Fischer Panda AGT 6000 PVMV-N User manual

Panda AGT 6000 PVMV-N
Super silent technology
24V / 6kW
Fischer Panda GmbH

2
Current revison status
Dokument
Actual: AGT 6000 PVMV-N 12V_24V.R01_8.4.08
Replace: AGT_6000PVMV-N_
Revision Page
Design changed - installation drawing starter battery changed
Copyright
Duplication and change of the manual is permitted only in consultation with the manufacturer!
Fischer Panda 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 previous notice may be undertaken without notice. Before installation, it must be ensu-
red that the pictures, diagrams and related material are applicable to the genset supplied. Enquiries must be
made in case o doubt.

8.4.08 AGT 6000 PVMV-N 12V_24V.R01 - Table of contents Page 1
Table of contents
Current revison status........................................................................................................... 2
Safety first............................................................................................................................... 6
Tools........................................................................................................................................ 7
Safety Precautions............................................................................................................... 10
5 Safety steps to follow if someone is the victim of electrical shock ............................. 13
WHEN AN ADULT STOPS BREATHING.............................................................................. 14
A The Panda Generator................................................................................................... 15
A.1 Type plate at the Generator ........................................................................................... 15
A.2 Description of the genset .............................................................................................. 16
A.2.1 Right side view .................................................................................................................. 16
A.2.2 Left side view ..................................................................................................................... 17
A.2.3 Front view .......................................................................................................................... 18
A.2.4 View from back side .......................................................................................................... 19
A.2.5 View from above ................................................................................................................ 20
A.3 Detailed views of the operation units ........................................................................... 21
A.3.1 Remote control panel - see remote control panel datasheet ............................................. 21
A.3.2 Components of the cooling system ................................................................................... 21
A.3.3 Components of the fuel system ......................................................................................... 25
A.3.4 Components of the combustion air .................................................................................... 27
A.3.5 Components of the electrical system ................................................................................ 30
A.3.6 Sensors and switches for operating surveillance .............................................................. 34
A.3.7 Components of the oil circuit ............................................................................................. 36
A.3.8 Externe Komponenten ....................................................................................................... 38
A.4 Operating instructions ................................................................................................... 39
A.4.1 Preliminary remark ............................................................................................................ 39
A.4.2 Daily routine checks before starting .................................................................................. 40
A.4.3 Starting Generator ............................................................................................................. 41
A.4.4 Stopping the Generator ..................................................................................................... 41
A.4.5 Starting the Generator by a „Failure bypass switch“ ......................................................... 42
B Installation Instructions .............................................................................................. 43
B.1 Generator Connections ................................................................................................. 43
B.1.1 General Instructions .......................................................................................................... 43
B.1.2 Connections ...................................................................................................................... 43
B.1.3 Fuel System Installation .................................................................................................... 44
B.2 Generator DC System-Installation ................................................................................ 45
B.2.1 Installation Panda AGT 12 V System ................................................................................ 45
B.2.2 Installation Panda AGT 24 V-system - Optional ................................................................ 46
B.3 Connection to Starter Battery-Block ............................................................................ 47
B.4 Remote control Panel - see remote control panel datasheet ..................................... 47
B.4.1 Electronic starter control unit ............................................................................................. 47
B.5 Voltage Control System - see VCS datasheet ............................................................. 48
B.6 The Battery Monitor - see battery monitor datasheet ................................................. 49
B.7 The fan control - see fan control datasheet ................................................................. 49
B.8 Insulation test ................................................................................................................. 50

Page 2 AGT 6000 PVMV-N 12V_24V.R01 - Table of contents 8.4.08
Table of contents
B.9.1 Connection of the external radiator ....................................................................................52
B.10 Exhaust Installation ........................................................................................................66
C Maintenance Instructions............................................................................................67
C.1 Maitenance Requirements .............................................................................................67
C.2 Oil Circuit Maintenance ..................................................................................................67
C.3 De-aerating the fuel system ...........................................................................................70
C.4 Ventilation of the coolant circuit ...................................................................................72
D Generator Failure..........................................................................................................77
D.1 Overloding the Generators ............................................................................................77
D.1.1 Automatic Voltage Monitoring and Auto-Shut Down ..........................................................78
D.1.2 Adjusting Instructions for the Spindle of the actuator ........................................................78
D.1.3 Adjustment of the maximum upper revolution ...................................................................79
D.1.4 Adjustment of the normal rev limitation ..............................................................................80
D.1.5 Lubrication of the spiral thread spindle ..............................................................................81
D.1.6 Effects of a longer overload of the generator to the actuator .............................................81
D.1.7 Low Generator Output Voltage ..........................................................................................83
D.2 Testing Generator Stator Windings ..............................................................................84
D.2.1 Testing Generator Stator Winding for "Shorts" to Ground .................................................84
D.2.3 Measuring the Coil Inductive Resistance ...........................................................................86
D.3 Starting Problems ...........................................................................................................87
D.3.1 Fuel Solenoid Valve and Hubmagnet ................................................................................87
D.3.2 Failure Bypass Switch .......................................................................................................88
D.4 Troubleshooting Table ...................................................................................................89
E Appendix.......................................................................................................................91
E.1 Maintenance Intervalls ...................................................................................................91
E.2 Operating Resources .....................................................................................................92
E.2.1 Engine oil ...........................................................................................................................92
E.2.2 Coolant specification ..........................................................................................................93
E.3 Troubleshooting .............................................................................................................94
E.4 Technical Data Engine ...................................................................................................99
E.5 Technical Data Generator ..............................................................................................99
E.6 Capsule Measurements ................................................................................................100
A VCS-AGT-U/I................................................................................................................101
A.1 VCS-AGT-U/I Versions ..................................................................................................101
A.2 Voltage control system ................................................................................................101
A.2.1 Gerneral working of the VCS ...........................................................................................102
A.2.2 Safety instructions for the voltage control ........................................................................103
A Battery monitor in DIN-tracks housing (RE9517)....................................................105
A.1 Safety instructions .......................................................................................................105
A.2 Brief description ...........................................................................................................106
A.3 Function .........................................................................................................................106

A.4 Technical data and settings ........................................................................................ 106
A.5 Additional products ..................................................................................................... 107
A Intelligent stepless automatic controller for DC-fan .............................................. 109
A.1 Brief desciption ............................................................................................................ 110
A.1.1 Function ........................................................................................................................... 110
A.1.2 Master - Slave - Operation .............................................................................................. 111
A.1.3 Function of the clamps for the Master-Slave-Operation .................................................. 112
A.1.4 Remote controlled switching on and off of the fan controller ........................................... 112
A.1.5 12V / 24V - Operation ...................................................................................................... 113
A.2 Technical Data .............................................................................................................. 113
A Remote Control Panda 6-50...................................................................................... 117
A.1 Cleaning and replacement of parts at the generator ................................................ 118
A.2 General information ..................................................................................................... 118
A.3 Operation instructions ................................................................................................. 119
A.3.1 Preliminary remark .......................................................................................................... 119
A.3.2 Daily routine checks before starting ................................................................................ 120
A.3.3 Starting Generator ........................................................................................................... 121
A.3.4 Stopping the Generator ................................................................................................... 122
A.3.5 Starting the Generator by a „Failure bypass switch“ ....................................................... 122
A.3.6 Installation of the Remote Control Panel ......................................................................... 123
A.3.7 Fuse on control panel board ............................................................................................ 123
A.3.8 Installation assembly kit automatic start - optional - F1WT5-95702 ................................ 123
A.3.9 Mounting of the circuit board on the remote control panel .............................................. 125
A.3.10 The speed sensor ............................................................................................................ 126
A.3.11 Requirement for Automatic Start ..................................................................................... 127
A.4 Slave Panel - optional .................................................................................................. 127
A.5 Slave panel and automatik start togther - optional ................................................... 127
A.6 Wiring diagrams ........................................................................................................... 128

5
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, Fischer Panda also supply the super compact high-tech sound-insulated battery char-
ging 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)
Fischer Panda 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.
Icemaster GmbH Fischer Marine
Generators Conclusion Fischer - Icemaster GmbH 100 % water cooled Pan- da generators Panda Vehicle Genera- tors
since
1977
since
1978
since
1988
since
1988
since
1988

6
Safety first
These symbols are used throughout this manual and on labels on the maschine itself to warn of the possibility of per-
sonal injutry. Read these instructions carefully. It is essential that you read the instructions and safety regulations
before you attempt to assemble or use unit.
This danger symbol refers to toxic danger and draws attention to special warnings,
instructions or procedures which, if not strictly observed, may result in severe per-
sonal injury or loss of life.
This danger symbol refers to electric danger and draws attention to special
warnings, instructions or procedures which, if not strictly observed, may result in
electrical shock which will result in severe personal injury or loss of life.
This danger symbol refers to electric danger and draws attention to special
warnings, instructions or procedures which, if not strictly observed, may result in
electrical shock which will result in severe personal injury or loss of life.
This warning symbol draws attention to special warnings, instructions or procedures
which, if not strictly observed, may result in damage or destruction of equipment,
severe personal injury or loss of life.
This warning symbol draws attention to special warnings, instructions or procedures
which, if not strictly observed, may result in damage or destruction of equipment

7
Tools
This symbols are used throughout this manual to show which tool must be used at maintenance or installation.
Spanners
X = number of spanner
Hook wrench for oil filter
Screw driver, for slotted head screws and for recessed head screws
Multimeter, multimeter with capacitor measuring
Infrared temperature mesuring pistol
Current clamp (DC for synchron generators; AC for asynchron generators)
X

8
Socket wrench set
Hexagon wrench keys

9
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 Fischer Panda.
3. The official guaranty confirmation will be completed by Fischer Panda 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: [e-mail]

10
Safety Precautions
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 rectifier block at the marine versions
The retifier block is cooled with fresh water. A normal cooling of the rectifier 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 fur-
nished 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 gene-
rator must be switched off, if the cooling water supply is impair.
The temperature safety device on the rectifier block can be regarded only as additional safety device. The tempera-
ture rise at the diods is so fast that the rectifiers can be damaged during a unique interruption of the cooling water
supply. A safe protection from damage of the rectifiers is not possible by the temperature monitoring on the rectifier
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 rectifiers will be damaged!
CAUTION!
Contact of the electrical contacts may be DANGER TO LIVE!

11
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 rectifiers 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 6 Nm.
The battery cable must be secured at the generator and at the batteries with appropriate safety devices.
The generator is also include into the CO
2
- fire-extinguishing system.

12
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.

13
5 Safety steps to follow if someone is the
victim of electrical shock
Do not try to pull or grab the individual.
Send for help as soon as possible.
If possible, turn off the electrical power.
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.
After the injured person is free of contact with the source of electrical shock, move them a
short distance away and immediately start necessary first aid procedures.
1
1
1
2
1
3
1
4
1
5

14
WHEN AN ADULT STOPS BREATHING
WARNING
DO NOT attempt to perform the rescue breathing techniques provided on this page, unless
certified. Performance of these techniques by uncertified personnel could result in further
injury or death to the victim.
1 Does the Person Respond? 2 Shout, "Help!"
Tap or gently shake victim.
Shout, "Are you OK?"
Call people who can phone for help.
3 Roll Person onto Back.
Roll victim toward you by pulling slowly.
4 Open Airway. 5 Check for Breathing.
Tilt head back, and lift chin.
Shout, "Are you OK?"
Look, listen, and feel for breathing
for 3 to 5 seconds.
6 Give 2 Full Breaths.
Keep head tilted back.
Pinch nose shut.
Seal your lips tight around victim's
mouth.
Give 2 full breaths for 1 to 1½ seconds
each.
7 Check for Pulse at side of Neck. 8 Phone EMS for Help.
Feel for pulse for 5 to 10 seconds. Send someone to call an ambu-
lance.
9 Begin Rescue Breathing. 10 Recheck Pulse Every Minute.
Keep head tilted back.
Lift chin.
Pinch nose shut.
Give 1 full breath every 5 seconds.
Look, listen, and feel for breathing bet-
ween breaths.
Keep head tilted back.
Feel for pulse for 5 to 10 seconds.
If victim has pulse, not breathing,
continue rescue breathing. If no
pulse, begin CPR.

The Panda Generator
AGT 6000 PVMV-N 12V_24V - Chapter A: The Panda Generator Page 15
A. The Panda Generator
A.1 Type plate at the Generator
Fig. A.1-1: Type plate
Fig. A.1-2: Discription type plate

The Panda Generator
Page 16 AGT 6000 PVMV-N 12V_24V - Chapter A: The Panda Generator
A.2 Description of the genset
A.2.1 Right side view
Fig. A.2.1-1: Right side view
11
03 05
01 02 06
1009
07
13
12
04
14 15 16
08
01. V-belt
02. DC-alternator
03. Thermoswitch at exhaust elbow
04. Water-cooled exhaust elbow
05. Cooling water pipe, exhaust elbow - silencer
06. Compensator under heat isolation
07. Coolant hose for external expansion tank
08. Water-cooled pre-silencer
09. Oil filter
10. Oil pressure switch
11. Starter motor
12. Coolant intake (from radiator)
13. Generator housing with coil
14. Coolant output (to radiator)
15. Exhaust output
16. Connection external expansion tank

The Panda Generator
AGT 6000 PVMV-N 12V_24V - Chapter A: The Panda Generator Page 17
A.2.2 Left side view
Fig. A.2.2-1: Left side view
16
06 07
15
0401 02
17 18
03 08 09
11 12 10 13 14
19
05
01. Water-cooled pre-silencer
02. Ventilation screw at silencer
03. Thermoswitch at silencer
04. Air suction housing with air filter
05. Voltage controller for alternator
06. Air suction hose to induction elbow
07. Actuator
08. Fuel solenoid valve
09. Pulley for internal cooling water pump and alternator
10. Electrical fuses (blue=15A, white=25A)
11. Starter-relay Ks
12. Pre-glow relay K2
13. Relay fuel pump K3
14. Failure bypass switch
15. Speed sensor
16. Fuse 1,5A
17. Oil dipstick
18. Water-cooled diode plate
19. Fuel filter

The Panda Generator
Page 18 AGT 6000 PVMV-N 12V_24V - Chapter A: The Panda Generator
A.2.3 Front view
Fig. A.2.3-1: Front view
05
01
02
03
04
06
07
08
23 22 21 20
1109 10 1412 13 15 16 17 18
19
01. Pulley for internal cooling water pump and alternator
02. Fuel filter
03. Oil dipstick
04. Coolant pipe
05. Main battery connection (-)
06. Main battery connection (+)
07. Passage for battery connection
08. Passage for battery connection
09. Fuel intake
10. Fuel output
11. Cable for fuel pump
12. Cable for remote control panel
13. Oil drain hose
14. Cable for VCS
15. Cable for Shunt
16. Cable for measuring voltage
17. Passage for starter battery
18. Passage for starter battery
19. Oil filter
20. DC-alternator
21. Clamping device for alternator
22. Ventilation screw thermostat housing
23. Ventilation screw cooling water pump