Fischer Panda Panda AGT/DC 10000 PMS User manual

Marine Generator
Panda AGT/DC 10000 PMS
Super silent technology
24V - 360A / 10kW
Icemaster Fischer Panda
Operation Manual
Description of the generator and operation manual

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 correct-
ness. Technical modifications for improving the product without previous notice may be undertaken without notice. Before installation, it must be ensured that the Pictures,
diagrams and related material are applicable to the aggregate supplied. Enquiries must be made in case o doubt.
since 1977
Icemaster GmbH since 1978 Fischer Marine
Generators
since 1988
Conclusion Fischer -
Icemaster GmbH
since 1988
100 % water cooled
Panda generators
since 1988
Panda Vehicle
Generators
25 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 per 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.

Panda PMS AGT-DC 10000 - Table of contents - Page 1
Table of contents
AThe Panda Generator .........................................................................................................3
A.1 Description of the Generator ................................................................................................ 3
A.1.1 Right Side View......................................................................................................................... 3
A.1.2 Right Side View......................................................................................................................... 4
A.1.3 Front View.................................................................................................................................5
A.1.4 Back View.................................................................................................................................. 6
A.1.5 View from Above ....................................................................................................................... 7
A.2 Details of functional units ....................................................................................................8
A.2.1 Remote control panel ................................................................................................................ 8
A.2.2 Components of Cooling System (Seawater)............................................................................. 9
A.2.3 Components of Cooling System (Freshwater) ........................................................................ 10
A.2.4 Components of the fuel system............................................................................................... 14
A.2.5 Components of combustion air................................................................................................ 16
A.2.6 Components of the electrical system ...................................................................................... 19
A.2.7 Sensors and switches for operating surveillance .................................................................... 23
A.2.8 Components of the oil circuit................................................................................................... 26
A.2.9 External components............................................................................................................... 27
A.3 Operation Instructions ........................................................................................................ 28
A.3.1 Preliminary remark .................................................................................................................. 28
A.3.2 Daily routine checks before starting ........................................................................................ 29
A.3.3 Starting Generator................................................................................................................... 30
A.3.4 Stopping the Generator........................................................................................................... 30
A.3.5 Starting the Generator by a „Failure bypass switch“............................................................... 31

Page 2 Panda PMS AGT-DC 10000 - Table of contents

The Panda Generator
Panda PMS AGT-DC 10000 - Chapter A: The Panda Generator Page 3
A. The Panda Generator
A.1 Description of the Generator
A.1.1 Right Side View
11
01
02
03
05
06
04 12
07 08 09
15
16
10
19
17
13 14
18
01) DC-alternator 12V
02) V-belt für DC-alternator and cooling water pump
03) Oil pressure switch
04) Oil filter
05) Engine bracket
06) Sound cover base part
07) Thermo-switch exhaust
08) Exhaust output
09) Exhaust connection port
10) Water-cooled exhaust elbow
11) Solenoid for starter motor
12) Starter motor
13) Cooling water return pipe
14) Generator housing with coil
15) Connections for external cooling water expansion tank
16) Coolant hose to the external expansion tank
17) Suction port for coil cooling
18) Air suction housing with air filter
19) Coolant filler neck

The Panda Generator
Page 4 Panda PMS AGT-DC 10000 - Chapter A: The Panda Generator
A.1.2 Right Side View
01 27
14
13
15
02 03 04 05 06 07
25
24
23
22
21
20
19
09
18
08
17
12
10 11
16
26
01) Air suction housing with air filter
02) Electrical fuse 15A (blue)
03) Electrical fuse 25A (white)
04) Starter-relay Ks
05) Pre-glow relay (glow plugs) K2
06) Fuel pump start relay K3
07) Failure bypass switch
08) Speed sensor
09) Charge control for DC-alternator
10) Electronic starter control unit
11) Fuse for measuring voltage
12) Generator housing with coil
13) Sound cover base part
14) Connection for external ventilation valve
15) Diodesplate under protection cover
16) Cooling water pipe, diodeplate - cooling water pump
17) Seawater intake
18) Time relay for stop solenoid
19) Oil dipstick
20) Seawater pump
21) Actuator for rpm-regulation
22) Fuel solenoid valve
23) Pulley for internal cooling water pump
24) Stop solenoid
25) Ventilation screw cooling water pump
26) Ventilation screw thermostat housing
27) Suction hose, air suction housing - induction elbow

The Panda Generator
Panda PMS AGT-DC 10000 - Chapter A: The Panda Generator Page 5
A.1.3 Front View
01 26
24
22
11 20 2112 13 14 15 16 19 17 18
03
04
05
25
23
02
07
08
09
10
06
01) Ventilation screw internal cooling water pump
02) Pulley for internal cooling water pump
03) Stop solenoid
04) Internal cooling water pump
05) Seawater pump
06) Pipe, formed, for cooling intake
07) Seawater intake hose
08) Fuel filter
09) Passage for battery cable
10) Passage for battery cable
11) Seawater intake
12) Connection fuel out
13) Connection fuel in
14) Cable fuel pump (2x1,5mm²)
15) Oil drain hose
16) Cable remote control panel (12x1mm²)
17) Cable voltage control VCS (5x1mm²)
18) Measuring shunt
19) Measuring voltage 24V (red/black)
20) Starter battery minus (-)
21) Starter battery plus (+)
22) Exhaust hose
23) Oil filter
24) V-belt for internal cooling water pump
25) DC-alternator 12V
26) Ventilation screw thermotast housing

The Panda Generator
Page 6 Panda PMS AGT-DC 10000 - Chapter A: The Panda Generator
A.1.4 Back View
01
04
03
08 09 07
02
05
06
01) Cooling water filler neck
02) Water-cooled exhaust elbow
03) Air suction housing with air filter
04) Suction poet for coil cooling
05) Cooling water hose to external expansion tank
06) Generator front cover
07) In-flow to external cooling water expansion tank
08) Return from external cooling water expansion tank
09) Connection external ventilation valve

The Panda Generator
Panda PMS AGT-DC 10000 - Chapter A: The Panda Generator Page 7
A.1.5 View from Above
14
02
09
10
05
08
04 06 07
03
13 12
01
11
01) Suction port for coil cooling
02) Air suction housing with air filter
03) Thermo-switch cylinder head
04) Suction hose, aie suction housing - induction elbow
05) Oil filler neck
06) Fuel solenoid valve
07) Stop solenoid
08) Ventilation screw internal cooling water pump
09) Ventilation screw thermostat housing
10) Thermostat housing with thermostat
11) DC-alternator 12V
12) Water-cooled exhaust elbow
13) Cooling water filler neck
14) Cooling water hose to external expansion tank

The Panda Generator
Page 8 Panda PMS AGT-DC 10000 - Chapter A: The Panda Generator
A.2 Details of functional units
A.2.1 Remote control panel
Remote control panel
The remote control panel is necessary to control the generator and to evaluate the motor/genera-
tor properties. The generators will automatically cutout if it does not run as required. The genera-
tor may not be run without the remote control panel.
Fig. A.1: Fernbedienpanel
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. (See Component Automatic Start)
01 02 03 04 05
08
09 10
11
15 12 13
14
06 07
01. Warning light for cooling water temperature
02. Warning light for leak (Sensor optional)
03. Warning light for AC fault
04. AC-Voltage control light
05. Warning light for windings temperature
06. Warning light for oil pressure
07. Battery charge voltage 12Volt -DC control lamp
08. LED display for pre-glow
09. Pre-glow button (Heat)
10. Generator „Start“-button
11. Control light for Generator-“Start“
12. Generator „Off“ button
13. Generator „On“ button
14. Generator „Stand by“ control light
15. Running hours counter

The Panda Generator
Panda PMS AGT-DC 10000 - Chapter A: The Panda Generator Page 9
A.2.2 Components of Cooling System (Seawater)
Seawater intake
The diagram shows the supply pipes for
the generator. The connection neck for
the seawater connection is shown on the
left hand side. The cross-section of the
intake pipe should be nominally larger
than the generator connection.
Fig. A.2: Seawater intake
Seawater impeller pump
The seawater pump is fitted with a rubber
impeller. This pump is self-inductive. If,
for example, you forget to open the sea
valve, then you must expect the impeller
to be destroyed after a short period of
time. It is recommended to store several
impellers on board as spare parts.
Fig. A.3: Seawater impeller pump
Heat exchanger
Separates the seawater system from the
freshwater system.
Fig. A.4: Heat exchanger

The Panda Generator
Page 10 Panda PMS AGT-DC 10000 - Chapter A: The Panda Generator
Ventilation valve
A siphon must be installed if the genera-
tor sinks below the water line because of
the rocking of the boat, even if it is only
for a short period of time. A hosepipe on
the generator casing has been produced
for this. Both connecting pieces are brid-
ged by a formed piece of hose.
Fig. A.5: Connection ventilation valve
Cooling water injector nozzle
The injection point for the marine genera-
tor water-cooled exhaust system is situa-
ted at the exhaust connection pieces The
exhaust connections must be regularly
checked for signs of corrosion.
Fig. A.6: Cooling water injector nozzle
A.2.3 Components of Cooling System (Freshwater)
Cooling water filler neck
The cooling water filler nck situated at the
water-cooled manifold are only used,
when the generator is initially started.
Since the generator is normally already fil-
led with cooling water, these components
are only by the user, if repairs are to be
carried out. Topping up with cooling water
may only carried out at the external coo-
ling water compensation tank. Note that
the water level in the cooling water com-
pensation tank is only 20% of the volume
in a cold state.
Fig. A.7: Cooling water filler neck

The Panda Generator
Panda PMS AGT-DC 10000 - Chapter A: The Panda Generator Page 11
Freshwater backflow
The cooling water is fed to the heat
exchanger from the water-cooled manifold
by means of the pipe shown in the dia-
gram.
Fig. A.8: Freshwater backflow
Ventilation pipe
The ventilation pipe at the water-cooled
exhaust manifold leads to the external
expansion tank. This pipe only serves as a
ventilation pipe, if both pipes are to be
connected to the external expansion tank
(ventilation pipe and intake pipe).
Fig. A.9: Ventilation pipe
Hose connection pieces for the exter-
nal expansion tank
The external expansion tank is connected
by two hose connections. The connecting
pieces shown here serves as constant
ventilation for the water-cooling system.
In case the external expansion tank is
connected with two hoses, the system will
ventilate itself. In this case, additional
ventilation is only necessary when the
generator is initially filled, or if the cooling
water is not circulating.
Fig. A.10: External expansion tank

The Panda Generator
Page 12 Panda PMS AGT-DC 10000 - Chapter A: The Panda Generator
Heat exchanger
Separates the seawater system from the
freshwater system.
Fig. A.11: Heat exchanger
Cooling water connection block
The diode plate is cooled with the cooling
water connection block. The cooling water
connection block must be regulary chek-
ked about tightness and leakage.
Fig. A.12: Cooling water connection block
Internal cooling water pump
The diesel motor cooling water pump (see
arrow) aids the circulation of the internal
freshwater system.
Fig. A.13: Internal cooling water pump

The Panda Generator
Panda PMS AGT-DC 10000 - Chapter A: The Panda Generator Page 13
Cooling water intake
A.) To the thermostat housing
B.) From the external expansion tank
The intake pipe from the external cooling
water expansion tank is connected to the
point shown with „B“.
Fig. A.14: Cooling water intake
Ventilation screw cooling water pump
The ventilation screw above the cooling
water pump casing may not be opened,
whilst the generator is running. If this
occurs by mistake, air will be drawn
through the opening. Extensive ventilation
of the whole system is then necessary.
Fig. A.15: Ventilation screw cooling water pump
Ventilation screw thermostat housing
The ventilation screw on the thermostat
housing should occasionally be opened
for control purposes. Standing machinery
should principally carry out ventilating.
Fig. A.16: Ventilation screw thermostat housing
A
B

The Panda Generator
Page 14 Panda PMS AGT-DC 10000 - Chapter A: The Panda Generator
Water-cooled exhaust elbow
The manifold is cooled by means of the
internal cooling system (freshwater). The
cooling water filler necks on the casing of
the elbow may not be opened. These cool-
ing water necks are only required to fill the
motor with cooling water in cases of repair.
The normal cooling water controls may
only be carried out at the external expan-
sion tank.
Fig. A.17: Water-cooled exhaust elbow
A.2.4 Components of the fuel system
External fuel pump
The Panda generator is always supplied
with an external, electrical (12 V of DC) fuel
pump. The fuel pump must be always
installed in the proximity of the tank. The
electrical connections with the lead planned
for it are before-installed at the generator.
Since the suction height and the supply
pressure are limited, it can be sometimes
possible that for reinforcement a second
pump must be installed.
Fig. A.18: External fuel pump
Connecting pieces for the fuel pipe
1. Fuel intake
2. Fuel backflow
Fig. A.19: Fuel connections
1
2