Generator type: Panda 18 NE PVK-UK Icemaster Fischer

Generator type: Panda 18 NE PVK-UK Icemaster Fischer
Generator type:
Panda 18 NE PVK-UK
230V - 50 Hz / 15kW
Icemaster Fischer Panda
30
20
10
10
10
since 1972
Established in the
Marine technology
since 1978
Fischer Marine
Generators
since 1988
Conclusion Fischer Icemaster GmbH
since 1988
100 % water cooled Panda generators
since 1988
Panda Vehicle Generators
Fischer Panda
FISCHER GENERATORS have been manufactured since 1978 and are a well-known brand for first class diesel generators 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 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.
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.
The electrical Installations may only be carried out be trained and
tested personnel!
CE-Conformity
The generator is constructed so that all components comply with the CE guidelines. The declaration of CE conformity is acceptable only when the complete system has been connected to the generator, includes exhaust and cooling systems, as well as, the electrical system. The manufacturer of the finished system must declare this. Later
installation in a ship or vehicle is the responsibility of the engineer. When installing into new ships or vehicles, the
aggregate must be included in the conformity declaration for the complete product (ship or vehicle).
Technical Support per Internet:
info@fischerpanda.de
iii
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.
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.
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 conductors 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 disconnection 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.
iv
Table of Contents
A
The Panda Generator .........................................................................................................3
A.1
Description of the genset ..................................................................................................... 3
A.1.1
A.1.2
A.1.3
A.1.4
A.2
Detais of functional units ..................................................................................................... 7
A.2.1
A.2.2
A.2.3
A.2.4
A.2.5
A.2.6
A.2.7
A.2.8
B
Safety Instructions .............................................................................................................. 27
B.1.1
B.1.2
B.2
Protection Conductor: .............................................................................................................. 27
Instructions for Capacitors ....................................................................................................... 27
Operating Instructions ........................................................................................................ 28
B.2.1
B.2.2
B.2.3
B.2.4
B.2.5
B.2.6
B.2.7
Routine „Pre-Start“ Checks (daily) ..........................................................................................
Preliminary remarks ................................................................................................................
Overloading of Engine during longer Operation ......................................................................
Starting Generator ...................................................................................................................
Stopping the Generator ...........................................................................................................
Starting the Generator when overheated by a "Failure Bypass Switch“..................................
Operating Control System on the Panda Generator ...............................................................
28
28
30
30
31
31
32
Maintenance Instructions ................................................................................................35
C.1
Maintenance Requirements ................................................................................................ 35
C.2
Oil Circuit Maintenance ...................................................................................................... 35
C.3
De-aerating of the coolant circuit ...................................................................................... 38
C.3.1
C.4
Draining the coolant ................................................................................................................ 40
Air-bleeding of the Fuel System ........................................................................................ 41
C.4.1
D
Remote control panel ................................................................................................................ 7
Components of coolant system................................................................................................. 8
Components of fuel system .................................................................................................... 13
Components of combustion air ................................................................................................ 15
Components of electrical system ............................................................................................ 17
Sensors and switches for operating surveillance .................................................................... 20
Components of oil curcuit........................................................................................................ 23
Ecternal components............................................................................................................... 24
Generator Operating Instructions ..................................................................................27
B.1
C
Front View ................................................................................................................................. 3
Back View.................................................................................................................................. 4
Right Side View ......................................................................................................................... 5
View from above........................................................................................................................ 6
Exchange of the fuel filter ........................................................................................................ 42
C.5
Exchange the air filter ......................................................................................................... 43
C.6
Exchange of the V-belt ........................................................................................................ 44
Generator Failure .............................................................................................................47
D.1
Overloading the Generator ................................................................................................. 47
D.1.1
D.1.2
D.1.3
D.1.4
D.1.5
D.1.6
Generator Voltage Fluctuations and Monitoring ......................................................................
Automatic Voltage Monitoring and Auto-Shut Down ...............................................................
Adjusting Instructions for the Spindle of the actuator ..............................................................
Adjustment of the maximum upper revolution: ........................................................................
Adjustment of the normal rev limitation ...................................................................................
Lubrication of the spiral thread spindle....................................................................................
48
48
48
49
50
51
Panda 18 NE PVK-UK S00405 - Table of contents - Page 1
D.1.7
D.1.8
D.1.9
D.1.10
Testing Generator Stator Winding for "Shorts" to Ground ............................................. 57
D.3
Coil Resistance Measurements in Stator Windings ......................................................... 57
D.4
D.5
Measuring the Coil Inductive Resistance ............................................................................... 58
Rotor Magnetism Loss and "Re-magnetizing" ........................................................................ 59
Starting Problems ................................................................................................................ 60
D.4.1
D.4.2
Fuel Solenoid Valve and Hubmagnet ..................................................................................... 60
Failure Bypass Switch ............................................................................................................ 61
Troubleshooting Table ........................................................................................................ 62
Installation Instructions .................................................................................................. 63
E.1
Generator Connections ....................................................................................................... 63
E.1.1
E.1.2
E.1.3
E.1.4
E.1.5
E.2
General Instructions ...............................................................................................................
Connections............................................................................................................................
Fuel System Installation .........................................................................................................
Connection to 12V Starter Battery-Block................................................................................
Connection of electrical components......................................................................................
63
63
64
65
66
AC-Control box .................................................................................................................... 67
E.2.1
F
51
53
54
55
D.2
D.3.1
D.3.2
E
Effects of a overload to the actuator.......................................................................................
Low Generator Output Voltage...............................................................................................
Checking the Generator Voltage ...........................................................................................
Checking the Capacitors ........................................................................................................
Voltage control system ........................................................................................................... 69
E.3
Cooling system .................................................................................................................... 70
E.4
Exhaust installation .............................................................................................................71
Appendix .............................................................................................................................I
F.1
Maintenance intervalls ........................................................................................................... I
F.2
Engine oil ...............................................................................................................................II
F.3
Coolant specifications ......................................................................................................... III
F.4
Troubleshooting .................................................................................................................. IV
F.5
Technical Data Engine ........................................................................................................ IX
F.6
Technical Data Generator ................................................................................................... IX
F.7
Measurements ...................................................................................................................... X
F.8
Wiring diagram control panel ............................................................................................. XI
F.9
AC-wiring diagram .............................................................................................................. XII
F.10 DC-wiring diagram ............................................................................................................. XIII
Page 2
Panda 18 NE PVK-UK S00405 - Table of contents
The Panda Generator
A. The Panda Generator
A.1 Description of the genset
A.1.1 Front View
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
22
01. Watercooled pre-silencer
02. De-aerating screw at the pre-silencer
03. Thermo-switch at the pre-silencer
04. Oil filter
05. Air suction housing with air filter
06. Luftansaugrohr, Luftfilter - Motor
07. Solenoid for engine stop
08. Fuel solenoid valve
09. Thermoswitch at thermostat housing
10. De-aerating screw at internal cooling water pump
11. Pulley for internal cooling water pump and DC-alternator
21
20 19
18
17
16
12. Failure bypass switch
13. Actuator for rpm-regulation
14. Oil dipstick
15. Fuel filter
16. Fuel pump-Relay K3
17. Passage for oil drain hose
18. Pre-glow Relay K2
19. Starter-Relay Ks
20. Electrical fuses (blue=15A; white=25A)
21. Plug for rpm-sensor
22. Generator housing with coil
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
Page 3
The Panda Generator
A.1.2 Back View
02
01
03
08
10
06
07
09
11
01. Service- and inspektion hatch
02. Cooling water intake radiator
03. Cooling water intake generator
04. Cooling water output generator
05. Exhaust output
06. Return pipe expansion tank
Page 4
04 05
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
12
07. Cooling water output radiator
08. Starter motor
09. Generator housing with coil
10. Generator power terminal box
11. Cooling water pipe, connection block - water pump
12. Coolant connection block
The Panda Generator
A.1.3 Right Side View
01
02
03
04
05
06
07
08
09
10
11 12 13
01. De-aerating screw at thermostat housing
02. De-aerating screw at internal cooling water pump
03. Pulley for internal cooling water pump and DC-alternator
04. V-belt
05. Oil drain hose
06. Fuel filter
07. Air suction intake
08. Connection fuel in
09. Connection fuel out
14
15
16
17
18
10. Cable for thermoswitch radiator
11. Cable for fan
12. Cable for fuel pump
13. Cable for VCS
14. Cable for remote control panel
15. Cable for Load
16. Cable for AC-Control box
17. Battery plus (+)
18. Battery minus (-)
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
Page 5
The Panda Generator
A.1.4 View from above
01
15
02
14
03
04
05
13
01. De-aerating screw at the internal cooling water pump
02. Thermoswitch at thermostat housing
03. Cap oil filler neck
04. Cylinder head
05. Thermo-switch and -sensor at the cylinder head
06. Air suction housing with air filter
07. Oil filter
08. Thermo-switch at the silencer
Page 6
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
06
12
07
08
09
10
11
09. De-aerating screw at the silencer
10. Watercooled pre-silencer
11. Compensator under heat isolation
12. Cooling water hose, manifold - silencer
13. Watercooled exhaust manifold
14. DC-alternator 12V
15. De-aerating screw at the thermostat housing
The Panda Generator
A.2 Detais of functional units
A.2.1 Remote control panel
The remote control panel is equipped with some new monitoring functions, which increases the
operational safety of the generator. A failure message is shown over contacts which are normaly
closed. If a connection is intermitted triggers this a failure message.
01
02
08
04
05
06
07
11
09
01.
02.
03.
04.
05.
06.
07.
08.
03
10
14
15
Warning light for coolant temperature
Warning light for water leak (sensor optional)
Warning light für AC-fault
AC-power indicator light
Warning light for coil temperature
Warning light for oil pressure
Battery charge voltage 12V-DC control light
Glow plug pre-heat indicator light
09.
10.
11.
12.
13.
14.
15.
12
13
Glow plug pre-heat button
System „START“-button
System „START“ light
Main power switch „OFF“
Main power switch „ON“
Indicator light Generator „STAND BY“
Hours of operation counter
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. (See
Component Automatic Start)
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
Page 7
The Panda Generator
A.2.2 Components of coolant system
Coolant filler neck
Fig. A.2: Coolant filler neck
This connection is connected with the
external radiator. From here the cool
water flows first into the cooling water
connection block, thus into the generator
coil.
Fig. A.3: Coolant in-flow
Cooling water connection block
The cooling water is fed to the generator
and drained via the cooling water connection block. The cooling water connection
block consists of an aluminium alloy,
which can behave like a sacrificial anode.
Fig. A.4: Cooling water connection block
Page 8
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
The Panda Generator
Cooling water pipe
From the cooling water connection block
the water leads to the internal cooling
water pump.
Fig. A.5: Coolant flow
Internal cooling water pump
The diesel motor cooling water pump (see
arrow) aids the circulation of the internal
freshwater system.
Fig. A.6: Internal cooling water pump
De-aerating screw cooling water pump
The de-aerating 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.7: De-aerating screw internal cooling water pump
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
Page 9
The Panda Generator
De-aerating screw thermostat housing
The de-aerating screw on the thermostat
housing should occasionally be opened
for control purposes. Standing machinery
should principally carry out ventilating.
Fig. A.8: De-aerating screw thermostat housing
Water-cooled exhaust manifold
The exhaust elbow union is cooled by the
water withdrawing from the cylinder head.
Fig. A.9: Water-cooled exhaust manifold
Cooling water pipe
Cooling water pipe from the water-cooled
exhaust elbow union to the water-cooled
pre-silencer.
Fig. A.10: Cooling water pipe
Page 10
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
The Panda Generator
Water-cooled pre-silencer
Fig. A.11: Water-cooled pre-silencer
De-aerating screw at pre-silencer
The de-aerating screw at the water-cooled
pre-silencer is used at first time filling or
after repair work.
Fig. A.12: de-aerating screw pre-silencer
Cooling water return flow
From here the cooling water heated up
flows into the radiator.
Fig. A.13: Cooling water return flow
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
Page 11
The Panda Generator
Return flow expansion tank
The breather pipe at the water-cooled presilencer leads to the external expansion
tank which is interated in the radiator.
Fig. A.14: Return flow
Cooling water drain hose
The coolant can be discharged by a drain
hose at the radiator.
Fig. A.15: Cooling water drain hose
Drain valve
Fig. A.16: lDrain valve
Page 12
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
The Panda Generator
A.2.3 Components of fuel system
Electrical 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.17: Electrical fuel pump
Connecting pieces for the fuel pipe
1. Fuel intake
2. Fuel backflow
1
2
Fig. A.18: Fuel connections
Fuel filter
A fine filter, which is firmly attached to the
inside of the sound insulation capsule, is
supplied on delivery, and loose for other
makes. In all cases a further pre-filter with
water separator must be installed. See
directions for fuel filter installation.
Fig. A.19: Fuel filter
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
Page 13
The Panda Generator
Fuel solenoid valve
3
1
2
The fuel solenoid valve opens automatically if „START“ is pressed on the remote
control panel“. The solenoid closes, if the
generator is switched to „OFF“ position. It
takes a few seconds before the generator
stops. If the generator does not start or
does not run smoothly (i.e. stutters), or
does not attain full speed, then the cause is
fore-mostly the solenoid.
1) Fuel solenoid valve
2) Ventilation screw solenoid valve
3) Magnetic coil
Fig. A.20: Fuel solenoid valve
Injection nozzles
Fig. A.21: Injection nozzles
Glow plugs
Glow plugs heat the pre-chamber up.
Fig. A.22: Glow plugs
Page 14
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
The Panda Generator
A.2.4 Components of combustion air
Suction air intake at sound cover
Do not cover!
Fig. A.23: Suction ait intake
Air suction housing
The air suction housing sucks in fresh air
from the sound cover.
Fig. A.24: Air suction housing
Air suction housing with air filter
Type: MANN C2039
Fig. A.25: Air filter
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
Page 15
The Panda Generator
Induction elbow
Fig. A.26: Induction elbow
Watercooled exhaust manifold
Fig. A.27: Watercooled exhaust manifold
Compensator under heat isolation
This part is flexible by the internal structure and compensates vibrations.
Fig. A.28: Compensator
Page 16
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
The Panda Generator
Exhaust outlet
The silencer must be attached here.
Fig. A.29: Exhaust outlet
A.2.5 Components of electrical system
Connection starter battery
1. Cable for load
2. Cable for AC-control box
1
2
3
4
3. Cable for starter battery (plus)
4. Cable for starter battery (minus)
Fig. A.30: Cable for starter battery
Electrical connections
1. Thermoswitch radiator
2. Fan
1
2
3
4
5
3. Fuel pump
4. VCS
5. Remote control panel
Fig. A.31: Electrical connections
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
Page 17
The Panda Generator
Starter motor with solenoid switch
1. Starter motor and
2. Solenoid switch
2
1
Fig. A.32: Anlasser
Actuator for rpm-regulation
The generator voltage is determined by
progressive speed control through "VCS"
in conjunction with the speed actuator.
Speed increases with increasing load.
Fig. A.33: Actuator
Solenoid for engine stop
Fig. A.34: Solenoid for engine stop
Page 18
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
The Panda Generator
DC-alternator
Usually a 12V DC-alternator, which uploads the starting battery.
Fig. A.35: DC-alternator
Generator power terminal box
N
L1
Z
PE
Fig. A.36: Generator power terminal box
Terminal block for remote control cable
with fuse and power relais
F1 fuse 15A for DC wiring
F2 fuse 25A for starter relay
F1 F2
Ks power relais for Starter
K2 power relais for Glow plugs
K3 power relais for Fuel pump
Ks
K2
K3
Fig. A.37: Terminal block
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
Page 19
The Panda Generator
A.2.6 Sensors and switches for operating surveillance
Thermo-switch and -sensor at cylinder
head
110°C
130°C
Fig. A.38: Thermo-switch and -sensor at cylinder head
Thermo-switch at thermostat housing
98/83°C
Fig. A.39: Thermo-switch at thermostat housing
Thermo-switch at watercooled exhaust
manifold
105/90°C
Fig. A.40: Thermo-switch at exhaust manifold
Page 20
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
The Panda Generator
Thermo-switch at pre-silencer
At this point th coolant usually achieves its
highest value. From here it flows back into
the radiator.
105/90°C
Fig. A.41: Thermo-switch at silencer
Thermo-switch at radiator
Fig. A.42: Thermo-switch at radiator
Thermo-switch at the generator coil
1. Generator coil
2. Thermo-switch 4x160°C
1
3. Housing
2
3
Fig. A.43: Thermo-switch coil
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
Page 21
The Panda Generator
Oil pressure switch at engine
Fig. A.44: Oil pressure switch
Failure bypass switch
The failure bypass switch offers the possibility of starting the generator if the electrical control switched off due to an error in
the cooling system by overheating.
Fig. A.45: Failure bypass switch
Page 22
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
The Panda Generator
A.2.7 Components of oil curcuit
Engine oil filler neck with cap
Engine oil filler neck to maintenance work.
See details of oil specification.
Fig. A.46: Engine oil filler neck with cap
Engine oil dipstick
If the level fell below maximum and minimum, the oil level must be filled up to
maximum.
Fig. A.47: Engine oil dipstick
Engine oil filter
The oil filter should be exchanged with an
oil change.
Fig. A.48: Engine oil filler neck
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
Page 23
The Panda Generator
Engine oil drain hose
At changing oil the sound cover passage
must be opened and the drain hose must
be pulled out.
The screw on this hose must be opened
when changing the oil.
Fig. A.49: Engine oil drain hose
A.2.8 Ecternal components
AC-Control box
At operating the generator the operating
voltage of 230/400V lies at the AC-Control
box. It must be guaranteed that the generator cannot be inadvertently started, if the
Control box is opened. For this reason the
negative pole of the starter battery is to be
disclamped with all work on the electrical
system.
Fig. A.50: AC-Control box
Voltage control VCS
The voltage is regulated by the VCS in
connection with the actuator. The adjusting points serve only as security for the
fact that on disturbances of the VCS the
upper and lower point cannot be exceeded. The illustration shows the printed
board, which is accommodated in the ACControl box
Fig. A.51: VCS
Page 24
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
The Panda Generator
Electrical 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.52: Electrical fuel pump
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
Page 25
The Panda Generator
Page 26
Panda 18 NE PVK-UK S00405 - Chapter A: The Panda Generator
Generator Operating Instructions
B. Generator Operating Instructions
B.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 all required regulations of the regional authorities. The electrical installation should be performed by a qualified technician.
B.1.1Protection Conductor:
The standard Panda generator is grounded. The 3-phase connection (delta) centre point is bridged 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 electrical 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 generator or the electrical system in order to prevent accidental starting of the generator.
B.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. Therefore 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 normal 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!
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Generator Operating Instructions
B.2 Operating Instructions
B.2.1Routine „Pre-Start“ Checks (daily)
1. Check engine oil level (should be on MAX).
LOW OIL PRESSURE WARNING LIGHT!
The generator switches off in the case of insufficient oil-pressure. Do not run the generator with the oil at the lowest
level in the crankcase. (A smaller volume of oil will become contaminated considerably quicker than a larger
volume and there is the possibility that small air bubbles will get in the oil.) Therefore daily oil-checks are required.
The oil-level should always be refilled to MAX. Check oil level prior to starting motor or at least 5 minutes after the
motor has stopped.
Change the type of engine oil according to the ambient temperature. See TableF.2, “Engine oil,”
on PageII
For Oil-Quantities see TableF.5, “Technical Data Engine,” on PageIX
2. Check engine cooling system (all hoses and hose connections for leaks)
3. Check thermal switches and all cables and cable end terminal connections
a. Exhaust temperature switch
b. Engine temperature switch
c. Oil temperature switch
d. Oil pressure switch
4. Check tightness of all retaining and connection bolts on the engine & generator and generator
base mount bolts.
5. Switch main battery switch "ON" (if installed).
6. Open fuel inlet valve (if installed).
B.2.2Preliminary remarks
Damage to Starter Motor
The starter is fitted with a free wheel or axial rotating spring cog, which prevents the starter being
driven externally by means of the motor. The free wheel will be heavily worn, if the starter still
operates, thereby causing damage to the springs, roller bearings or cog teeth. This could lead to
complete destruction of the starter.
It is important that every person who operates the generator is informed of this situation.
This is practically the only handling error that can be made on board that can lead to fatal
consequences for both generator and operator.
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Generator Operating Instructions
Pre-heating the diesel motor
The motor must be pre-heated, if the diesel motor is designed as a "pre-combustion chamber
motor" for indirect fuel injection. A quick glow fitting is used for all Kubota-diesel motors. This glow
fitting may only be used for a maximum of 20 seconds without a pause. A pre-glow period of 5 - 6
seconds suffices for ambient temperatures above 20°C (plus). For lower temperatures the preglow period should be increased.
The motor can be started for temperatures up to minus 20°C, as long as running conditions are
suitable. The fuel must be suitable for such conditions, as conventional diesel fuel can produce a
paraffin coating at temperatures lower than minus 8°C. so blocking all filters and pipes. It is normal in Europe to use an additive, obtainable from gas stations to ensure use at temperatures as
low as minus 15°C. If a generator is to be used for temperatures below minus 8°C, then it must be
ensured the fuel is suitable for winter. By use of extra additive, the fuel can also be used at lower
temperatures. The appropriate regulations can be obtained from the fuel suppliers. The mineral
oil trade have stocks of fuel, which are suitable for use for temperatures below minus 20°C.
Pre-heating procedure
If the engine is to be started at a temperature below minus 15°C, then the pre-heating device
must be pressed for 20 seconds before starting. Pre-heating must be continued whilst the generator is being started. The starter motor should not be used for a period longer than 20 seconds
without interruption. If the engine does not start after 20 seconds, then a pause of at least one
minute should be made. Then a further start can be attempted.
If the diesel motor does not start as expected, then an initial check should be made to check whether the fuel intake is correct.
Tips regarding Starter Battery
Fischer Panda recommends normal starter battery use. If an aggregate is required for extreme
winter conditions, then the starter battery capacity should be doubled. It is recommended that the
starter battery be regularly charged by a suitable battery-charging device (i.e., at least every 2
Months). A correctly charged starter battery is necessary for low temperatures.
Motor Oil Quality during extreme Winter Conditions
Suitable motor oil is recommended for extremely low temperatures. The advice of mineral oil dealers is recommended. Normally, synthetic oil with the appropriate viscosity is especially suitable
for this type of cold start.
Improvement by using additional cold start sprays is not recommended.
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Generator Operating Instructions
B.2.3Overloading 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 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).
B.2.4Starting Generator
1. If necessary open the fuel valve.
2. If necessary, close the main battery switch.
3. Check if all the consumers have been switched off.
The consumers are switched off, before the generator is switched off. The generator is not to be started with consumers connected. If necessary, the main switch or fuse should be switched off or the consumers should be individually switched off.
4. Press "ON" button (Position 13 on Control panel).
Control light for "ON" Button must light up (Position 14 on Control panel).
5. Pre-heat engine (Position 09 on Control panel).
Pre-heating is necessary for every running temperature. Pre-heating is not necessary, only if the generator has just
been run. The heating period should take at least 6 seconds, however, 20 seconds at the maximum. Heating must
last for 20 seconds at a temperature of +5°C. If a second attempt is to be made, then a pause of at least 60
seconds is required.
The generator can be started with the assistance of a pre-heating device at temperatures as low as - 20°C. Please
note that the generator can only be run at temperatures below -8°C with winter fuel and additional special additives.
6. Press "START" button (Position 10 on Control panel).
The electric starter may only be used for a maximum of 20 seconds. Thereafter, a pause of, at least, 60 seconds is
required. If the aggregate does not immediately start, then the fuel intake should be checked to ensure it is flowing
freely. (For temperatures below - 8°C check whether there is winter fuel)
7. Check circuit- voltmeter, to test whether there is AC voltage and is within the tolerance range
(Frequency and voltage).
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Generator Operating Instructions
B.2.4Starting Generator (cont.)
The AC voltage should be within a tolerance of ± 3 Volt without load at the nominal voltage. When running without
load, the generator frequency should be 4% below the nominal voltage. The generator should be checked, before
the consumers are switched on, if the current remain at this level.
8. Switch on consumers.
The consumers should only be switched on if the generator voltage is within the permissible range. Parallel connection of several consumers should be avoided, especially if there are consumers with electric motors, such as
air-conditioning units in the system. In this case, the consumers must be connected Step by Step.
B.2.5Stopping the Generator
1. Switch off consumers.
2. If the load is higher than 70% of the nominal load, then generator temperature should be stabilised by switching off the consumers for at least 5 minutes.
At higher ambient temperatures (more than 25°C) the generator should always run for at least 5 minutes without
load, before it is switched off, regardless of the load.
3. Press generator "OFF" button and switch off (Position 12 on Control panel).
4. If necessary, press additional switch (battery switch, fuel stop valve).
B.2.6Starting the Generator when overheated by a "Failure Bypass Switch“
There is a "pressure switch" on the operation unit. Faults (e.g. caused by overheating) can be
manually overcome by means of this switch. The generator can be started by using the remote
control panel. The operating temperature can be reduced for a short period of time (without stress
of course), so that the fault switch returns to the original position should overheating cause the
generator to shut down because of overheating.
ATTENTION:
Before using the failure bypass switch, it is important to check the oil level, since the oil
gauge is deactivated by the switch.
For a further reason it is important to switch off the generator electrical load before the
generator is shut down:
Before stopping the generator it is highly recommended that electrical devices (e.g. refrigerating
compressors, air conditioning compressors etc) are switched off, because the voltage drops as
the rotational speed (rpm) decreases as the engine comes to a halt.
(Also see information regarding voltage control with automatic shut-off for protection of consumers when over or undervoltage occurs).
This is also the case when the generator is started when consumers are switched on.
Normally the generator will no longer excitate if a certain amount of base load is stepped up.
The electrical load should also be shut-off before starting the generator.
If started under electrical load, the engine will still run but the generator will not generate the proper voltage (or even no voltage) since the stator windings do not have the chance to reach full
excitation. Electrical units which are switched on in this condition could possibly be damaged
(special caution should be practised with electric motors to avoid burnout).
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Generator Operating Instructions
B.2.7Operating 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:
1. Thermo-switch fitted to the thermostat housing
2. Thermo-switch fitted to the exhaust elbow
3. Thermo-switch and -sensor fitted to the cylinder head
4. Thermo-switch fitted to the radiator
5. Thermo-switch fitted to the silencer
6. Thermo-switch in the genset coil
7. Oil pressure switch
Thermo-switch at thermostat housing
98/83°C
Fig. B.1: Thermo-switch thermostat housing
Thermo-switch at watercooled exhaust
silencer
105/90°C
Fig. B.2: Thermo-switch watercooled exhaust silencer
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Panda 18 NE PVK-UK S00405 - Chapter B: Generator Operating Instructions
Generator Operating Instructions
Thermo-switch and -sensor at cylinder
head
110°C
130°C
Fig. B.3: Thermo-switch and -sensor cylinder head
Thermo-switch at silencer
105/90°C
Fig. B.4: Thermo-switch silencer
Thermo-switch at radiator
Fig. B.5: Thermo-switch radiator
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Generator Operating Instructions
Thermo-switch at coil
01. Thermo-switch coil 4x160°C
01
02. Generator housing
02
Fig. B.6: Thermo-switch coil
Oil pressure switch
Fig. B.7: Oil pressure switch
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Panda 18 NE PVK-UK S00405 - Chapter B: Generator Operating Instructions
Maintenance Instructions
C. Maintenance Instructions
C.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 TableF.1, “Maintenance intervalls,” on PageI
C.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:
TableF.2, “Engine oil,” on PageII and TableF.5, “Technical Data Engine,” on PageIX
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.
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Maintenance Instructions
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 (oilfilter strap)
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Panda 18 NE PVK-UK S00405 - Chapter C: Maintenance Instructions
Maintenance Instructions
Oil filter seal ring
Before reinsert the gasket of the new oil filter should be coated with something oil.
Oil filler neck
The new oil is filled here.
With the help of the engine oil dipstick the
oil level is too examined. The prescribed
filling level may not exceed the „Max“ marking.
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Maintenance Instructions
C.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 air 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 rerunned several times.
Open de-aerating screw at the cooling
water pump.
Open de-aerating screw at the thermostathouing
Open de-aerating screw at the watercooled silencer.
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Panda 18 NE PVK-UK S00405 - Chapter C: Maintenance Instructions
Maintenance Instructions
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 generator.
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 aggregate also gets warm. After a short time the radiator and the reverse-flow pipe from the radiator to
the aggregate 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-aerating procedure after a few days, in order to
ensure that remaining air bubbles have been finally removed.
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Maintenance Instructions
C.3.1Draining the coolant
Put a bucket under the radiator to collect
the draining cooling water. Put the hose
through the grid and open the drainage
screw.
Fig. C.1: Coolant drain
Open the the drain valve.
Fig. C.2: Coolant drain
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Panda 18 NE PVK-UK S00405 - Chapter C: Maintenance Instructions
Maintenance Instructions
C.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 control panel to "ON".
2.) Push failure bypass switch and hold
tight. The electric fuel pump has to be running 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 bleeding 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
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
the "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 injection pipe a few millimeter. Try again to
start the unit. After the unit has started the
pipe union nut has to be tightened again.
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Maintenance Instructions
5.) The injection line must be raised some
millimeters.
6.) Main power switch "OFF".
C.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
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Maintenance Instructions
C.5 Exchange the air filter
Open the combustion air housing by loosen the clamp at the cover.
Open the combustion air housing by loosen the clamp at the cover.
Loose the wing bolt and lift the frame that
holds the air filter.
Change the air filter (MANN C2039).
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Maintenance Instructions
C.6 Exchange of the V-belt
The relative 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 compound 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 interval 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 alternator.
Loosen the fixing screw below the alternator only a little bit.
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Panda 18 NE PVK-UK S00405 - Chapter C: Maintenance Instructions
Maintenance Instructions
Press the alternator to the direction of the
thermostat housing.
Now the v-belt can be changed (type:
XPZ 925).
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.
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Maintenance Instructions
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Panda 18 NE PVK-UK S00405 - Chapter C: Maintenance Instructions
Generator Failure
D. Generator Failure
D.1 Overloading the Generator
Please ensure that the genset is not overloaded. This is especially the case with multi-power
aggregates. Overloading 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 genset can be run for several hours at partial load (i.e. 2/3 of rated power), however it is not advised
that it is run for more than 2-3 hours at full load.
The Panda is designed so as not to overheat even under extreme conditions. Note: The exhaust
gas will become sooty during peak-load operation.
Effects of Short Circuiting and Overloading on the Generator
The generator cannot be damaged by short circuiting or overloading. Short circuiting and overloading suppress the magnetic excitation of the generator, thus, no current is generated and the
voltage will collapse. This condition is immediately offset once the short-circuit has been eliminated 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 solutions (for example: stronger capacitors, gradual power-up switches, or a specially designed starting unit for electric motors).
System efficiency can be improved by up to 50% 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".
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Generator Failure
D.1.1Generator Voltage Fluctuations and Monitoring
ATTENTION! Before working (installation) on the System read the section Safety Instructions 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, 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 consumers are 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, especially 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).
D.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 monitor will also shut down the on board grid automatically when the generator is stopped). The monitoring system also switches the grid back on once the required voltage level is again reached.
This ensures no damage is caused to the consumers 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.
D.1.3Adjusting Instructions for the Spindle of the actuator
There are two independent regulation devices for the rev range of the generator. Limited upward
and downward:
a) With the regulation nuts at the spindle of the actuator left and right of the spindle nut.
b) With an adjusting screw directly at the base of the rev regulator lever. (only up)
After all work at the components of the rev regulation is done the adjustment of the limitation must
be checked.
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Panda 18 NE PVK-UK S00405 - Chapter D: Generator Failure
Generator Failure
01. Actuator
02. Spiral thread spindle
03. Regulating nuts max. revolution
04. Spindle nut with rev regulator lever
05. Regulating nuts min. revolution
01
02
03 04
05
During any operation at the generator all consumers have to be switched off to avoid damages at
the equipments. Also the solid state relay, which is installed in the AC-control box must be disconnected to avoid an accidentally activation of the booster capacitors.
D.1.4Adjustment of the maximum upper revolution:
1. Disconnect the plug at the electrical supply line of the actuator.
2. Unclamp the countering nut at the limitation screw with a wrench SW 10.
3. Connect an electrical voltage instrument (voltmeter) with a display range until 300V AC to AC
outlet in the electrical cabinet.
4. Be sure that no electrical load is adjusted.
5. Start the generator.
6. Increase the rev of the generator by turning the spindle of the actuator manually until the voltmeter reach a value of 260V (130V).
7. Turn the limit stop screw tight against the limit stop point at the rev regulator lever.
8. Protect the limit stop screw with the countering nut.
9. Check again if the voltage of the generator is limited to max. 260V (130V) without load.
The adjustment of the upper limitation of the rev serves an additional safety. The value of the
max. voltage lies 5V above the normal operating border.
01. Adjusting screw upper keystroke
02. Countering nut
03. Rev regulator lever
01
This adjustment should not be changed, otherwise the warranty expires.
02
03
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Generator Failure
D.1.5Adjustment of the normal rev limitation
a) Adjusting the lower limitation:
1. Disconnect the plug at the electrical supply line of the actuator.
2. Unclamp the countering nuts with two wrench SW 13.
3. Connect an electrical voltage instrument (voltmeter) with a display range until 300V AC to AC
outlet in the elektrical cabinet.
4. Be sure that no electrical load is adjusted.
5. Start the generator.
6. Decrease the rev of the generator by turning the spindle of the actuator manually until the voltmeter reach a value of 220V (110V).
7. Both nuts must be screwed tight.
8. Check again if the lower voltage of the generator is limited to min. 220V (110V) without load.
b) Adjusting the upper limitation:
1. Proceed like before and tighten the countering nuts at a voltage of max. 260V (130V) without
load.
2. Check again if the upper voltage of the generator is limited to this value.
01. Adjusting nut for upper rev limitation
02. Adjusting nut for bottom rev limitation
01
02
If the adjustment is finished the plug of the actuator must be re-connect for operation.
Re-connect the connections if the electrical supply lines in the AC-control box were also be disconnected.
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Panda 18 NE PVK-UK S00405 - Chapter D: Generator Failure
Generator Failure
D.1.6Lubrication of the spiral thread spindle
The spiral thread spindle must be lubricated carefully and regularly. Please only use a temperatur
independence lubricant (up to 100°C) witch is also equiped with "emergency run qualities".
Spread also lubricant to the end of the nuts.
It is possible that the spindle could clamp if the spindle is not enough lubricated. Then the generator can be switched off by over- or undervoltage.
All screws at the actuator and the spindle must be ensured "solveable" with a screw safety
grease.
01. Rev actuator
02. Spiral thread spindle
01
02
D.1.7Effects of a overload to the actuator
If the generator is overloaded the voltage falls on account of a not adequate motor power under
the nominal value. The actuator stays at the upper keystroke and tries to rev up the diesel engine.
An internal regulation limits the current to the actuator, nevertheless a longer overload can
damage the winding of the actuator. (short of the winding). The motor gets not strictly inoperative
but it can happen that the cranking torque of the actuator is getting weak. This has the consecuence that the rev spindle can not be turned to all positions faultless. Therefore the voltage of the
generator is regulated not good or sometimes not at all.
If you notice that the spindle of the actuator doesn´t run faultless, first check if the aggregate was
overloaded for a short time and if thereby the winding of the actuator was damaged.
Then the actuator has to be changed.
Check the electrical fuse (miniature slow-to-blow fuse 1,6A) on the control printed circuit board if
the actuator will not turn at all.
Change fuse here (1,6A slow to blow)
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Generator Failure
The generator can’t be damaged by an overload because the winding is overload- and short-circuit safety. But damages are possible in the periphery. Especially connected consumers are
endangered because a lower voltage can damage them by order.
Possible disturbances in the area of the rev regulation "VCS"
Failure
The spindle of the actuator jams
Cause
• not regularly lubricated.
• surface is mechanical damaged.
• actuator is defect.
• defect of the VCS control (short of winding).
• signal 230V (115V) AC missing.
• limiting nut jams the spindle.
Fuse on the printed circuit board of the
VCS control is melted.
• constant overload of the generator.
Steps to check the voltage control by a disturbance:
1. Switch off all electrical consumers.
2. Disconnect the plug of the actuator.
3. Turn the actuator manually to check if the adjusting nut is jamed to the limit stop points.
4. Turn the actuator manually to check if the adjusting nut on the spindel runs faultless.
If there is no result by these steps the actuator is working mechanically correct. After this the
electrical components must be checked:
1. Connect the plug of the actuator.
2. Start the generator.
3. Turn the actuator by hand and check if the spindle turns back by the motor.
4. If the motor react on the turn by manual strongly (the motor can normally hold with the fingers)
the drive will be working faultless. If there are nevertheless faults in the voltage control there is
a fault in the control VCS.
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Panda 18 NE PVK-UK S00405 - Chapter D: Generator Failure
Generator Failure
If the actuator is not moving the following points are necessary:
1. The motor turns not strongly rather weak:
a. The actuator has shorts in the winding and must be changed. (pay attention that the generator is not
overloaded anymore.)
2. The actuator does not move but the spindle can be turned manually. Disconnect the plug of
the actuator. Connect provisional an external voltage source 12V-DC to the motor.
a. The actuator don’t turns with the external voltage source. The actuator is defect and have to be changed.
b. The control must be inspected by the following steps if the actuator turns und works faultless with the
external voltage source:
1. Check the fuse on the VCS printed circuit board.
2. Check if the sense voltage is wired to the VCS printed circuit board.
3. Check if the VCS supply voltage is wired to the VCS.
4. Check if the VCS outlet signal for the actuator is wired.
Change the VCS printed circiut board if the points above carries no clearance.
The mechanical voltage limitation must be checked regularly. The following steps have to be
done:
1. Disconnect the plug of the actuator.
2. Switch off all consumers.
3. Connect an electrical voltmeter.
4. Start the generator.
5. Turn the actuator manually to the lower limit stop point.
6. The voltage must be 220V (110V).
7. Turn the actuator manually to the upper limit stop point. The max. voltage is 260V (130V).
8. A new adjustment is necessary in case of deviants.
D.1.8Low Generator Output Voltage
ATTENTION! Before working (installation) on the System read the section "Safety Instructions" 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
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Generator Failure
D.1.9Checking 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 on the system read the section "Safety Instructions"
in this manual.
Capacitors for excitation 400µF (5x80F)
After that, the generator should be restarted and the voltage checked at the terminals with a voltmeter.
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.
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Generator Failure
D.1.10Checking the Capacitors
ATTENTION! Before working (installation) on the System read the section "Safety Instructions" in this Manual.
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
1
3. Capacitor
3
2
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: acoustic signal“ and touch both capacitor terminals with the meter end probes.
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Generator Failure
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 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, N and Z 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. L1-Z
The capacitors must not be removed from the electrical cabinet before a check is made. The procedure 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.
ATTENTION! Do not contact the capacitor. Before working on the System read the Section
"Safety instructions" in this Manual.
AC Output Terminal box 230V-50Hz
N
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L1
Z
PE
Panda 18 NE PVK-UK S00405 - Chapter D: Generator Failure
Generator Failure
Wiring Diagram
D.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 follows:
1. Ensure that the generator is "OFF" and cannot be accidentally started. Disconnect the battery
leads.
2. Remove AC output terminal box lid (mounted on generator casing).
3. All terminal box connections are to be removed. (See appropriate circuit diagram.)
4. Remove all cables (also earth lead).
5. 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: Z, L1 and 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 tradesperson/technician. Winding diagrams can be obtained from ICEMASTER GmbH, Germany, if necessary.
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.
D.3 Coil Resistance Measurements in Stator Windings
When there are neither faults with the capacitors nor any low or high voltage "shorts" in the windings to ground, the windings should then be tested for the correct coils resistance (for shorts between 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.
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Generator Failure
Checking windings.
• Disconnect all the cables from the terminals in the AC-connection box.
• 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 MegaGiga 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 shorted 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 required 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.
D.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 winding'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 the 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
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Generator Failure
D.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 achieving 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 below). 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 external current from a 4,5 - 9 volt
battery. (No car-battery !)
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Generator Failure
D.4 Starting Problems
D.4.1 Fuel Solenoid Valve and Hubmagnet
For start problems the possibility of an error exists with the solenoid for engine stop or fuel solenoid valve, which both effect affect simultaneous on the fuel system.
1. Fuel solenoid valve
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 properly, the first item to suspect in most cases is the fuel solenoid valve and should be inspected
first.
A check of the fuel solenoid valve by removing the plug from the fuel solenoid valve for a short
period whilst in operation (first remove the small retention screw) and replace it immediately. The
motor should "react immediately" by revving high.If the motor does not react sharply to the reconnection of the solenoid wire, it is a sign that the solenoid valve could be faulty.
2. Solenoid for engine stop
The solenoid for engine stop is located at the injection pump.
1. Energized to stop
By pressing the "OFF"-button on the remote control panel, the solenoid is supplied with voltage
and attracts, whereby the fuel injection pump resets to the zero position and the generator stops.
2. Energized to run
This version is equipped with two solenoids an actuating and a stop solenoid. After being fed with
current, the actuating solenoid attracts the adjusting lever of the fuel injection pump, through
which the fuel can flow. The actuating solenoid is switched parallel to the starter motor, the stop
solenoid is switched parallel to the fuel pump. The position is held by the stop solenoid as long as
the generator is running.
01. Fuel solenoid valve
02. Fuel injector line
02
03. Ventilation screw
01
03
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Panda 18 NE PVK-UK S00405 - Chapter D: Generator Failure
Generator Failure
solenoid for engine stop
D.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 circumstances, since the generator is enclosed in a sound-insulated casing, which prevents heat
loss.
Failure bypass switch
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Generator Failure
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 overheating and not lack of oil, the generator can be run for several minutes without load, so that the
motor is cooled by the circulating coolant.
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.
D.5 Troubleshooting Table
For Troubleshooting see TableF.4, “Troubleshooting,” on PageIV
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Installation Instructions
E. Installation Instructions
E.1 Generator Connections
ATTENTION! Before working on the System read the “Safety Instructions” on Pageiv.
E.1.1 General Instructions
• It is important to pay attention to the fresh air intake.
• Sufficient space must be available below the generator, in order to allow flow of cooling air. (Underside and side: Underneath is not sufficient!)
• The radiator may not be covered.
• Untrained personnel should never open the generator.
E.1.2 Connections
01
02
03
04
05
01. Connection fuel in
02. Connection fuel out
03. Cable for thermoswitch radiator
04. Cable for fan
05. Cable for fuel pump
06. Cable for VCS
06
07
08
09
10
11
07. Cable for remote control panel
08. Cable for Load
09. Cable for AC-Control box
10. Battery plus (+)
11. Battery minus (-)
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Installation Instructions
E.1.3 Fuel System Installation
A fuel filter with 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 shutoff 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 "Ventilation of the Fuel System" should be considered.
see “Air-bleeding of the Fuel System” on page41.
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.
Anschluß des Kraftstoffsystems
1
4
3
2
1. Generator
2. Non-return valve
3. External fuel pump
Page 64
4. External fuel filter
5. Fuel tank
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5
Installation Instructions
E.1.4 Connection to 12V Starter Battery-Block
An own separate 12V starter battery must be installed for the generator.
The positive cable (+) of the battery is attached directly at the solenoid switch of the starter motor
The negative cable (-) of the battery is attached underneath the starter motor at the engine
mount.
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
2
1. Generator
2. Battery block 12V
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Installation Instructions
E.1.5 Connection of electrical components
Connection of electrical components
1
4
2
3
1. Generator
2. External fuel pump
Page 66
3. Remote control panel
4. AC-Control box
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Installation Instructions
E.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 voltage and low-voltage)
to the generator.
The front panel must always be closed, since the AC-Control box produces 400V during
operation.
1
2
3
4
1. VCS-printed board
2. Circuit breaker for fan (1x6A)
3. Terminal block for excitation cable, fan, thermo-switch
radiator and capacitors
4. Excitation capacitors (400µF)
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Installation Instructions
1
3
2
1. Cable for fan
2. Cable for thermoswitch radiator
Page 68
3. Cable for AC/Control box
Panda 18 NE PVK-UK S00405 - Chapter E: Installation Instructions
Installation Instructions
E.2.1 Voltage control system
The VCS control is used for the adjustment of the number of revolutions of the engine and thus
the voltage of the generator. It belongs to the accessories and is externally attached.
VCS-printed board
1
2
3
6
4
7
5
1.
2.
3.
4.
Connection measuring voltage
Adjustment booster voltage (do not adjust!)
Adjustment VCS-voltage
Connection VCS inlet
5. Electrical fuse (1,6A slow to blow)
6. Potentiometer for booster time
7. Connection for PC
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Installation Instructions
E.3 Cooling system
Coolant expansion tank
It is absolutely essential, that a exoansion tank, that can be aerated, is fitted adjacent to the radiator. 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 further 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 itself. The coolant expansion tank is not normally supplied by ICEMASTER. For this a standard
vehicle expansion tank is the most suitable. Vehicle accessory range is the most suitable.
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 occasioned 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.
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 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.
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 should be tested at 70% 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).
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Installation Instructions
E.4 Exhaust installation
Exhaust connection for roof outlet
3
4
6
5
7
8
2
1
1.
2.
3.
4.
Exhaust oulet
Generator
Dachdurchführung mit Winkel
Vibration damper
5.
6.
7.
8.
External pre-silencer
Exhaust pipe
External series silencer
End pipe
Exhaust connection for mounting below the vehicle
1
1.
2.
3.
4.
Generator
Exhaust outlet
Compensator
External pre-silencer
2
3
4
5
5.
6.
7.
8.
6
7
8
Vibration damper
Exhaust pipe
External series silencer
End pipe
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Installation Instructions
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Panda 18 NE PVK-UK S00405 - Chapter E: Installation Instructions
Appendix
F. Appendix
After operating hours:
35-50h
100h
200h
300h
400h
500h
600h
700h
800h
900h
1000h
F.1 Maintenance intervalls
Check all coolant and water hoses
X
X
X
X
X
X
X
X
X
X
X
Check waterpump
X
X
X
X
X
X
X
X
X
X
X
Empty water separator/fuel pre-filter (if present)
X
X
X
X
X
X
X
X
X
X
X
Change motor oil
X
X
X
X
X
X
X
X
X
X
X
Change of oil filter
X
X
X
X
X
X
X
X
X
X
X
Check air intake suction & flow, air filter, intake
manifold, etc.
X
X
X
X
X
X
X
X
X
X
X
Check fuel lines
X
X
X
X
X
X
X
X
X
X
X
Readjust valve clearance (every 500 h only)
X
X*)
X*)
Replace valve cover gasket (every 500 h only)
X
X*)
X*)
Check all sensors & switches
a) Coolant temperature sensor
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Check all electrical cables
X
X
X
X
X
X
X
X
X
X
X
Check battery
X
X
X
X
X
X
X
X
X
X
X
Idle run voltage (Volts)
X
X
X
X
X
X
X
X
X
X
X
Voltage under load (Volts)
X
X
X
X
X
X
X
X
X
X
X
Current under load (Amperes)
X
X
X
X
X
X
X
X
X
X
X
Engine speed (rpm) or frequency (Hz)
X
X
X
X
X
X
X
X
X
X
X
Change of the fuel filter
X
X
X
X
X
X
X
X
X
X
X
Change of the air filter
X
Cooler fan under load at bridged temperature
sensor/ temperature switch
X
X
X
X
X
X
X
X
X
X
X
Uptake of the ambient temperature
X
X
X
X
X
X
X
X
X
X
X
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
X*)
X*)
X*)
X*)
X*)
Panda 18 NE PVK-UK S00405 - Chapter F: Appendix
Page I
After operating hours:
35-50h
100h
200h
300h
400h
500h
600h
700h
800h
900h
1000h
Appendix
Temperature switch / watertemperature IN/OUT,
at full load and max. speed of cooler, bridged
temperature sensor / temperature switch
X
X
X
X
X
X
X
X
X
X
X
Actuate all ventilation valves -screws
X
X
X
X
X
X
X
X
X
X
X
With actuate the failure override switch check if
the waterpump works faultless (only at gents without v-belt drived waterpump)
X
X
X
X
X
X
X
X
X
X
X
Check v-belt
X
X
X
X
X
X
X
X
X
X
X
*) 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.)
F.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 (larger number = more viscous, lower number = more highly liquidly) e.g. to 0W, 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 designation is to be found on each engine oil bundle. The first letter is always a C.
API C for diesel engines
The second letter is for the quality of the oil. The more highly the letter in the alphabet, the better the C für Dieselmotoren.
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 18 NE PVK-UK S00405 - Chapter F: Appendix
Appendix
F.3 Coolant specifications
Use a mixture of water and antifreeze. The antifreeze needs to be suitable for aluminium. The antifreeze concentration 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
ASTM D 1121
13 – 15 ml HCl 01 mol/l
Density, 20°C
DIN 51 757 procedure 4
1,121 – 1,123 g/cm 3
Water content
DIN 51 777 part 1
max. 3,5 %
pH-value undiluted
7,1 – 7,3
Coolant mixture ratio
Water/antifreeze
Temperature
70:30
-20°C
65:35
-25°C
60:40
-30°C
55:45
-35°C
50:50
-40°C
Panda 18 NE PVK-UK S00405 - Chapter F: Appendix
Page III
Appendix
F.4 Troubleshooting
GENERATOR OUTPUT VOLTAGE TOO LOW
For 50Hz versions: less than 200V
For 60Hz versions: less than 100V
Cause
Solution
Generator is overloaded.
Reduce the electrical load. (Switch off consumers)
Motor is not reaching the rated rpm.
Refer to "motor faults" section.
Defective capacitor(s).
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 following potential causes should be investigated:
Cause
Solution
Over-energizing due to wrong capacitors.
Check capacitors type and replace if necessary.
Measurering voltage on the VCS circuit board is missing.
Check VCS System, check cable connections.
Motor is running too fast (rpm too high).
Check motor speed with rpm-meter or frequency meter
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
Cause
Solution
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
Cause
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.
Solution
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.
Page IV
Panda 18 NE PVK-UK S00405 - Chapter F: Appendix
Appendix
DIESEL MOTOR FAILS TO START
Cause
Solution
Starter battery switched "OFF".
Check position of battery switch and switch "ON" (if
installed).
Starter battery voltage insufficient (battery too weak).
Inspect battery terminals and cables for a good electrical 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.
STARTER IS TURNING MOTOR, BUT FAILS TO START
Cause
Solution
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.
Glow-plugs not working correctly.
Check glow plugs and heating time.
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
Cause
Solution
Starter battery voltage insufficient.
Check battery.
Damaged bearing(s) piston (seized).
Repairs need to be carried out by Kubota-Service.
(refer to Kubota motor-manual)
Cooling water in combustion chamber.
1. Turn generator "OFF" at control panel.
2. Remove the glow plug (see Kubota-manual).
3. Rotate the motor by hand carefully.
4. Check if there is water in the oil and change both oil
and filter if necessary.
5. Determine 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 18 NE PVK-UK S00405 - Chapter F: Appendix
Page V
Appendix
MOTOR RUNS IRREGULARLY
Cause
Solution
Faulty centrifugal injector governor.
Have the centrifugal governor inspected by a KubotaService technician.
Too much air in fuel lines.
Bleed air from fuel system.
MOTOR SPEED DROPS
Cause
Lack of fuel
Solution
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 installed).
Generator overloaded by too many consumers.
Reduce the electrical load (switch off consumers).
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
Cause
Fuel inlet solenoid valve or throttle shut solenoid is not
switching off.
Solution
Check wire connections to solenoid. Check valve
functions as in the "Inlet Fuel Solenoid Valve" or in the
trottle shut off solenoid sections. Replace if necessary.
MOTOR STOPS BY ITSELF
Cause
Solution
Lack of fuel.
Check fuel supply system.
Excess heat in cooling system (thermo switch tripped)lack of cooling water. Is indicated on the remote control
panel.
Check cooling water system flow: water pump, inlet
water filter, extra heat exchanger coolant flow.
Lack of oil (oil pressure sensor tripped). Is indicated on
the remote control panel.
Check oil-level and if necessary top up.
Page VI
Panda 18 NE PVK-UK S00405 - Chapter F: Appendix
Check motor's oil-pressure and have repaired by
Kubota-Service if necessary.
Appendix
SOOTY, BLACK EXHAUST
Cause
Solution
Generator is overloaded.
Check electrical load and switch off unnecessary consumers.
Insufficient intake air.
Check intake air filter; clean if necessary.
Fuel injector faulty.
Replace injector.
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 adjustment. Have motor serviced by Kubota.
Low compression pressure.
See Kubota motor manaul.
GENERATOR MUST BE SHUT OFF IMMEDIATELY IF:
Cause
- motor rpm suddenly rises or drops
- unusual noise comes from genset
- exhaust colour suddenly becomes dark
- leakage in the cooling water system.
Solution
Refer to respective section of manual and if necessary,
have repaired by Kubota-Service, or Panda representative.
Troubleshooting VCS System:
Cause
Throttle control servo motor does not move.
Solution
Check voltage supply 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, disconnect 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 18 NE PVK-UK S00405 - Chapter F: Appendix
Page VII
Appendix
Page VIII
Panda 18 NE PVK-UK S00405 - Chapter F: Appendix
Technical Data Engine
Anhang
F.5
Technical Data Engine
Generator
Panda 18 NE PVK-UK
Type
Kubota D1105
Governor
mechanical + VCS
Automatic Startbooster
yes
No. cylinders
3
Bore
78 mm
Stroke
78,4 mm
Stroke volume
1123 ccm
max. Power (DIN 6271-NB) at 3000rpm
18,7 kW
Rated speed 50Hz
3000 UpM
Idle running speed
2900 rpma
Valve clearance (engine cold)
0,2 mm
Cylinder head nut torque
68 Nm
Compression ratio
22:1
Lubrication oil capacity
5,1 l
Fuel consumption b
approx. 1,6 - 4,2 l
Oil consumption
max. 1% of fuel consumption
Permissible max. permanent tilt of engine
a) 25° across the longitudinal axis
b) 20° in the longitudinal direction
a. Progressive govenor by VCS
b. 0,35l/kW electrical power, the randomized values between 30% and 80% of the power rating.
F.6
Technical Data Generator
Generator
Panda 18 NE PVK-UK
Permanent output power
15 kW , 3000mtr alt., 50°C
Output voltage
230 V
Output current
70 A
Frequency
50 Hz
Stator Da
300 mm
Stator Di
170 mm
Rotor Lfe
150 mm
1-phase
Panda 18 NE PVK-UK S00405 - Chapter F: Appendix
Page IX
Measurements
F.7
Page X
Measurements
Panda 18 NE PVK-UK S00405 - Chapter F: Appendix
Wiring diagram control panel
F.8
Wiring diagram control panel
Panda 18 NE PVK-UK S00405 - Chapter F: Appendix
Page XI
AC-wiring diagram
F.9
Page XII
AC-wiring diagram
Panda 18 NE PVK-UK S00405 - Chapter F: Appendix
DC-wiring diagram
F.10 DC-wiring diagram
Panda 18 NE PVK-UK S00405 - Chapter F: Appendix
Page XIII
DC-wiring diagram
Page XIV
Panda 18 NE PVK-UK S00405 - Chapter F: Appendix
5 Safety steps to follow if someone is the
victim of electrical shock
1
Do not try to pull or grab the individual.
12
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.
13
If possible, turn off the electrical power.
14
Send for help as soon as possible.
15
After the injured person is free of contact with the source of electrical shock, move the person a short distance away and immediately start necessary first aid procedures.
XV
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?"
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?"
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.
•
9
Begin Rescue Breathing.
10 Recheck Pulse Every Minute.
•
Keep head tilted back.
•
Keep head tilted back.
•
Lift chin.
•
Feel for pulse for 5 to 10 seconds.
•
Pinch nose shut.
•
•
Give 1 full breath every 5 seconds.
If victim has pulse, not breathing,
continue rescue breathing. If no
pulse, begin CPR.
•
Look, listen, and feel for breathing
between breaths.
XVI
Call people who can phone for
help.
Look, listen, and feel for breathing for 3 to 5 seconds.
Send someone to call an ambulance.
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