or valuable equipment is used voltage control with circuit breaker C 1 2Automatic Voltage Monitoring and Auto Shut Down If air conditioning units compressors or other such valuable equipment are installed on board an automatic voltage monitoring unit should be installed to protect this equipment from possible sharp voltage drops The voltage monitoring system shuts down the entire system and therefore all users through a circuit breaker relay as soon as the voltage falls below a set value the moni tor will also shut down the on board grid automatically when the generator is stopped The moni toring system also swit
26. d tilted back e Pinch nose shut Sedl your lips tight around victim s mouth e Give 2 full breaths for 1 to 1 secon ds each T Check for Pulse at side of Neck e Feel for pulse for 5 to 10 seconds 9 Begin Rescue Breathing Keep head tilted back Lift chin e Pinch nose shut Give 1 full breath every 5 seconds Look listen and feel for breathing between breaths 2 Shout Help Call people who can phone for help 5 Check for Breathing 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 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
27. e 230V 1 phasig Current 23A Frequency 50 Hz Stator Da 300 mm Stator Di 170 mm Hotor Lfe 120 mm Page VIII Panda 9000ND PVMV N Chapter E Appendix Tischer Ponda Water leak Olpress Voli 9 eu IT KI 3 Auto modul Panda 9000ND PVMV N Chapter E Appendix Page IX a lt as ris her Rondo PageX Panda 9000ND PVMV N Chapter E Appendix gt SS 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 XI 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 Tap or gently shake victim e Shout Are you OK 3 Holl 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 Keep hea
28. e I ed After operating hours Temperature switch watertemperature IN OUT at full load and max speed of cooler bridged temperature sensor temperature switch Actuate all ventilation valves screws x IXIX X X EJ With actuate the failure override switch check the waterpump works faultless only at gents wit hout v belt drived waterpump Shek be ESESESESERESESESESERES or every 12 month The motor manufacturer s regulations and instructions must be observed especially operating and inspection instructions See the motor manufacturer s operating instructions E 2 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 e g 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
29. e meer einen 27 D 1 2 GOMMCCHOINS antes ee ee ia enact 27 D 1 3 Fuel System Installation ass ee aa 28 D 1 4 Connection to 12V Starter Battery BIOCK 29 D 1 5 Connection of electrical components e 30 D 1 6 Connection of the external radiator nennen nennen nennen nnn nnn 31 D 2 AG CGONTOLDOX mc 32 DS TRE tan Control a a cilea 33 D 4 Coolingisysiemi acacia 34 D5 Exhaust installation ui ia 47 Panda 9000ND PVMV N Table of contents Page 1 Q 7 mu e aus rischer Ponda E APPENA via a aa E eeee Ei Maintenance intervall aia l UMEN Ze rr eR Il E S Coolant specificalionsi sane Il EJE Iroublesho0ollng mem IV E gt TECHNICAL Data Engine ee Vill E 6 Technical Data Generator ua VIII E 7 Wiring diagram remote control panel eeseeeeeee eee eee enne IX Page2 Panda 9000ND PVMV N Table of contents B us Generator Operating Instructions E Fischer Panda A Generator Operating Instructions A 1 Safety Instructions Do not run the generator with an open capsule There are dangerous rotating machine components which could cause injury All servicing maintenance and repair works must be carried out with the generator switched off High Voltage DANGER The genset output Voltages can all be lethal Ensure that all electrical installations comply with
30. e the motor by hand carefully Check if there is water in the oil and change both oil and filter if necessary Determine cause for excess water in the combustion chamber The excess water can be caused by a defective air vent in the cooling water system which should be checked and cleaned or replaced if faulty Panda 9000ND PVMV N Chapter E Appendix Page V a lt as ris her Honda MOTOR RUNS IRREGULARLY e RN 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 MOTOR SPEED DROPS REM ston NN Lack of fuel Check fuel supply system fuel filter renew if necessary check fuel pump check fuel lines bleed if necessary Lack of intake air Check air intake paths Check and clean air filter and intake muffler if instal led Generator overloaded by too many load Reduce the electrical load switch off load Generator overloaded by over energizing 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 Repair of bearing damage etc by Kubota Service MOTOR RUNS IN OFF POSITION O ME Fuel inlet solenoid valve or throttle shut solenoid is not Check wire connections to solenoid Check valve swi
31. ectrical 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 A 1 4Operating Control System on the Panda Generator Panda generators are equipped with various sensors One of these sensors is to stop excitation should a short circuit occur The combustion engine is further equipped with a oil pressure control switch which switches the motor off if the oil pressure sinks to a particular level Apart from this all generators are equipped with four temperature switches The thermo switches are placed at the following locations Thermo switch fitted to the cylinder head Thermo switch fitted to the exhaust manifold Thermo switch fitted to the silencer Thermo switch fitted to the front plate Thermo switch in the genset coil UE DE a Oil pressure switch Page4 Panda 9000ND PVMV N Chapter A Generator Operating Instructions uas Tischer Ponda Thermo switch at cylinder head Fig
32. ed to ground maybe you are not able to measure this because the voltage of your meter is a few volts In this case to get a save reading use a MEGA meter with a high test voltage If you find any anormality when doing this test please ask your Fischer Panda dealer If the measured resistance values deviate from each other significantly then there is probably a short within the coils A short within the coils can prevent the generator from achieving the requi red excitation and therefore from reaching the rated power output The values listed in the above table represent the approximate range of acceptable resistances Most important is that the measures values do not deviate significantly from one another Large resistance value deviations between phases indicate a short circuit in the windings In this case the generator must be newly wound by a qualified technician C 3 1 Measuring the Coil Inductive Resistance Unfortunately a reliable assessment of the winding s performance cannot be attained through checking only coil resistances However the symmetry of the coil resistances is a good indicator of winding performance If the coil resistances are symmetric the next step is to measure the win ding s inductive resistance using a special meter capable of measuring milli Henrys The coil induction is measured and compared in the same manner as the electrical resistance i e the windings are compared for symmetry These parts must have t
33. elf whether the con necting pipe has been connected correctly to the coolant backflow pipe by means of a T piece This pipe should have an internal diameter of 12mm Since the coolant pipes for technical rea sons can only be gradually laid out with difficulty resistance builds up during refilling which can only be displaced with difficulty by the air in the generator or motor This process can be made easier by producing excess pressure by means of the above mentioned ventilation pipe The pro cess is eased considerably in that a transparent ventilation hose draws in air this can also be carried out by mouth if done cautiously Meanwhile the coolant expansion tank should at the same time be refilled with water The generator can be started as soon as the drawn in water is seen in the ventilation pipe all other measures must of course be considered for example checking whether the motor oil has been topped up etc as stipulated in the generator operating instructions During the starting process the coolant expansion tank must be continually refilled with coolant so that no further air can force its way into the system from above The other end of the ventila tion pipe should be laid in the open coolant expansion tank filling opening so that outflowing coo lant runs back into the tank During the starting process the open coolant expansion tank must continually be filled with coo lant so that no further air can force its way into
34. elow It suffices if DC is applied for a short period 1 2 seconds The remaining magnetism can be restored and the generator can be started in the normal manner again ATTENTION Before this procedure is performed to restore the magnetic field it is crucial to ensure that the generator is not running otherwise it is very DANGEROUS TO LIFE Initializing the magnetic field in the windings through exter nal current from a 4 5 9 volt battery No car battery Page 24 Panda 9000ND PVMV N Chapter C Generator Failure Tischer Ponda C 4 Starting Problems C 4 1Fuel Solenoid Valve All engines are equipped with an electric inlet fuel solenoid valve 12V which switches off the motor The fuel solenoid valve is located in front of the injection pump It 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 reach 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 immedi
35. f the battery is attached directly at the solenoid switch of the starter motor position 1 The negative cable of the battery is attached underneath the starter motor at the engine mount position 2 ATTENTION It must be guaranteed that first the cables are attached at the generator and then at the battery To avoid large voltage drops the battery should be installed as near as possible to the generator The positive terminal of the battery is attached at the red cable the negative pole at the blue cable 1 Generator 2 Battery block 12V Panda 9000ND PVMV N Chapter D Installation Instructions Page 29 Tischer Ponda D 1 5 Connection of electrical components Connection of electrical components 1 Generator 3 Remote control panel 2 External fuel pump 4 AC Control box Page 30 Panda 9000ND PVMV N Chapter D Installation Instructions Tischer Ponda D 1 6 Connection of the external radiator Connection of the external radiator 1 Generator 2 External radiator Panda 9000ND PVMV N Chapter D Installation Instructions Page 31 Q ni ys Tischer Ponda Installation Instructions _ D 2 AC Control box In the AC Control box the needed capacitors for the excitation of the generator are placed as well as the electronic control for voltage speed regulation VCS and the starting current reinforcement ASB The AC Control box must be connected with the conductions high volt
36. g occurs when the electrical load demand induces a load torque in the generator which is higher than what the diesel drive motor can provide Overloading causes the engine to run rough burn oil create excessive exhaust environmentally unfriendly and even to stall 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 order to prolong the genset s life expectancy the nominal electrical demand on the system should not be more than 70 of the rated genset power Bear this in mind when switching on electrical devices This ensures a longer life expectancy Continuous performance is the uninterrupted running of the generator for many hours The gen set 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 overloa ding 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
37. h water separator is already installed at the generator Generally fuel intake and fuel return must be attached with its own fuel intake at the Diesel tank If the generator is installed more highly than the tank the return pipe should be led to the tank up to the same submergence into the tank as the sucking in line in order to avoid that after the shut off the generator the fuel can run back into the tank which leads to substantial initial problems after longer shut off the generator If the return pipe cannot put as immersion tube into the tank it should be absolutely ensured by a non return valve in the sucking in line that the fuel cannot flow back after shut off the generator Basically the Panda is airing out After the first line up or after longer downtime the notes Venti lation of the Fuel System should be considered see Air bleeding of the Fuel System on page 12 The following components must be installed 1 Fuel pre filter 2 external fuel pump 3 non return valve The external electrical fuel pump is to be installed in the proximity of the tank Anschlu des Kraftstoffsystems 1 Generator 4 External fuel filter 2 Non return valve 5 Fuel tank 3 External fuel pump Page 28 Panda 9000ND PVMV N Chapter D Installation Instructions Tischer Ponda D 1 4 Connection to 12V Starter Battery Block An own separate 12V starter battery must be installed for the generator The positive cable o
38. he START button The unit should start after a short while Should the unit not start the pipe union nuts of the injection nozzles has to be loosen and lift the injec tion pipe a few millimeter Try again to start the unit After the unit has started the pipe union nut has to be tightened again Page 12 Panda 9000ND PVMV N Chapter B Maintenance Instructions 5 The injection line must be raised some millimeters 6 Main power switch OFF B 4 1 Exchange of the fuel filter The exchange of the filter depends on the contamination of the fuel should take place at least all 300 operation hours Before the exchange of the filter the inlet must be clamped Remove the hoses from the used filter and fasten them to the new filter The arrow on the filter housing indicates the direction of the fuel flow A clogged filter causes a decreased power output of the generator Panda 9000ND PVMV N Chapter B Maintenance Instructions Tischer Ponda Page 13 n Wa c Tischer Ponda B 5 Exchange the air filter Page 14 Panda 9000ND PVMV N Chapter B Maintenance Instructions Open the combustion air housing by loo sen the clamp at the cover Open the combustion air housing by loo sen the clamp at the cover Loose the wing bolt and lift the frame that holds the air filter Change the air filter MANN C2039 Tischer Ponda B 6 Exchange of the V belt The relative
39. he appropriate nominal width should be ordered from ICEMA STER This is a cylinder which takes up relatively large amou nt of room Total length approx 700mm Diameter 100mm Vehicle Generator with Centrifugal Coolant Pump An impeller pump can also be provided if the radiator for technical reasons is to be installed rela tively distant from the radiator and addtionally requires a number of changes to the direction of the pipe This coolant impeller pump is mounted on the generator as an additional pump and is driven by pulleys The pump action is carried out by a rubber impeller Page38 Panda 9000ND PVMV N Chapter D Installation Instructions Q CO Tischer Ponda ATTENTION Temperature restriction This pump may only be used if it is ensured that the temperature of the coolant entering the pump does not exceed 70 C during continual duty 75 C is permissible for short periods These may however in no case be for longer periods If the coolant temperature exceeds the permissible rate this can lead to the impeller blades being torn off The advantage of this impeller pump is that this pump as a positive displacement pump is self suctioning and is therefore very sensitive to air bubbles etc Ventilating the cooling system with the aid of a self suction impeller pump is very simple In some cases the pump is additionally installed for this reason alone Unfortunately the operating noise of these pumps is very loud
40. he same values An alternative test method to check the stator windings can be performed as follows 1 Ensure that the connection to the circuit system is disconnected 2 All electrical wires in the generator terminalbox must be disconnected 3 Reconnect the battery connections 4 Start the generator 5 Measure the voltages between the following terminals and compare for symmetry L1 N L1 Z Panda 9000ND PVMV N Chapter C Generator Failure Page 23 e Fischer Panda AAA C 3 2Rotor Magnetism Loss and Re magnetizing After having stood idle for a longer period of time or after having been shut down abruptly from operating under a heavy electrical load most asynchronous generators have difficulties achie ving full excitation independently The remaining rotor magnetism is lost ATTENTION Before working on the System read the section Safety Instructions in this Manual The magnetism required for excitation can be easily restored using a simple DC Battery The generator must be stopped to do this that means the starter may not be actuated DC is fed to a desired part of the winding from the exterior for a short period This can for example be carried out for by feeding DC to the windings from both terminals of a 230V 115V socket of the vehicles system This of course can only happen if there is no connection to any power source There must be a connection between socket and the generator see diagram b
41. herefore it is essential that the connectors are not touched Should it be necessary to check or test the capacitors they should be shorted out by using an insulated screw driver The operating capacitors are automatically discharged when the generator is stopped in the nor mal way The booster capacitors will be discharged through internal resistor s For safety however the capacitors have to be discharged short circuited prior to carrying out any work on the AC Control box CAUTION Do not touch the capacitor contact terminals Panda 9000ND PVMV N Chapter A Generator Operating Instructions Page 3 Q A 1 3Overloading 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 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 Please ensure that the genset is not overloaded Overloading occurs when the el
42. instruments are installed 1 Cooling water inlet 2 Cooling water outlet It does not matter at which place the measurement is made T pieces for hose elements can be obtained from ICEMASTER into which the usual trade sensors can be installed Monitoring of temperature 1 Temperature at the cylinder head 2 l emperature at the manifold 3 Temperature in the generator winding area only Panda 8000 upwards The winding temperature monitor is not fitted with a special display unit The fuel solenoid valve is switched on as a circuit breaker for the motor stop solenoid or the fuel pump If the generator switches off because the winding overheats nothing is displayed In this case a long period of waiting can in circumstances be necessary This can be bridged by using the switch This must be carried out by an electrician who should use the circuit diagram for this It suffices in this case when the plug which leads to the guage wire is opened and both conducters in the plug are brid ged This shut down should however be a last resort It is only applicable if the generator tem perature exceeds the permissible value on account of inaccessible working conditions It must then be explained which measures are necessary to restore normal operating conditions Recording the temperature values Installation records are delivered with every handbook which must be completed after installation and returned to the manufacturer Copy The generator
43. ir has permeated into the cooling system by other reasons a careful ventilation of the cooling system is necessary The de aerating process has to be rerun ned several times Open de aerating screw at the cooling water pump Open de aerating screw at the thermostat houing Open de aerating screw at the watercoo led silencer Page 10 Panda 9000ND PVMV N Chapter B Maintenance Instructions as Tischer Ponda Pour in coolant through the cooling water filler cap The coolant flows in very slow If it is to be recognized that the cooling water level does not sag any longer with cold cooling water the cooling water level must cover the sheet metal in the exhaust elbow union close the de aerating screws and start the generator Run the generator to maximally 60 Switch off gene rator Open the cooling water filler neck again and also the de aerating screws at the same time Fill in again cooling water Repeat this procedure several times The generator can be started for 5 minutes if there is no change De aerating must be then repeated two or three times To be sure that the coolant circulates it is very important that the hose pipe away from the genset also gets warm After a short time the radiator and the reverse flow pipe from the radiator to the genset also get warm Please wait until the temperatures raise more and check if the fan will activate It makes sense to once again repeat the de ae
44. l Do not check the capacitors whilst the generator motor is running Charged capacitors can be lethal Do not contact the capacitors with bare fingers or non insulated metallic objects In order to test the capacitors the terminal lead wires have to be disconnected using pliers or a screwdriver with insulated handle s Once the wires have been removed the capacitors must discharged by bridging the capacitor terminals together with a slot screwdriver with an isulated handle Discharge the capacitor 1 Screw driver blade 2 Capacitor connections 3 Capacitor The capacitors can be checked using a normal multimeter with a continuity beeper Check that the multimeter beeps when the selector is set to continuity and the end probes are contacted together Checking Switch the multimeter to Continuity acou stic signal and touch both capacitor termi nals with the meter end probes Page 20 Panda 9000ND PVMV N Chapter C Generator Failure Q es as rischer Ponda Test each capacitor by touching the multimeter set on continuity end probes on the capacitor terminals only a brief beep should be audible from the multimeter Once this has been done reverse the end probe positions and repeat the check The multimeter battery charges the capacitor and then the capacitor discharges quickly The discharge to the multimeter closes the circuit briefly and continuity is achieved for a brief instant
45. lant BEWARE If the temperature is the reason for the generator cutting out when it is running under load then an immediate check must be made to determine the cause It could be a fault with the cooling system one of the fans the air intake or a fault with the external cooling system Continual use of the starter failure bypass switch should be avoided while the generator cuts out during operation The generator must always run without load for several minutes before being switched off so that a temperature compensation occurs Heat accumulation can cause the generator to overheat even after ist has been switched off Should the overheating alarm be set off caused by heat accumulation after the generator has been switched off then this can also be bypassed using the switch C 5 Troubleshooting Table For Troubleshooting see Table E 4 Troubleshooting on Page IV Page 26 Panda 9000ND PVMV N Chapter C Generator Failure Q I Installation Instructions y 0 ierher Bondo D Installation Instructions D 1 Generator Connections D 1 2 Connections 03 04 01 Connection fuel IN 06 Cable for AC Control box 02 Connection fuel OUT 07 Load 03 Cable for fuel pump 08 Battery minus 04 Cable for remote control panel 09 Battery plus 05 Oil drain hose Panda 9000ND PVMV N Chapter D Installation Instructions Page 27 Tischer Ponda D 1 3 Fuel System Installation A fuel filter wit
46. maximum load 2 Coolant outlet max 85 C during constant duty 3 Difference of both values This point is especially important and gives an indication of the coo lant circulating The difference should amount to a maximum of 17 C for a water cooled system with an integrated water cooled pre silencer as a rule it should however lie between 10 12 C The circulating coolant is not sufficient if the difference amounts to more than 15 C and the amount of water circulating must be increased This can be solved for example if the pipe pas sage is improved or the pulley diameter is reduced It is absolutely essential to measure the per formance of the cooling system after installation of the generator The above named values should be considered as the maximum permissible values They are also valid for operation at high temperatures During constant duty at normal temperatures 20 C the values should be well below the above named data Panda 9000ND PVMV N Chapter D Installation Instructions Page 39 Q as rischer Ponda Installation Instructions _ Installing a Coolant Temperature Display A remote display unit for coolant temperatures should be installed when fitting sensitive systems i e Television broadcasting vehicles ambulances or other vehicles with sensitive measuring instruments In this case a standard coolant display device with remote thermometer can be used It is absolutely essential that two display
47. ng potential causes should be investigated Check capacitors type and replace if necessary Check VCS System check cable connections Check motor speed with rpm meter or frequency meter Motor is not reaching the rated rpm Defective capacitor s Cause Over energizing due to wrong capacitors Measurering voltage on the VCS circuit board is mis sing Motor is running too fast rpm too high and adjust to proper speed under zero electrical load 3120 rpm 50Hz 3720 rpm 60Hz Inspect ESC or VCS Systems if installed GENERATOR VOLTAGE FLUCTUATES 1 Disturbances on the electrical system user side 1 Check if electrical load is fluctuating 2 Motor disturbances 2 Refer to section Motor runs irregular GENERATOR NOT ABLE TO START ELECTRIC MOTOR REEL NNNM MN If the generator is unable supply enough power to start an electric motor 120V 60Hz or 231V 50Hz it is usually because the motor draws too much current during starting process PageIV Panda 9000ND PVMV N Chapter E Appendix Check the motor s current draw required for starting switch to 380V if possible This could be remedied by providing stronger capacitors or installing an optional Easy Start Booster Set See App G Enquire at your nearest Panda dealer or directly at the manufacturer Q rischer Ponda DIESEL MOTOR FAILS TO START KEEN MEME MN Starter battery switched OFF Check position of battery switch and s
48. o 3500 kW from the 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 correctness Technical modifications for improving the product without pre vious 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 ii 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 The official guaranty confirmation will be completed by ICEMASTER after receipt and sent to the customer 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 opera
49. on the system read the section Safety Instructions in this manual Capacitors After that the generator should be restarted and the voltage checked at the terminals with a volt meter If the generator still does not supply sufficient voltage the following steps must be undertaken 1 Check the rev speed of the motor If the rev speed is too low the generator may not be able to achieve full magnetic excitation and thus the required output voltage If the engine rotational speed is too high the generator excitation will improve but the generated voltage can also be too high 2 If the rev speed is normal and the output voltage is still outside the acceptable range the capacitors should be inspected Do not contact the capacitor terminals Normally however it is highly unlikely that more capacitors than one are faulty In the event that one or more of the capacitors are indeed faulty the generated voltage will always be too low With the system electrical load disconnected and with the generator motor running a weak generator voltage is a sure sign that at least one of the capacitors is faulty An unusually warm capacitor is also a sign that it is faulty or near the end of its life span Panda 9000ND PVMV N Chapter C Generator Failure Page 19 ed 2 as rischer Honda C 1 5Checking the Capacitors ATTENTION Before working installation on the System read the section Safety Instruc tions in this Manua
50. onductors in the AC control box must be disconnected in order to avoid the boat capacitors being activated The minus pole of the battery ought to be removed Capacitors are required to run the generator These have two varying functions A The working capacitors B The Booster capacitors Both Groups are located in a separate AC Control box Capacitors are electrical stores There could be a residual of high electrical current at the contacts for a period dis connection from the circuit The contacts my not be touched for safety reasons If the capacitors are to be exchanged or checked then a short circuit between the contacts should be made so that the stored energy is discharged If the generator is switched off in the normal manner the working capacitors are automatically discharged by means of the windings The booster capacitors are discharged by means of internal discharge resistors All capacitors must be short circuited before work is carried out on the AC Control box for safety reasons 1V La Fischer Ponda Generator Operating Instructions uausssnsannonnnanunnnnnnnnnnnnnunnnnnnnnnnnnnunnnnnnunnnnnnnnnnnnnennn 3 AA Safety InSIrUCtIOns 3 A 1 1 PIOLCCIIONY COMOUCION HMM HET THER 3 A 1 2 Iristr cHons dor C apdOllOE S de 3 A 1 3 Overloading of Engine during longer Operation e 4 A 1 4 Operating Control System on the Panda Generator
51. ostats for switching on the fan which are installed in the generator s coolant pipes ICEMASTER can accept no liability if the cooling system does not function correctly Chassis construction companies and companies manufacturing vehicle assemblies should be aware that there could be problems with the motor or vehicle manufacturer regarding the gua ranty if consequential damage occurs to the motor because of coolant pipe leaks ICEMASTER will not accept any liability if further units i e vehicle motor are damaged when a part of the generator cooling system itself breaks down Panda 9000ND PVMV N Chapter D Installation Instructions Page 41 Q as rischer Ponda Installation Instructions _ External radiator should be installed when initially being put into operation or after repairs A ventilating valve is fitted as a rule to all units manufactured since the Spring 1995 A hose must be placed on the connecting nozzle ventilation valve to aerate the unit nominal width 6 8mm A transparent hose is recommended since the ventilation process is easy to observe The hose is to be fixed with light hose clips to the connecting nozzle The hose must be sufficiently long to be able to feed the other end into the open coolant expansion tank during operation The coolant expansion tank is initially filled with coolant The air valve must be completely ope ned before the following procedure is carried out You should assure yours
52. rating procedure after a few days in order to ensure that remaining air bubbles have been finally removed Panda 9000ND PVMV N Chapter B Maintenance Instructions Page 11 ed 2 Fischer Panda Maintenance Instructions B 4 Air bleeding of 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 air bleed 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 Switch the main power switch on con trol panel to ON 2 Push failure bypass switch and hold tight The electric fuel pump has to be run ning audibly By moving the failure bypass switch you can hear the solenoid valve of the generator starting and stopping when the sound cover is taken off 3 After the fuel pump has been running 3 to 4 minutes because the failure bypass switch has been pushed down the blee ding screw of the solenoid valve has to be unscrewed When opening the screw one has to carry on pushing the switch To avoid fuel getting in the sound cover a E piece of cloth or absorbent paper should be put under the connection As soon as fuel is running out without bubbles the air bleeding screw can be screwed in again Now stop pushing the failure bypass switch 4 Now the unit can be started by pushing t
53. s the most suitable Vehicle accessory range is the most suitable Panda 9000ND PVMV N Chapter D Installation Instructions Page 37 Q as rischer Ponda Installation Instructions _ Coolant Pump This Is normally equipped with a independent impeller suction pump This pump suffices if the cooling water pipes etc equate to the normal standard ICEMASTER can give no guaranty It must be determined whether the amount of cooling water circulating is sufficient Consideration must always be given to the fact that the water flow is supported by an external pump Antifreeze The antifreeze concentration must be regularly checked in the interests of safety The antifreeze solution supplied from the factory provides protection to 15 C If lower temperatures are occasio ned during transportation or storage then the coolant must be drained The cooling system is however so arranged that the draining of the coolant is only possible in the assembled state when air under pressure is blown into the system Air pressure of approx 0 5b suffices in order to blow out the water Suction filter as a source of noise The external suction filter not included on delivery must always be used if the generator is to be used in a dust free environment This filter is connected by means of a hose with a connecting piece to the generator housing The filter can be the source of considerable noise If this is the case an air intake muffler with t
54. superiority in 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 1596 more effective output than the majority of conventional generators This superiority in efficiency also ensures a fuel saving to the same extent The 10096 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 5096 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 t
55. tching off functions as in the Inlet Fuel Solenoid Valve or in the trottle shut off solenoid sections Replace if necessary MOTOR STOPS BY ITSELF Lack of fuel Check fuel supply system Excess heat in cooling system thermo switch tripped Check cooling water system flow water pump inlet lack of cooling water Is indicated on the remote control water filter extra heat exchanger coolant flow panel Lack of oil oil pressure sensor tripped Is indicated on Check oil level and if necessary top up Emo CanivOh Pale Check motor s oil pressure and have repaired by Kubota Service if necessary Page VI Panda 9000ND PVMV N Chapter E Appendix Q rischer Ponda ee as 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 manaul GENERATOR MUST BE SHUT OFF IMMEDIATELY IF motor rom suddenly rises or drops Refer to respective section of manual and if necessary unusual noise comes from genset have repaired by Kubota Service or Panda represen exhaust colour suddenly becomes dark tative leakage in the cooling water system Troubleshooting VCS System SE sotto Throttle control servo motor does not move Check voltage supply
56. tion engine 2 Water cooled pre silencer 6 Vehicle radiator 3 Combustion motor 7 Fan for radiator 4 Coolant expansion tank Connecting the Generator Cooling System with the Vehicle Cooling System can bring the following advantages 1 Pre warming of the vehicle motor in winter The generator can also be automatically started via a time switch 2 Exploitation of the generator heat for vehicle heating systems i e buses conference vehicles promotion vehicles etc 3 Otherwise saves the required space and the cost for an additional generator radiator We must however point out that connection of the vehicle cooling system to the motor cooling system requires a relative amount of experience of vehicle cooling systems Various require ments must be considered For example it must be considered that the system acts as a Bypass when opening the cooling system thermostat In some cases heating systems are con nected to the system which can then also operate as a Bypass No liability is assumed when a recommendation is made by the generator manufacturer to con nect the generator to the motor cooling system The person making the installation must also ensure in this case that all conditions of this type are considered It should also be considered that the vehicle thermostat or the thermo switch must be adjusted to the starting point for the radiator fan In certain circumstances it is also essential to use additional therm
57. tion 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 Technical Support per Internet info fischerpanda de 111 Safety Instructions Electrical installation is only allowed to be fitted by trained and exami ned personnel The generator may not be taken into use with the cover removed 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 volt
58. wer the difference in temperature If the necessary cooling performance cannot be achieved the amount circulating can be increased by adjusting the pulley on the pump and thereby raising the performance ATTENTION The coolant pressure may however not exceed 0 7 bar Construction and position of the radiator The radiator can be assembled away from the generator in a well ventilated position Attention must be paid that the radiator emission direction is completely free of obstruction Turbulence is to be avoided There is often a clash between the streamline appearance of the chassis and the technical requirements The radiator can be installed vertically or horizontally Consideration must be given to the fact that air is drawn in via a fan motor The best result is achieved if the radiator is fitted vertically on the vehicle roof Panda 9000ND PVMV N Chapter D Installation Instructions Page 35 as rischer Ponda 3 Radiator under the vehicle 1 Radiator on the roof 2 Radiator vertical Pay attention to the following item at the horizontal assembly of the radiator To avoid damages of the fan motor please bore some holes on the backside of the fan diameter approx 4mm Because water can enter the fan rainwater condenswater sweatwater etc The water can run out through these holes see below 02 Generally a fan is a wearing part and should be changed one time a year Page36 Panda 9000ND PVMV N Chapter D
59. witch ON if installed Starter battery voltage insufficient battery too weak Inspect battery terminals and cables for a good electri cal connection Inspect against corrosion tattered wires etc Starting current disrupted During the normal starting process the battery voltage drops to 11V with a fully charged battery If the voltage does not drop during starting the electrical connection is faulty If the battery voltage drops lower than 11V then the battery has been discharged SIARTER IS TURNING MOTOR BUT FAILS TO START cane Mn NN Fuel inlet solenoid valve not opening Check wire connections and circuitry to solenoid valve ref DC wiring diagram Relay K2 Fuse Fuel pump not working Check fuel filter and pump clean if necessary Lack of fuel Check fuel supply Check glow plugs and heating time Glow plugs not working correctly Too much air in fuel lines Test fuel system for leakage Bleed air from fuel system refer to section Bleeding Air from Fuel System Fuel filter blocked Replace fuel filter Low compression pressure See Kubota motor manual MOTOR DOES ACHIEVE ENOUGH SPEED DURING STARTING PROCESS 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 Turn generator OFF at control panel Remove the glow plug see Kubota manual Rotat
60. xhaust connection for mounting below the vehicle 00000 O 1 Generator 5 Vibration damper 2 Exhaust outlet 6 Exhaust pipe 3 Compensator 7 External series silencer 4 External pre silencer 8 End pipe Panda 9000ND PVMV N Chapter D Installation Instructions Page 47 Q as rischer Hondo Page48 Panda 9000ND PVMV N Chapter D Installation Instructions Q s rischer Ponda E Appendix E 1 Maintenance intervalls After operating hours COLEI ooo eee EJES EE EEE xX Ene vate spari weiter ise X xX p x X x x x x DC CT X X X X X X X X X ang totti X X X X X X K X X pe e e e Ju JoY Po manifold etc x pxpxpxpxpx x Be 9 1 ie Im Replace vave co gatas son x m m Check all sensors amp switches a Coolant temperature sensor b Exhaust temperature sensor C Oil pressure sensor Check all securing and fastening screws a All base mount screws b Exhaust manifold screws C Starter fixing d Connection screws generator engine mexameakacnes ELIT X X X X X de DO 0 Do COCO X X X X X X X X X X X ET X DX X X X DG X X X Gane under gres X X x x X X X X X X Engine speed rpm or frequency Hz IXIXIX X X X X X px px px UI ANA EEE pep pa pay BBBBHEBBBOE sensor temperature switch Uptake of the ambient temperature x xI x xI xI xI xIx xIx x Panda 9000ND PVMV N Chapter E Appendix Pag

Installation Manual Panda PVMV-N 9.000ND Super silent

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