Fischer Panda AGT 4000 PVMV-N User manual

Panda_AGT4000_PVMV-N_Book_Vossloh_s00670 29.12.04
Generator type:
Panda AGT 4000 PVMV-N
24V/140A - 4kW
Icemaster Fischer Panda

ii
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 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 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.
since 1972
Established in the
Marine technology
since 1978
Fischer Marine
Generators
since 1988
Conclusion Fischer -
Icemaster GmbH
since 1988
100 % water cooled Pan-
da generators
since 1988
Panda Vehicle Genera-
tors
30 20 10 10 10

iii
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!
1. The installation certificate must be completed when taken into use, and certified by a signature.
2. The installation certificate must be despatched within two weeks of use to ICEMASTER.
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 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:
• Thus you receive to extended product informations, which are sometimes safety-relevant
• 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 by Internet: [email protected]

iv
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 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 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 Ampère, 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!".
Cooling 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!

v
CAUTION!
The AGT-generator is not allowed to be connected to an inverter (without batteries)!
The Inverter generates voltage peaks, which can destroy the rectifier diodes of the generator!
A battery must always be connected to the inverter as a capacity!
Recommended capacity at 12V ≥240Ah at 24V ≥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 CO2- fire-extinguishing system.

vi
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, 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.

29.12.04 Panda AGT-DC 4000 PVMV-N s00670 - Table of contents - Page 1
AThe Panda Generator .........................................................................................................3
A.1 Description of the Generator ................................................................................................ 3
A.1.1 Front View.................................................................................................................................3
A.1.2 Back View.................................................................................................................................. 4
A.1.3 View from Above ....................................................................................................................... 5
A.1.4 Right side View.......................................................................................................................... 6
A.1.5 Left side View............................................................................................................................ 7
A.1.6 Radiator View............................................................................................................................ 8
A.2 Details of functional units ....................................................................................................9
A.2.1 Remote control panel ................................................................................................................ 9
A.2.2 Components of the cooling system ......................................................................................... 10
A.2.3 Components of the fuel system............................................................................................... 17
A.2.4 Components of the combustion air.......................................................................................... 19
A.2.5 Componenta if the electrical system ....................................................................................... 21
A.2.6 Sensors and switches for operating surveillance .................................................................... 24
A.2.7 Components of the lubircation system .................................................................................... 27
A.2.8 External components............................................................................................................... 29
BGenerator Gebrauchsanweisung ...................................................................................31
B.1 Safety instructions .............................................................................................................. 31
B.2 Generator operation instruction ........................................................................................ 31
B.2.1 Daily routine checks before starting ........................................................................................ 31
B.2.2 Starting - Preliminary remarks................................................................................................. 32
B.2.3 Overloading of engine during longer operation ....................................................................... 33
B.2.4 Starting the Generator............................................................................................................. 33
B.2.5 Stopping the Generator........................................................................................................... 34
B.2.6 Operating control system on the Panda Generator................................................................. 34
CMaintenance Instructions ................................................................................................37
C.1 Maintenance Requirements ................................................................................................37
C.1.1 Checks before every start ....................................................................................................... 37
C.1.2 Hose elements and rubber formed component in the sound cover......................................... 37
C.2 Intervalle für den Ölwechsel ............................................................................................... 37
C.3 De-aerating of the cooling water circuit ............................................................................ 40
C.4 De-aerating the fuel system ............................................................................................... 41
C.5 Exchange the air filter ......................................................................................................... 43
C.6 Additional maintenance ...................................................................................................... 43
DGenerator Failure .............................................................................................................47
D.1 Overloading the Generator ................................................................................................. 47
D.2 Adjusting the nominal charge current .............................................................................. 47
D.2.1 Lubrication of the spiral thread spindle.................................................................................... 48
D.2.2 Effects of a overload to the actuator........................................................................................ 49
D.2.3 Low Generator-Output Voltage ............................................................................................... 51
D.3 Testing Generator Stator Windings ................................................................................... 52
D.3.1 Testing Generator Stator Winding for "Shorts" to Ground....................................................... 52
D.3.2 Coil Resistance Measurements in Stator Windings ................................................................ 53
D.3.3 Measuring the Coil Inductive Resistance ................................................................................ 54

Page 2 Panda AGT-DC 4000 PVMV-N s00670 - Table of contents 29.12.04
D.4 Starting Problems ................................................................................................................55
D.4.1 VCS does not work................................................................................................................. 55
D.4.2 De-aerating the fuel system.................................................................................................... 56
D.4.3 Fuel Solenoid Valve................................................................................................................ 57
D.5 Troubleshooting Table ........................................................................................................57
EInstallation Instructions ..................................................................................................59
E.1 Generator Connections .......................................................................................................59
E.1.1 General Instructions ............................................................................................................... 59
E.1.2 Connections............................................................................................................................ 59
E.1.3 Fuel System Installation ......................................................................................................... 60
E.1.4 Connection of the starter battery............................................................................................ 62
E.1.5 Installation electronic components ......................................................................................... 63
E.2 Voltage Control System ......................................................................................................64
E.3 The battery monitor .............................................................................................................65
E.3.1 Adjustments............................................................................................................................ 65
E.3.2 Installation of the remote control panel................................................................................... 67
E.3.3 Remote control panel for AGT-Generators............................................................................. 67
E.4 Cooling system ....................................................................................................................72
E.4.1 Connection of the external radiator ........................................................................................ 72
E.5 Exhaust installation .............................................................................................................75
FAppendix .............................................................................................................................I
F.1 Maintenance intervals ............................................................................................................I
F.2 Operating resources .............................................................................................................II
F.2.1 Engine oil specification............................................................................................................. II
F.2.2 Coolant specification ............................................................................................................... III
F.3 Troubleshooting .................................................................................................................. IV
F.4 Technical data engine ......................................................................................................... IX
F.5 Technical data generator .................................................................................................... IX
F.6 Measurements ..................................................................................................................... XI

The Panda Generator
29.12.04 Panda AGT-DC 4000 PVMV-N s00670 - Chapter A: The Panda Generator Page 3
A. The Panda Generator
A.1 Description of the Generator
A.1.1 Front View
13
01 02 06
14 15
03 04 05 07 08 09 10 11 12
16 17 18
01. Water-cooled pre-silencer
02. Ventilation screw on the pre-silencer
03. Air suction socket
04. Air suction housing with air filter insert
05. Protection resistor for thermo-switch 75°C/70°C
06. Starter motor
07. Adjusting nut
08. Oil pressure switch
09. Electrical fuses (white=25A; blue=15A; 2x red=10A)
10. Starter relay Ks
11. Pre-glow relay Kp
12. Cooling water pump relay Kf2
13. Fuel pump relay Kf
14. Fuel solenoid valve
15. Engine oil filler
16. Oil dipstick
17. Actuator for speed regulation
18. Passage for oil drain hose

The Panda Generator
Page 4 Panda AGT-DC 4000 PVMV-N s00670 - Chapter A: The Panda Generator 29.12.04
A.1.2 Back View
10 12
03
18
17
05
0201 04 08
09 13 14 16
15
06
11
07
01. Cooling waterpump
02. Cooling water connection block for diode block
03. Generator housing with coil
04. Generator front cover
05. Bracket for silencer
06. Cooling water hose
07. Compensator under heat isolation
08. Water-cooled pre-silencer
09. Cable for DC/DC converter
10. Socket for remote control panel
11. Drive shaft
12. Socket for external VCS
13. Fuel OUT
14. Fuel IN
15. Thermo-switch at exhaust manifold 98°C/83°C
16. Water-cooled exhaust manifold
17. Cooling water back-flow
18. Exhaust output

The Panda Generator
29.12.04 Panda AGT-DC 4000 PVMV-N s00670 - Chapter A: The Panda Generator Page 5
A.1.3 View from Above
03
17
0201
11
12
13
15
06
0504 0807 09 10
18 19 20 21 22
14 16
01. Water-cooled pre-silencer
02. Exhaust output
03. Compensator under heat isolation
04. Cooling water hose
05. Water-cooled exhaust manifold
06. Thermo-switch at exhaust manifold 98°C/83°C
07. Ventilation vlave on the exhaust manifold
08. Generator front cover
09. Generator housing with coil
10. Cooling waterpump
11. Thermo-switch 75°C/70°C
12. Thermo-switch 82°C/77°C
13. Thermo-switch 98°C/83°C
14. Thermo-switch at engine 98°C/83°C
15. Ventilation screw engine
16. Schottky diode under protection cover
17. Ventilation screw on the silencer
18. Air suction socket
19. Air suction housing with air filter insert
20. Protection resistor for thermo-switch 75°C/70°C
21. Starter motor
22. Terminal block

The Panda Generator
Page 6 Panda AGT-DC 4000 PVMV-N s00670 - Chapter A: The Panda Generator 29.12.04
A.1.4 Right side View
01 02 03
06 08
07 09
04 05
01. Terminal block
02. Schottky diode under protection cover
03. Cooling water pump
04. Earth switch relay
05. Engine Kubota EA 300
06. Connection cooling water flow to the radiator
07. Connection cooling water flow from radiator
08. Cable for fan
09. Non-return valve

The Panda Generator
29.12.04 Panda AGT-DC 4000 PVMV-N s00670 - Chapter A: The Panda Generator Page 7
A.1.5 Left side View
02
01 03
04
01. Water-cooled pre-silencer
02. Starter motor 03. Ventilation screw on the pre-silencer 04. Exhaust output

The Panda Generator
Page 8 Panda AGT-DC 4000 PVMV-N s00670 - Chapter A: The Panda Generator 29.12.04
A.1.6 Radiator View
03
02
01 04
05
06
01. Connection for cooling water overflow
02. Fan
03. Connection cooling water in-flow (cold side)
04. Cooling water filler
05. Radiator
06. Connection cooling water back-flow (hot side)

The Panda Generator
29.12.04 Panda AGT-DC 4000 PVMV-N s00670 - Chapter A: The Panda Generator Page 9
A.2 Details of functional units
A.2.1 Remote control panel
The remote control panel is necessary for the controlling of the genset and for the interpretation
the engine/generator monitoring. In the case of deviation of the operational data from the desired
values the generator is switched off automatically. The operation of the generator without remote
control panel is not permissible.
Fig. A.1: Remote control panel
Automatic Start Option
An automatic start option is available as an accessory. This includes a separate control board,
which is connected to the main remote control board panel. The Automatic Start Option allows
the generator to be started by means of an external signal (i.e Battery Monitor). A speed gauge
and a sensor for speed pick-up are additionally necessary in addition to the automatic start
option.
01
06
02 03 04 05
07
01) Display operating hours
02) Control light for engine temperature
03) Control light for oil pressure
04) Control light for battery charge voltage
05) Control light for operating status
06) Generator „Start“-button
07) Panel „Stand by“-button

The Panda Generator
Page 10 Panda AGT-DC 4000 PVMV-N s00670 - Chapter A: The Panda Generator 29.12.04
A.2.2 Components of the cooling system
Cooling water filler neck
Fig. A.2: Cooling water filler neck
Output of radiator
The cooling water (cold side) flows from
here to the generator.
Fig. A.3: Output of radiator
Cooling water in-flow
This connection is connected with the
external radiator. From here the cold coo-
ling water flows into the cooling water-
pump.
Fig. A.4: Cooling water in-flow

The Panda Generator
29.12.04 Panda AGT-DC 4000 PVMV-N s00670 - Chapter A: The Panda Generator Page 11
Cooling waterpump
The cooling water is conducted by the
waterpumpe into the diode block.
Fig. A.5: Cooling water pump
Cooling water pipe into diode block
The diode block is cooled with cooling
water.
Fig. A.6: Cooling water pipe
Cooling water pipe
After the cooling water flows through the
diode block it is conducted into the
engine.
Fig. A.7: Cooling water pipe

The Panda Generator
Page 12 Panda AGT-DC 4000 PVMV-N s00670 - Chapter A: The Panda Generator 29.12.04
Engine input
Fig. A.8: Engine input
Ventilation screw engine
The ventilation screw on the engine may
not be opened, while the generator runs. If
this happens inadvertently, by the opening
air is sucked in. A very complex ventilation
of the entire system is necessary thereaf-
ter.
Fig. A.9: Ventilation screw
Bypass for preheating unit
Fig. A.10: Bypass

The Panda Generator
29.12.04 Panda AGT-DC 4000 PVMV-N s00670 - Chapter A: The Panda Generator Page 13
Preheat pump
Fig. A.11: Preheat pump
Inlet into engine
Fig. A.12: Inlet into engine
Water-cooled exhaust manifold
The exhaust manifold is cooled by the
water withdrawing from the engine.
Fig. A.13: Water-cooled exhaust manifold

The Panda Generator
Page 14 Panda AGT-DC 4000 PVMV-N s00670 - Chapter A: The Panda Generator 29.12.04
Ventilation valve exhaust manifold
The ventilation valve on the housing of the
exhaust manifold may not be opened,
while the generator runs. If this happens
inadvertently, by the opening air is sucked
in. A very complex ventilation of the entire
system is necessary thereafter.
Fig. A.14: Ventilation valve exhaust manifold
Cooling water pipe
Cooling water pipe from the water-cooled
exhaust manifold to the water-cooled pre-
silencer.
Fig. A.15: Coolng water pipe
Water-cooled pre-silencer
Fig. A.16: Water-cooled pre-silencer