Fischer Panda Panda PMS AGT-DC 11000 Marine Generator Installation and operation manual
Below you will find brief information for AGT-DC 11000. This super-silent marine generator offers 10.6kW of power, a 48V battery system with 150A continuous current, and features a patented voltage control system for stable voltage output. It's designed for reliable power generation in marine applications.
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Manual
Description of the generator - Installation andd operation manual
Marine Generator
Panda PMS AGT-DC 11000
Super silent technology
56,7V - 187A / 10,6kW
Battery system 48V - I
cont
= 150A
Fischer Panda GmbH
Actual:
Replace:
Revision
Current revision status
Document
AGT-DC_11000_48V_PMS_eng.R01_18.12.08
Page
Copyright
Duplication and change of the manual is permitted only in consultation with the manufacturer!
Fischer Panda GmbH, 33104 Paderborn, reserves all rights regarding text and graphics. Details are given to the best of our knowledge. No liability is accepted for correctness. Technical modifications for improving the product without previous notice may be undertaken without notice. Before installation, it must be ensured that the pictures, diagrams and related material are applicable to the genset supplied. Enquiries must be made in case o doubt.
2
Table of contents
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AGT-DC_11000_48V_PMS_eng.R01 - Table of contents Page 1
Table of contents
Hose elements and rubber formed component in the sound cover ................................... 69
Page 2 AGT-DC_11000_48V_PMS_eng.R01 - Table of contents 18.12.08
Table of contents
Running modes - Automatic mode, manual mode and power save mode ............. 107
Master-Slave Operation (In Preparation - available 11/2008) ................................... 118
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AGT-DC_11000_48V_PMS_eng.R01 - Table of contents Page 3
Table of contents
Page 4 AGT-DC_11000_48V_PMS_eng.R01 - Table of contents 18.12.08
since
1977
Icemaster GmbH since
1978 since
1988 since
1988 since
1988
Fischer Marine
Generators
Conclusion Fischer -
Icemaster GmbH
100 % water cooled Panda generators
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, Fischer Panda 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)
Fischer Panda GmbH, 33104 Paderborn, reserves all rights regarding text and graphics. Details are given to the best of our knowledge. No liability is accepted for correctness. Technical modifications for improving the product without previous notice may be undertaken without notice. Before installation, it must be ensured that the Pictures, diagrams and related material are applicable to the aggregate supplied. Enquiries must be made in case o doubt.
5
Safety first
These symbols are used throughout this manual and on labels on the maschine itself to warn of the possibility of personal injutry. Read these instructions carefully. It is essential that you read the instructions and safety regulations before you attempt to assemble or use unit.
This danger symbol refers to toxic danger and draws attention to special warnings, instructions or procedures which, if not strictly observed, may result in severe personal injury or loss of life.
This danger symbol refers to electric danger and draws attention to special warnings, instructions or procedures which, if not strictly observed, may result in electrical shock which will result in severe personal injury or loss of life.
This danger symbol refers to electric danger and draws attention to special warnings, instructions or procedures which, if not strictly observed, may result in electrical shock which will result in severe personal injury or loss of life.
This warning symbol draws attention to special warnings, instructions or procedures which, if not strictly observed, may result in damage or destruction of equipment, severe personal injury or loss of life.
This warning symbol draws attention to special warnings, instructions or procedures which, if not strictly observed, may result in damage or destruction of equipment
6
Tools
This symbols are used throughout this manual to show which tool must be used at maintenance or installation.
Spanners
X = number of spanner
X
Hook wrench for oil filter
Screw driver, for slotted head screws and for recessed head screws
Multimeter, multimeter with capacitor measuring
Infrared temperature mesuring pistol
Current clamp (DC for synchron generators; AC for asynchron generators)
7
Socket wrench set
Hexagon wrench keys
8
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.
Attention, Important Directions regarding Operation!
1. The installation certificate must be completed when taken into use, and certified by a signature.
2. The installation certificate must be despatched within two weeks of use to Fischer Panda.
3. The official guaranty confirmation will be completed by Fischer Panda after receipt and sent to the customer.
4. A guaranty must be shown to make any claims.
Claims against the guaranty will not be accepted of the above said instructions are not, or only partially, carried out.
Manufacturer declaration in terms of the machine guideline 98/37/EG .
The generator is in such a way developed that all assembly groups correspond to the CE guidelines. If machine guideline 98/37/EG is applicable, then it is forbidden to bring the generator into operation until it has been determined that the system into which the generator is to be installed in also corresponds to the regulations of the machine guideline 98/37/EG. This concerns among other things the exhaust system, cooling system and the electrical installation.
The evaluation of the "protection against contact" can only be accomplished in connection with the respective system. Likewise among other things responsibility for correct electrical connections, a safe ground wire connection, foreign body and humidity protection, protection against humidity due to excessive condensation as well as the overheating through appropriate and inappropriate use in its installed state on the respective machine lies within the responsibility of those who undertake installation of the generator in the system.
Use the advantages of the customer registration:
• Thus you receive to extended product informations, which are sometimes safety-relevant
• you receive, if necessarily free Upgrades
Far advantages:
By your full information Fischer Panda technicians can give you fast assistance, since 90% of the disturbances result from errors in the periphery.
Problems due to errors in the installation can be recognized in the apron.
Technical Support per Internet: [email protected]
9
Safety Precautions
The electrical Installations may only be carried out be trained and tested personnel!
The generator may not be taken into use with the cover removed.
The rotating parts (belt-pulley, belts, etc) must be so covered and protected do that there is no danger to life and body!
If a sound insulation covering must be produced at the place of installation, then well-placed signs must show that the generator can only be switched on with a closed capsule.
All servicing-, maintenance or repair work may only carried out, when the motor is not running.
Electrical voltages above 48 volts ( battery chargers greater than 36 volts) are always dangerous to life). The rules of the respective regional authority must be adhered to. Only an electrician may carry out installation of the electrical connections for safety reasons.
General safety references for the enterprise of a AGT generator.
With all energized systems, with which the current is more than 50 Ampère, special safety precautions must be made, in order to protect the environment of the components against fire.
It is to be ensured absolutely that at the battery a main switch in well accessible place is accommodated, so that with danger of the main switches can be separated immediately. The main switch must be however also directly at the battery installed. If this place is not well accessible, a power relay must be used instead of the main switch which can be served manually, which can be served then if necessary from different places. The switches for the power relay are to mark accordingly as main switches DC battery "with danger switch off!".
Cooling of the rectifier block at the marine versions
The retifier block is cooled with fresh water. A normal cooling of the rectifier block is therefore only possible, as long as the cooling water supply of the generator functions duly. The cooling water supply of the generator must be so furnished therefore that by a wide dirt deflector it is guaranteed that from outside no dirt can be sucked in into the line system. If this is not attainable, the supply must be secured by a flow switch or a negative pressure switch. The generator must be switched off, if the cooling water supply is impair.
The temperature safety device on the rectifier block can be regarded only as additional safety device. The temperature rise at the diods is so fast that the rectifiers can be damaged during a unique interruption of the cooling water supply. A safe protection from damage of the rectifiers is not possible by the temperature monitoring on the rectifier radiator box. Thus this can take place only by means of an appropriate external monitoring of the cooling system.
ATTENTION!
Do not connect the minus pole of the starter battery to the ground of the boat because of galvanic reason.
Warning!
Never start the generator with the battery disconnected, the rectifiers will be damaged!
CAUTION!
Contact of the electrical contacts may be DANGER TO LIVE!
10
CAUTION!
The AGT-generator is not allowed to be connected to an inverter (without batteries)!
The Inverter generates voltage peaks, which can destroy the rectifier rectifiers of the generator!
A battery must always be connected to the inverter as a capacity!
Recommended capacity at 12V
≥
240Ah at 24V
≥
120Ah
The screws at the electric rectifier may be pulled tight only with a torque wrench. Torque 6 Nm.
The battery cable must be secured at the generator and at the batteries with appropriate safety devices.
The generator is also include into the CO
2
- fire-extinguishing system.
11
Measures to the fire protection.
All construction units in the environment of energized parts, which carry more than 50 Amp., must be fire protectionmoderately secured.
All junction points at the energized parts must be examined regularly on heating up (infrared thermometers).
Safety Instrictions for the Handling with Batteries
These instructions must be noticed additionally to the instructions of the battery manufacturer:
• If the batteries are working, someone should be in your near area to help you in a case of emergency.
• Water and soap must be hold ready if battery acid corrode your skin.
• Wear eye protection and protective clothing. During working with the batteries don´t touch the eyes.
• If you got a acid splash on your skin or clothing grow it with much water and soap out.
• If you got acid in your eyes rinse them immediately with clear water until no cauterization is noticeable. Visit immediate a doctor.
• Don´t smoke in the near of the batteries. Avoid naked flames or open fires. In the area of batteries exists danger of explosions.
• Pay attention that no tools fall on the battery poles, if necessary cover them.
• During the installation don´t wear a wrist watch or arm jewels, you can create under these circumstances a battery short-circuit. Burning of the skin could be the result.
• Protect every battery contact against unintentional touch.
• Use only cyclical profoundly dischargeable batteries. Starter batteries are not appropriate. Lead-gel batteries are commended. They are maintenance-free, profoundly dischargeable and not produce gas.
• Do not charge a frozen battery.
• Avoid a batterie short-curcuit.
• Take care of a good ventilation of the battery to drain off developing gas.
• The battery connection terminals must be checked of a tight contact at least before operating.
• The battery connection cable must be carefully mounted and checked about incorrect heating at operation with load. The vibrating devices must be regulary checked about scour points and flaw in the isolation.
12
5 Safety steps to follow if someone is the victim of electrical shock
Do not try to pull or grab the individual.
1
2
Send for help as soon as possible.
1
3
If possible, turn off the electrical power.
1 4
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.
1 5
After the injured person is free of contact with the source of electrical shock, move them a short distance away and immediately start necessary first aid procedures.
13
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.
2
Shout, "Help!"
Call people who can phone for help.
1
Does the Person Respond?
Tap or gently shake victim.
Shout, "Are you OK?"
3
Roll Person onto Back.
Roll victim toward you by pulling slowly.
4
Open Airway.
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.
Feel for pulse for 5 to 10 seconds.
9
Begin Rescue Breathing.
Keep head tilted back.
Lift chin.
Pinch nose shut.
Give 1 full breath every 5 seconds.
Look, listen, and feel for breathing between breaths.
5
Check for Breathing.
Look, listen, and feel for breathing for 3 to 5 seconds.
8
Phone EMS for Help.
Send someone to call an ambulance.
10
Recheck Pulse Every Minute.
Keep head tilted back.
Feel for pulse for 5 to 10 seconds.
If victim has pulse, not breathing, continue rescue breathing. If no pulse, begin CPR.
14
The Panda Generator
A. The Panda Generator
A.1 Type ID plate at the Generator
Fig. A.1-1: Type ID plate
18.12.08
Fig. A.1-2: Discription type plate
AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator Page 15
07
08
09
10
A.2 Description of the generator
A.2.1 Right side view
01 02
06
03 04 05
The Panda Generator
18
17
16
11 12 13 14 15
01) Water-cooled exhaust elbow
02) Starter motor
03) Thermo-switch exhaust elbow
04) Ventilation pipe to external cooling water expansion tank
05) Rectifier
06) Thermostat housing
07) DC-alternator 12V
08) V-belt
09) Oil pressure switch
10) Oil filter
11) Sound cover base part
12) Cooling water return hose
13) Generator housing with coil
14) Connections for external cooling water expansion tank
15) Exhaust output
16) Exhaust pipe
17) Thermo-switch exhaust
18) Injection hose raw water
Fig. A.2.1-1: Right side view
Page 16 AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator 18.12.08
The Panda Generator
A.2.2 Left side view
01 02 03
17
21
20
19
18
04 05 06
07
08 11 12 13 14 15 16
01) Air suction housing with air filter
02) Raw water intake hose
03) Actuator for rpm-regulation
04) Connection external ventilation valve
05) Passage for battery bank cable
06) Raw water hose cooling plate rectifier in
07) Generator housing with coil
08) Raw water hose cooling plate rectifier out
11) Electrical fuses
12) Oil dipstick
18.12.08
13) Power relays
14) Fuses for voltage sense, AC-voltage (3x1,6A) and failure bypass switch
15) Sound cover base part
16) Raw water intake
17) Time relay for stop solenoid
18) Fuel filter
19) Fuel solenoid valve
20) Stop solenoid
21) Thermostat housing
Fig. A.2.2-1: Left side view
AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator Page 17
A.2.3 Front view
01
02
03
04
05
The Panda Generator
22
21
20
19
06 09 10 11 12 13 14 15 16 17 18
01) Ventilation screw internal cooling water pump
02) Stop solenoid
03) Pulley for internal cooling water pump
04) V-belt
05) Fuel filter
06) Raw water intake
07) Passage for service battery cable
08) Passage for service battery cable
09) Connection fuel in
10) Connection fuel out
11) Cable fuel pump
12) Oil drain hose
13) Cable AGT-control panel
14) Cable voltage control VCS
15) Cable voltage sense (clamp 7+8)
16) Cable shunt measurement (clamp 9+10)
17) Starter battery minus (-)
18) Starter battery plus (+)
19) Oil filter
20) DC-alternator 12V
21) Clamp device for DC-alternator
22) Thermostat housing
Fig. A.2.3-1: Front view
Page 18 AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator 18.12.08
The Panda Generator
A.2.4 Back view
01
02
03
04
05
12
11
06
07 08
01) Rectifier
02) Water-cooled exhaust elbow
03) Injection hose raw water
04) Generator front cover
05) Exhaust pipe
06) Exhaust output
18.12.08
09
10
07) In-flow from external cooling water expansion tank
08) Return to external cooling water expansion tank
09) Connection external ventilation valve
10) Sound cover base part
11) Cooling water connection block
12) Air suction housing with air filter
Fig. A.2.4-1: Back view
AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator Page 19
The Panda Generator
A.2.5 View from above
01 02 03
04 05 06 07 08
09 10
11 12 13 14 15
01) Rectifier
02) Exhaust connection
03) Ventilation hose to external expansion tank
04) Water-cooled exhaust elbow
05) Valve cover
06) Oil filler neck
07) DC-alternator
08) Ventilation screw thermostat housing
09) Air suction housing with air filter
10) Induction elbow
11) Actuator
12) Fuel solenoid valve
13) Stop solenoid
14) Ventilation screw internal cooling water pump
15) Pulley for internal cooling water pump
Fig. A.2.5-1: View from above
Page 20 AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator 18.12.08
The Panda Generator
A.3 Details of functional units
A.3.1 Components of cooling system (raw water)
18.12.08
Fig. A.3.1-1: Cooling system raw water
AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator Page 21
The Panda Generator
Raw water intake
The diagram shows the supply pipes for the generator. The connection neck for the raw water connection is shown on the left hand side. The cross-section of the intake pipe should be nominally larger than the generator connection.
Fig. A.3.1-2: Raw water intake
Raw water impeller pump
The raw water pump is fitted with a rubber impeller. This pump is self-inductive. If, for example, you forget to open the sea valve, then you must expect the impeller to be destroyed after a short period of time. It is recommended to store several impellers on board as spare parts.
Fig. A.3.1-3: Raw water impeller pump
Impellerfilter
Fig. A.3.1-4: Bypass
Page 22 AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator 18.12.08
The Panda Generator
Rectifier
The raw water cools the rectifier and diodes. and is then lead to the oil cooler.
Fig. A.3.1-5: Bypass
Heat exchanger
Separates the raw water system from the freshwater system.
18.12.08
Fig. A.3.1-6: Heat exchanger
Ventilation valve
A siphon must be installed if the generator sinks below the water line because of the rocking of the boat, even if it is only for a short period of time. A hosepipe on the generator casing has been produced for this. Both connecting pieces are bridged by a formed piece of hose.
Fig. A.3.1-7: Connection ventilation valve
AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator Page 23
Cooling water injector port
The injection point for the marine generator water-cooled exhaust system is situated at the exhaust connection pieces. The exhaust connections must be regularly checked for signs of corrosion.
Fig. A.3.1-8: Cooling water injector port
The Panda Generator
Page 24 AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator 18.12.08
The Panda Generator
A.3.2 Components of cooling system (freshwater)
18.12.08
Fig. A.3.2-1: Cooling system fresh water
AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator Page 25
The Panda Generator
Ventilation pipe
The ventilation pipe at the water-cooled exhaust manifold leads to the external expansion tank. This pipe only serves as a ventilation pipe, if both pipes are to be connected to the external expansion tank
(ventilation pipe and intake pipe).
Fig. A.3.2-2: Ventilation pipe
Hose connection pieces for the external expansion tank
The external expansion tank is connected by two hose connections. The connecting pieces shown here serves as constant ventilation for the water-cooling system.
In case the external expansion tank is connected with two hoses, the system will ventilate itself. In this case, additional ventilation is only necessary when the generator is initially filled, or if the cooling water is not circulating.
Fig. A.3.2-3: External expansion tank
Freshwater backflow
The cooling water is fed to the heat exchanger from the water-cooled manifold by means of the pipe shown in the diagram.
Fig. A.3.2-4: Freshwater backflow
Page 26 AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator 18.12.08
The Panda Generator
Heat exchanger
Separates the raw water system from the freshwater system.
18.12.08
Fig. A.3.2-5: Heat exchanger
Cooling water injection
A.) To the thermostat housing
B.) From the external expansion tank
C.) From the heat exchanger
The intake pipe from the external cooling water expansion tank is connected to the point shown with „B“.
C
B
Fig. A.3.2-6: Cooling water injection
Internal cooling water pump
The diesel motor cooling water pump (see arrow) aids the circulation of the internal freshwater system.
A
Fig. A.3.2-7: Internal cooling water pump
AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator Page 27
The Panda Generator
Ventilation screw cooling water pump
The ventilation screw above the cooling water pump casing may not be opened, whilst the generator is running. If this occurs by mistake, air will be drawn through the opening. Extensive ventilation of the whole system is then necessary.
Fig. A.3.2-8: Ventilation screw cooling water pump
Ventilation screw thermostat housing
The ventilation screw on the thermostat housing should occasionally be opened for control purposes. Standing machinery should principally carry out ventilating.
Fig. A.3.2-9: Ventilation screw thermostat housing
Water-cooled exhaust elbow
The manifold is cooled by means of the internal cooling system (freshwater). The cooling water filler necks on the casing of the elbow may not be opened. These cooling water necks are only required to fill the motor with cooling water in cases of repair. The normal cooling water controls may only be carried out at the external expansion tank.
Fig. A.3.2-10: Water-cooled exhaust elbow
Page 28 AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator 18.12.08
The Panda Generator
A.3.3 Components of the fuel system
18.12.08
Fig. A.3.3-1: Fuel system
AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator Page 29
The Panda Generator
External fuel pump
The Panda generator is always supplied with an external, electrical (12 V of DC) fuel pump. The fuel pump must be always installed in the proximity of the tank. The electrical connections with the lead planned for it are before-installed at the generator. Since the suction height and the supply pressure are limited, it can be sometimes possible that for reinforcement a second pump must be installed.
Fig. A.3.3-2: External fuel pump
Connecting pieces for the fuel pipe
1. Fuel intake
2. Fuel backflow
1
2
Fig. A.3.3-3: Fuel connections
Fuel filter
A consequential filtering of fuel is especially important for all marine systems. A fine filter, which is firmly attached to the inside of the sound insulation capsule for the marine version, 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.3.3-4: Fuel filter
Page 30 AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator 18.12.08
The Panda Generator
Fuel solenoid valve
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.
Fig. A.3.3-5: Fuel solenoid valve
Injection nozzles
If the engine does not start after the ventilation, the fuel injection lines must be deaerated individually.
18.12.08
Fig. A.3.3-6: Injection nozzle
Glow plugs
The glow plugs serve the pre-chamber for the heating with cold start. The heat-treat fixture must be operated, if the temperature of the generator is under 16°C. This is practically with each start the case. The heat-treat fixture may be held down also during start and favoured the starting procedure.
Fig. A.3.3-7: Glow plugs
AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator Page 31
Stop solenoid for engine stop
Some model are additional equipped with an stop solenoid. The generator is stopped by the co-operation of the stop solenoid immediately after switching off. The adjustment of the stop solenoid must always be checked, in order to be sure that the stop lever can move also during the operation freely and is not under prestressing.
Fig. A.3.3-8: Stop solenoid
The Panda Generator
Page 32 AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator 18.12.08
The Panda Generator
A.3.4 Components of combustion air
18.12.08
Fig. A.3.4-1: Combustion air system
AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator Page 33
The Panda Generator
Air suction openings at the sound cover
The sound cover is provided at the base part with drillings, through which the combustion air can influx.
It must be consistently paid attention that the generator is installed in such a way that from no water can arrive into the proximity of these air openings. (minimum distance 150 mm)
Fig. A.3.4-2: Combustion air intake
Air suction housing
Remove the cover to look indes the housing. There is a filter element. This must be checked from timt to time.
Fig. A.3.4-3: Air suction housing
Air suction housing with air filter set
The figure shows the air filter element in the air suction housing.
Fig. A.3.4-4: Air filter
Page 34 AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator 18.12.08
The Panda Generator
Induction elbow
The figure shows the induction elbow at the combustion engine. At the front of this induction elbow you can see the hose connection between air suction housings and induction elbow. The air filter must be checked, if this hose pulls together at operation.
Fig. A.3.4-5: Induction elbow
Valve cover
18.12.08
Fig. A.3.4-6: Valve cover
Exhaust elbow
On the back of the engine is the watercooled exhaust elbow. On the top side the pipe union for the internal raw water circuit is to be seen and the filler neck for the cooling water. This cooling water filler neck is used only at first filling. Control of the cooling water and if necessary refill takes place at the external cooling water expansion tank.
Fig. A.3.4-7: Water-cooled exhaust elbow
AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator Page 35
Exhaust connection at the exhaust elbow
Raw water from the external cooling circle is fed here.
Fig. A.3.4-8: Exhaust port
Exhaust outlet
Connect the exhaust pipe with the water lock.
Fig. A.3.4-9: Exhaust outlet
The Panda Generator
Page 36 AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator 18.12.08
The Panda Generator
A.3.5 Components of the electrical system
18.12.08
Fig. A.3.5-1: Electrical system
AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator Page 37
The Panda Generator
Connection starter battery
1. Cable for starter battery (-)
2. Cable for starter battery (+)
During the connection to the starter battery it must be always ensured that the contact is perfectly guaranteed.
See wiring diagram
Fig. A.3.5-2: Cable for starter battery
Service battery cables
At the front of the sound cover is also the withdrawal for the cable for the service batteries.
1. Passage for service battery (-)-cable
2. Passage for service battery (+)-cable
See wiring diagram
1
2
Fig. A.3.5-3: Service battery cables
Connection clamps for service battery cables
1. Clamp (-) for battery cable (-)
2. Clamp (+) for battery cable (+)
See wiring diagram
1 2
Fig. A.3.5-4: Connection clamps for service battery cables
Page 38 AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator
1 2
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The Panda Generator
Electrical connections for control
At the front of the generator also all remaining cables for the electrical connections are depending upon type. The allocation of the connections result from the plan for the AC-Control box. See here:
1. Fuel pump
2. AGT control panel
3. VCS
4. Voltage sense (clamp 7+8)
5. Shunt measurement (clamp 9+10)
See wiring diagram
1
Fig. A.3.5-5: Electrical connections
2
3
4
5
Starter motor
1. Starter motor and
2. Solenoid switch
The Diesel engine is electrically started.
On the back of the engine is accordingly the electrical starter with the solenoid switch.
See wiring diagram
1
2
Fig. A.3.5-6: Starter motor
Actuator for speed regulation
The generator voltage is determined by progressive speed control through "VCS" in conjunction with the speed actuator.
Speed increases with increasing load.
See wiring diagram
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Fig. A.3.5-7: Actuator
AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator Page 39
The Panda Generator
Alternator
All Panda generators from Panda 6.000
are provided with its own charge system for the 12V DC mains. This alternator is powered over a v-belt together with the internal cooling water pump.
The 12V charge system may be used only for the generator-own starter battery.
See wiring diagram
Fig. A.3.5-8: DC-alternator
Rectifier
See wiring diagram
Fig. A.3.5-9: Rectifier
Fuses for
1. 1,6A
2. 1,6A
3. 1,6A
See wiring diagram
Fig. A.3.5-10: Fuses
Page 40 AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator
1
2
3
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The Panda Generator
Terminal block for remote control cable with fuses and power relays
01. Fuses
02. Power relays
See wiring diagram
1 2
Time relay for stop solenoid
1. Time relay
See wiring diagram
Fig. A.3.5-11: Terminal block
1
Fig. A.3.5-12: Time relay
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AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator Page 41
A.3.6 Sensors and switches for operating surveillance
Thermo-switch at cylinder head
The thermo-switch at the cylinder head serves the monitoring of the generator temperature. All thermo-switches for the generators from Panda 6.000 upward are two-pole and laidout as "openers".
T=110°C NC for control panel alarm
T=130°C NC for redundance, direct switch for fuel relays
Fig. A.3.6-1: Thermo-switch at cylinder head
Thermo-switch at exhaust elbow
105/90°C NC
The Panda Generator
Fig. A.3.6-2: Thermo-switch at exhaust elbow
Thermo-switch at exhaust connection
If the impeller pump drop out and deliveres no more raw water, the exhaust connection becomes extremely hot.
98/83°C NC
Fig. A.3.6-3: Thermo-switch at exhaust connection
Page 42 AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator 18.12.08
The Panda Generator
Thermo-switch coil
4x165°C NC
For the protection of the generator coil there are three NTC´s inside the coil, which are for inserted parallel and safety's sake independently from each other.
Fig. A.3.6-4: Thermo-switch coil
Oil pressure switch
In order to be able to monitore the lubricating oil system, an oil pressure switch is built into the system. The oil pressure switch is on the back of the engine (before the electrical starter).
open < 0,7bar closed >0,7bar
Fig. A.3.6-5: Oil pressure switch
Thermo-switches on rectifier
1. Thermo-switch 120°C rectifier (+) rail
2. Thermo-switch 120°C rectifier (-) rail
3. Thermo-switch 85°C rectifier heat sink
1
2
3
Fig. A.3.6-6: Thermo-switches on rectifier
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AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator Page 43
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.3.6-7: Failure bypass switch
The Panda Generator
Page 44 AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator 18.12.08
The Panda Generator
A.3.7 Components of the oil circuit
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Fig. A.3.7-1: Lubrication system
Oil filler neck with cap
Normally the filler neck for the engine oil is on the top side of the valve cover. At numerous generator types a second filler neck is attached additionally at the operating side. Please pay attention that the filler necks are always well locked after filling in engine oil.
Consider also the references to the engine oil specification.
Fig. A.3.7-2: Oil filler neck
AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator Page 45
The Panda Generator
Oil dipstick
At the dipstick the permissible level is indicated by the markings "maximum" and
"minimum". The engine oil should be never filled up beyond the maximum conditions.
Fig. A.3.7-3: Oil dipstick
Oil filter
The oil filter should be exchanged with an oil change.
Fig. A.3.7-4: Oil filter
Oil drain hose
The Panda generator is equipped that the engine oil can be drained over an drain hose. The generator should be always installed therefore that a collecting basin can be set up deeply enough. If this is not possible, an electrical oil drain pump must be installed.
Note: Lubricating oil should be drained in the warm condition!
Fig. A.3.7-5: Oil drain hose
Page 46 AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator 18.12.08
The Panda Generator
A.3.8 External components
Voltage control VCS
The figure shows the control printed board for the VCS voltage regulation. Over this control printed board the control signals are given for the actuator for speed regulation. On the VCS board are also adjustment possibilities for the control parameters.
Fig. A.3.8-1: VCS
AGT control panel
The remote control panel is necessary to control the generator and to evaluate the motor/generator properties. The generators will automatically cutout if it does not run as required. The generator may not be run without the remote control panel.
Fig. A.3.8-2: AGT control panel
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AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator Page 47
The Panda Generator
A.4 Operation instructions
A.4.1 Preliminary remarks
Starter Battery
Adequate batteries are installed for extreme winter conditions. Unless the generator is being run frequently for extended (over 1 hour) periods, it is recommended that the starter battery is regularly charged by a suitable external battery-charging device, at least every 2 months. A correctly charged battery is essential for low temperature starts. Below minus 35°C it will probably be necessary to connect additional batteries or DC input from a running vehicle to provide enough power to start.
Motor Oil Quality during extreme Winter Conditions
Motor oil of the correct grade for the temperatures anticipated should be used. There is advice in section F.4, “Engine oil specification,” on Page 111 on the grades which are suitable for various environmental conditions.
Auxiliary Belt Failure
After starting a generator which has been cooled to below- 35°C, wait until normal operating tem erature has been reached, then switch off the generator and inspect the auxiliary belt. Even if damage is not found, it is recommended the belt is replaced (see section C.6, “Replace of the vbelt additional DC-alternator,” on Page 85 and following).
A.4.2 Daily routine checks before starting
1. Oil Level Control (ideal level: 2/3 of max. level).
AtTTENTION! OIL PRESSURE CONTROL!
True, the diesel motor automatically switches off when there is a lack of oil, but it is very damaging for the motor, if the oil level drops to the lowest limit. Air can be sucked in suddenly when the boat rocks in heavy seas, if the oil level is at a minimum. This affects the grease in the bearings. It is therefore necessary to check the oil level daily before initially running the generator. The oil level must be topped up to the 2/3 of the maximum level, if the level drops below the mark between maximum und minimum levels.
You should change the oil, regardless off the ambient temperature. See section F.3, “Engine oil
specification,” on Page 100. Engine oil amounts see section F.1, “Technical data,” on Page 93.
2. State of Cooling Water.
The external compensation tank should be filled up to a maximum of in a cold state. It is very important that large expansion area remains above the cooling water level.
3. Open Sea Cock for Cooling Water Intake.
For safety reasons, the seacock must be closed after the generator has been switched off. It should be re-opened before starting the generator.
4. Check Raw water Filter.
The raw water filter must be regularly checked and cleaned. The impeller fatigue increases, if residual affects the raw water intake.
Page 48 AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator 18.12.08
The Panda Generator
A.4.2 Daily routine checks before starting (Forts.)
5. Check all Hose Connections and Hose Clamps are Leakage.
Leaks at hose connections must be immediately repaired, especially the raw water impeller pump. It is certainly possible that the raw water impeller pump will produce leaks, depending upon the situation. (This can be caused by sand particles in the raw water etc.) In this case, immediately exchange the pump, because the dripping water will be sprayed by the belt pulley into the sound insulated casing and can quickly cause corrosion.
6. Check all electrical Lead Terminal Contacts are Firm.
This is especially the case with the temperature switch contacts, which automatically switch off the generator in case of faults. There is only safety if these systems are regularly checked, and these systems will protect the generator, when there is a fault.
7. Check the Motor and Generator Mounting Screws are Tight.
The mounting screws must be checked regularly to ensure the generator is safe. A visual check of these screws must be made, when the oil level is checked.
8. Switch the Land Electricity/Generator Switch to Zero before Starting or Switch Off all the Consumers.
The generator should only be started when all the load have been switched off. The excitation of the generator will be suppressed, if the generator is switched off with load connected, left for a while, or switched on with extra load, thus reducing the residual magnetism necessary for excitation of the generator to a minimum. In certain circumstances, this can lead to the generator being re-excitated by means of a DC source. If the generator does not excitate itself when starting, then excitation by means of DC must be carried out again.
9. Check the Automatic Controls Functions and Oil Pressure.
Removing a cable end from the monitoring switch carries out this control test. The generator should then automatically switch off. Please adhere to the inspection timetable (see Checklist in the appendix).
A.4.3 Starting generator- see remote control panel datasheet
A.4.4 Stopping the generator- see remote control panel datasheet
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AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator Page 49
The Panda Generator
A.4.5 Starting the generator by a „Failure bypass switch“
ATTENTION:
If the generator switches itself off at operation for temperature reasons, it must be examined immediately, which the cause is. That can be an error at the cooling system, drive belt or any error in the range of the outside cooling system. With cooling water loss: Errors locate and cooling water refill.
After the error was repaired, the lying error message (e.g. by temperature rise) can be bridged with failure bypass switch. As long as the switch is held down, the error messages are switched off. The generator can be started then over the remote control panel. If the generator switched off by temperature rise, the operating temperature can be lowered in this way by a short running time
(natural without load), so that the error message releasing switches decreases/goes back again into the starting position.
Failure bypass switch
Fig. A.4.5-1: Failure bypass switch
Page 50 AGT-DC_11000_48V_PMS_eng.R01 - Chapter A: The Panda Generator 18.12.08
Installation Instructions
B. Installation Instructions
B.1 Placement
B.1.1 Placement and basemount
Since Panda generators have extremely compact dimensions they can be installed in tight locations, attempts are sometimes made to install them in almost inaccessible places. Please consider that even almost maintenance-free machinery must still remain accessible at least at the front
(drive belt, water pump) and the service-side (actuator, dipstick). Please also note that in spite of the automatic oil-pressure sensor it is still essential that the oil level has to be checked regularly.
The generator should not be installed in the proximity of light walls, which can get into resonant vibrations by airborne sound. If this is not possible, these surfaces should line with 1mm lead foil, so the mass and the swinging behavior are changed.
Avoid to install the generator on a smooth surface with small mass (e.g. plywood plate). This affects in the unfavorable case like an amplifier the airborne sound waves. An improvement obtains by compound these surfaces by ribs. Also break-throughs should be sawed, which interrupt the surface. Disguising the surrounding walls with a heavy layer (e.g. lead) plus foam material improves the conditions additionally.
The engine draws its inlet combustion air through several holes in the capsule base. Therefore the capsule must be fitted with sufficient clearance between the capsule underside and the base plate (min. 12mm (½")).
The generator sucks its air from the surrounding engine room. Therefore it must be ensured that sufficient ventilation openings are present, so that the genset cannot overheat.
High temperature of the intake air decline the power of the genset and increases the coolant temperature. Air temperatures of more than 40°C reduce the power by 2% per temperature rise of
5°C. In order to keep these effects as small as pos sible, the temperature in the engine room should not be higher than 15°C in relation to the o utside temperature.
B.1.2 Notice for optimal sound insulation
The convenient base consists of a stable framework, on which the generator is fastened by means of shock-mounts.
Since the genset is "free" downward, the combustion air can be sucked in unhindered.
In addition are void the vibrations, which would arise with a closed soil.
Fig. B.1.2-1: Convenient base
AGT-DC_11000_48V_PMS_eng.R01 - Chapter B: Installation Instructions Page 51 18.12.08
Installation Instructions
B.2 Generator connections - scheme
The generator comes supplied with all supply lines (i.e. electric cables, fuel lines etc.) already connected to the motor and generator. The supply lines are fed through the capsule's front base panel and are shielded at the capsule inlets with water-proof grommets.
All electrical connections, cable types and sizes must comply to the appropriate regulations. The supplied cables are rated for ambient temperatures up to 70°C (160°F). If the cables are required to meet higher temperature requirements, they must be run through conduits.
1
1.
Raw water intake
2.
Connection fuel IN
3.
Connection fuel OUT
4.
Cable for fuel pump
5.
Oil drain hose
6.
Cable for AGT control panel
2
3
4 5
6
7
8 9
10 11
7.
Cable for VCS
8.
Cable for voltage sense (clamp 7+8)
9.
Cable for measuring shunt (clamp 9+10)
10. Cable for starter battery minus (-)
11. Cable for starter battery plus (+)
Fig. B.2-1: Connections
3
1 2 4
1.
In-flow from external cooling water expansion tank
2.
Return to external cooling water expansion tank
3.
Exhaust outlet
4.
Connection external ventilation valve
Fig. B.2-2: Connections
Page 52 AGT-DC_11000_48V_PMS_eng.R01 - Chapter B: Installation Instructions 18.12.08
Installation Instructions
B.3 Cooling system installation - raw water
B.3.1 General references
The genset should have its own raw water (coolant water) inlet and should not be connected to any other engine systems. Ensure that the following installation instructions are complied with:
Avoid galvanic corrosion
For the avoidance of galvanic corrosion the chapter "Service instruction for marine gensets (corrosion protection)“ is to be considered.
B.3.2 Installation of the thru-vessel fitting in Yachts
It is good practice for yachts to use a hull inlet fitting with an integrated strainer. The thru-vessel fitting (raw water intake) is often mounted against the sailing direction to induce more water intake for cooling.
For Panda generators, the thru-vessel inlet should NOT point in the sailing direction! When sailing at higher speeds more water will be forced into the inlet than what the pump can handle and your generator will overflood!
Fig. B.3.2-1: Thru/vessel fitting
B.3.3 Quality of the raw water sucking in line
In order to keep the suction resistance in the line at a minimum, the raw water intake system (i.e.
sea cock, thru-hull fitting, inlet filter, etc.) must have an inner diameter of at least 1" (25mm).
This applies also to installation components such as thru-hull fitting, sea cock, raw water filter etc.
The intake suction line should be kept as short as possible. Install the raw water inlet in close proximity to the genset.
After start-up the cooling water quantity must be measured (e.g. by catching at the exhaust). The flow rate, as well as the necessary cross section of the cooling water pipe
take from section F.1,“Technical data,” on page 93.
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AGT-DC_11000_48V_PMS_eng.R01 - Chapter B: Installation Instructions Page 53
Installation Instructions
B.3.4 Installation above waterline
The Panda is equipped with a direct drive water intake pump mounted directly on the motor.
Since the intake pump is an impeller pump there are wearing parts which will likely require replacement after some time. Ensure that the genset is installed such that the intake pump can be easily accessed. If this is not possible, an external intake pump could be installed in an easily accessed location.
If the generator is installed above the waterline it is possible that the impeller wearout will be stronger. After the start the pump runs dry some seconds.
The raw water hose should describe a loop as near as possible to the raw water inlet of the generator (see picture below). With it the pump only sucks in air for a short time. The impeller will be lubricated by the raw water and its life time will rise.
By the installation of a check valve in the raw water inlet line, which is under the waterline, this problem can be limited a little .
It is very important to change the impeller every few month. When starting the generator you should pay attention and listen when raw water comes out from the exhaust. If this lasts longer than 5 seconds the impeller has to be changed, because he sucks to much air before raw water reaches the impeller and the impeller wears out strongly. In this case the impeller looses its function, which leads to an overheating of the engine.
If the impeller isn’t exchanged early enough, the impeller wings can break into pieces and clog the cooling circuit. Therefore it is very important to change the impeller every few month.
NOTE:
Never change the impeller for many years, without exchanging the old pump. If the sealing ring is defective within the pump, raw water runs into the sound cover of the genset. A repair is then very expensive.
Replacement impeller and also a spare pump should always be on board. The old pump can be sent back to Fischer Panda, where it is then economically overhauled completely.
1. Raw water filter
2. Water cock
3. Hull inlet
Make certain that the raw water filter lies above the water level, otherwise with cleaning water can penetrate by the hull inlet.
An external pre-pump can relieve the impeller.
1
2
3
Fig. B.3.4-1: Raw water filter
Page 54 AGT-DC_11000_48V_PMS_eng.R01 - Chapter B: Installation Instructions 18.12.08
Installation Instructions
B.3.5 Installation below waterline
If the generator can not be attached at least 600mm over the waterline, a vent valve must be installed into the raw water line. With location beside the "midship line" a possible heeling must be considered! The water hose for the external vent valve at the back of the sound cover splits on the pressure side of the pump and at both ends in each case extended with a connecting nipple by a hose end. Both hose ends must be led out outside of the sound cover to one point, if possible 600mm over the waterlinee in the midship line. The valve is connected at the highest place with the two hose ends. If the valve is blocked, the cooling water pipe cannot be ventilated after the stop of the generator, the water column is not interrupted and the water can penetrate into the combustion chamber of the engine. This leads to the destruction of the engine!
Fig. B.1: External ventilation valve
Cut the hose for the external vent valve...
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Fig. B.3.5-1: Connection external ventilation valve
...and bent it upwards.
Both hose ends must be led out outside of the sound cover to one point, if possible
600mm over the waterline in the midship line. The valve is connected at the highest place with the two hose ends.
Fig. B.3.5-2: Connection external ventilation valve
AGT-DC_11000_48V_PMS_eng.R01 - Chapter B: Installation Instructions Page 55
B.3.6 Raw water cooling
Installation Instructions
1. Raw water pump
2. Raw water in
3. Impellerfilter
4. Rectifier
5. Oil cooler
6. Heat exchanger
7. External ventilation valve
8. Raw water out
Fig. B.3.6-1: Raw water cooling system
Page 56 AGT-DC_11000_48V_PMS_eng.R01 - Chapter B: Installation Instructions 18.12.08
Installation Instructions
B.4 The freshwater - coolant circuit
B.4.1 Position of the external cooling water expansion tank
The Panda generator is normally supplied with an additional, external cooling water expansion tank. This tank must be installed in such a way that its lower edge is at least 500mm more highly arranged than the upper edge of the sound cover.
If this 500mm should be fallen below, i.e. the cooling water expansion tank is lower installed, very large problems can occur with filling and ventilating.
Extend and displace the hose lines to the outside or possibly even up to the deck.
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Fig. B.4.1-1: External cooling water expansion tank
ATTENTION! The external cooling water expansion tank may be filled only up to the lower edge of the lower tension tape (see note "max") in the maximum filling level in cold condition.
Anti-freeze
In the interest of safety, the freezing point of the closed circuit coolant should be checked on a
regular basis. Be sure that the coolant/antifreeze mixture is good for at least -15°C (5°F) and if it is possible that your genset experiences lower temperatures, for example during storage or transportation, then the entire cooling system should be drained and purged. To purge the cooling system, compressed air at about 0.5 bar (7.5 psi) is sufficient.
B.4.2 Pressure test for control of cooling water circuit
Check with the hand if a temperature difference exists whether between cooling water in-flow and cooling water return.
Feel the cooling water in-flow line at the internal cooling water pump.
Feel the cooling water return pipe either at the outlet of the water-cooled exhaust elbow union or at the side, where this pipe entry at the heat exchanger.
The temperature difference between in-flow and return is approx 10 degrees.
AGT-DC_11000_48V_PMS_eng.R01 - Chapter B: Installation Instructions Page 57
B.4.3 Scheme for freshwater circuit at two circuit cooling system
Installation Instructions
1. Thermostat housing
2. Internal water pump
3. Heat exchanger
4. Freshwater-cooled exhaust elbow
5. External cooling water expansion tank
Fig. B.4.3-1: Fresh water cooling system
Page 58 AGT-DC_11000_48V_PMS_eng.R01 - Chapter B: Installation Instructions 18.12.08
Installation Instructions
B.5 Watercooled exhaust system
By injecting the outlet raw water into the exhaust manifold, the exhaust gases are cooled and the noise emissions from the exhaust system are reduced.
B.5.1 Installation of the standard exhaust system
The generator exhaust system must remain completely independent and separate from the exhaust system of any other unit(s) on board. The exhaust hose has an inner diameter of 40mm
(1.6") (Panda 14000 and above approx. 50mm). The water lock must be installed at the lowest point of the exhaust system. An optional noise insulated water lock can also be installed. The exhaust hose descends from the capsule to the water lock. Then the hose rises via the "goose neck" to the silencer (see drawing). The goose neck must be vertical and sit preferably along the ship's keel centre line. The exhaust system must be installed so that the back pressure inside the exhaust does not exceed 0.4 bar (6 psi) and total length does not exceed 6m (20 ft.).
Exhaust diameter see section F.1,“Technical data,” on page 93.
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1. Generator
2. Water lock
3. Goose neck
4. Silencer (optional)
5. Hull inlet
Fig. B.5.1-1: Installation stanrd exhaust system - example
AGT-DC_11000_48V_PMS_eng.R01 - Chapter B: Installation Instructions Page 59
Installation Instructions
B.5.2 Exhaust / water separator
The exhaust/water separator
In order to reduce the noise level of the generator unit to a minimum, an optional exhaust outlet muffler mounted next to the thru-hull fitting can be installed. Additionally there is component at
Fischer Panda, which exercise both functions of a "exhaust goose neck", and the water separation. With this "exhaust/water separator" the cooling water is derived over a separate pipe. Thereby the exhaust noises at the exterior of the yacht are strongly decreased. Particularly the "water plash" allocate.
The water flow on the exhaust/water separator unit has an inner diameter (ID) of 30mm. If the path from the water separator to the raw water outlet is very short, the hose can be further reduced to 1" (25mm) ID.
1. Raw water outlet ø 30mm
2. Hose connector ø 30mm
3. Reducer 30/20mm (if required)
4. Hose
5. Hose connector
6. Sea cock
7. Hull outlet
8. Hose clips
Fig. B.5.2-1: Exhaust/water separator
Fig. B.5.2-2: Exhaust/water separator
Page 60 AGT-DC_11000_48V_PMS_eng.R01 - Chapter B: Installation Instructions 18.12.08
Installation Instructions
B.5.3 Installation exhaust/water separator
If the exhaust/water separator was sufficiently highly installed, a goose neck is no longer necessary. The exhaust/water separator fulfills the same function. If the "Supersilent" exhaust system were installed correctly, the generator will not disturb your boat neighbour. The exhaust noise should be nearly inaudible. The best result is reached, if the hose line, which derive the cooling water, is relocate on a short way "falling" directly to the outlet and this outlet is under the waterline.
1 2 3 4
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5
6
1. Generator
2. Silencer / Waterlock
3. Exhaust/water separator
4. Silencer (optional)
5. Sea valve
6. Hull outlet
Fig. B.5.3-1: Installation exhaust/water separator - example
If the thru-hull exhaust outlet has to be mounted far from the generator, an exhaust-water separator must definitely be installed. The raw water from the separator must then run along the shortest possible path is the thru-hull outlet. For such long exhaust routes, the exhaust hose diameter should also be increased from NW40mm to NW50mm in order to reduce the back-pressure. The exhaust may have a length of over 10m (32 ft.) if the exhaust hose diameter is increased to
50mm. An additional outlet exhaust muffler close to the hull outlet will help further to reduce noise emissions.
AGT-DC_11000_48V_PMS_eng.R01 - Chapter B: Installation Instructions Page 61
Example of an unfavorable installation:
- water lock not deeply enough under the hights level of the generator
- distance water lock to exhaust/water separator too largely
Fig. B.5.3-2: Unfavorable installation - example
Installation Instructions
Page 62 AGT-DC_11000_48V_PMS_eng.R01 - Chapter B: Installation Instructions 18.12.08
Installation Instructions
B.6 Fuel system installation
B.6.1 General references
Inside the generator capsule itself, there is the fuel filter installed (Exception Panda 4500). Additional fuel filters (with water seperator) must be mounted outside the capsule in easily accessible places in the fuel lines between the tank intake fuel pump and the diesel motor's fuel pump.
Generally forward and return fuel flow pipes must be mounted to the diesel tanks. Do not connect the generator fuel supply lines with any other fuel lines of other diesel systems.
The following items need to be installed:
- Fuel supply pump (12V-DC)
- Pre-filter with water separator (not part of the delivery)
- Fine particle fuel filter
- Return fuel line to fuel tank (unpressurized)
The fuel supply pump should be mounted as close to the fuel tank as possible. The electric cable for the fuel pump is already installed on the generator (length 5m).
1 2 3
4 5
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1. Generator
2. Fuel stopcock
3. Fuel filter
4. Fuel return
6
8
7
5. Condensation water suction pump
6. Fuel tank
7. Fuel supply
8. Electrical fuel pump (12V-DC)
Fig. B.6.1-1: Installation fuel system - example
AGT-DC_11000_48V_PMS_eng.R01 - Chapter B: Installation Instructions Page 63
Installation Instructions
B.6.2 The electrical fuel pump
Electrical fuel pump
With the Panda generator is usually supplied an external, electrical fuel pump (12V
DC). The fuel pump must be installed close at the fuel tank. The electrical connections are preloaded at the generator with the lead planned.
Fig. B.6.2-1: Fuel pump
• Suction hight of the pump: max. 1,2m at 02, bar
• Diameter of fuel lines: section F.1,“Technical data,” on page 93.
B.6.3 Connection of the fuel lines at the tank
Lead the return fuel pipe connected to the day tank to the floor
The return pipe connected to the tank must be dropped to the same depth as the suction pipe, if the generfator is mounted higher than the tank, in order to prevent fuel running back into the tank after the motor has been switched off, which can lead to enormous problems if the generator is switched off for a long period.
Non-return Valve in the Suction Pipe
A non-return valve must be fitted to the suction pipe, which prevents the fuel flowing back after the generator has been switched off, if it is not possible to use the return flow pipe as a submerge pipe be placing it in the tank. The instructions "Bleeding Air from the Fuel System" must be read after initial operation or after it has stood still for a long period, in order to preserve the starter battery.
ATTENTION! Non-return valve for the fuel return pipe
If the fuel tank should be installed over the level of the generator (e.g. daily tank), then a non-return valve must be installed into the fuel return pipe to guaranteed that through the return pipe no fuel is led into the injection pump.
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Installation Instructions
B.6.4 Position of the pre-filter with water separator
Additionally to the standard fine filter a pre-filter with water separator must be installed outside of the sound cover in the fuel system line. (is not included in delivery.)
Fig. B.6.4-1: Fuel filter
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Installation Instructions
B.7 Generator 12V DC system-installation
The Panda has its own dynamo to charge a 12V starter battery.
It is recommended to install an additional starter battery for the generator.
The generator is then independent from the remaining battery set. This enables you to start the genset at any time with its own starter battery even if the other batteries are discharged. A further advantage of a separate starter battery is that it isolates the generator’s electric systemfrom the the rest of the boat's DC system, i.e. minus pole (-) is not conected electrically to Earth/Ground.
The generator is then Earth/Ground free with regard to the rest of the boat.
B.7.1 Connection of the 12V starter battery
systems) comply with all required regulations of the regional authorities. This includes lightnening conductor, personal protection switch etc.
The positive (+) battery cable is connected direcly to the solenoid switch of the starter.
Fig. B.7.1-1: Connection positive battery cable
The negative (-) battery cable is connected to the engine foot.
Fig. B.7.1-2: Connection negative battery cable
Page 66 AGT-DC_11000_48V_PMS_eng.R01 - Chapter B: Installation Instructions 18.12.08
Installation Instructions
B.7.2 Installation Panda AGT 48V-system
systems) comply with all required regulations of the regional authorities. This includes lightnening conductor, personal protection switch etc.
1
9
8
9
8
4
5
7
2
3
6
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1. Generator
2. Battery block 48V
DC
3. Battery monitor
4. Fuel pump
5. AGT control panel
6. Voltage control VCS 48V
DC
7. Starter battery 12V
DC
8. Fuse
9. Battery switch
Fig. B.7.2-1: Installation DC-system - example
All electrical safety installations have to be made on board.
AGT-DC_11000_48V_PMS_eng.R01 - Chapter B: Installation Instructions Page 67
Installation Instructions
Electrical fuses
It is absolutely essential that the electrical system installation is inspected by a qualified electrical technician. The generator should have its own AC input electrical fuses. The fuses should be sized such that the rated current of the generator on each of the individual phases is not exceeded by more than 25%.
Data for gensets with power output greater than 30kW on request!
The fuses must be of the slow type. A 3-way motor protection switch must be installed to protect the electrical motor.
Required cable cross-sections
The following recommended electrical cable dimensions (cross sections) are the minimum requi-
red sizes for a safe installation. (see section F.1,“Technical data,” on page 93.)
B.7.3 Voltage control system - See VCS datasheet
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.
Page 68 AGT-DC_11000_48V_PMS_eng.R01 - Chapter B: Installation Instructions 18.12.08
Maintenance Instructions
C. Maintenance Instructions
ATTENTION! Before working on the System read the section “Safety Precautions,” on page 10.
C.1 General maintenance instructions
C.1.1 Checks 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 month
• Lubrication of actuator-trapezoid thread spindle
For Maintenance Intervalls see section F.3, “Engine oil specification,” on Page 100.
C.1.2 Hose elements and rubber formed component in the sound cover
Check all hoses and hose connections for good condition. The rubber hoses are very sensitive to enviromental influences. They can season fast with dry air, in which environment of muted oil and fuel steams and increased temperature. The hoses must be checked regularly for elasticity.
There are operating situations, at which the hoses must be renewed once in the year.
Additionally to usual tasks of maintenance (oil level check, oil filter control etc.) further maintenance activities are to be accomplished for marine gensets. It belongs control of the sacrificial anode (cooling water connection block) and the front seal cover at the generator.
C.2 Oil circuit maintenance
The first oil change is to be accomplished after a period of operation from 35 to 50 hours. Afterwards the oil is to be changed after 100 hours. For this the oil SAE30 for temperatures over 20°C and SAE20 for temperatures between 5°C and 20°C is to be used. At temperatures under 5°C oil of the viscosity SAE10W or 10W-30 is prescribed.
Type and amount of required oil see:
See section F.4, “Coolant specifications,” on Page 101 and section F.1, “Technical data,” on
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Maintenance Instructions
C.3 Oil change procedure
Oil drain hose
Open the passage for the oil drain hose and pull out the hose.
Fig. C.3-1: Oil drain hose
Oil drain screw
The oil can be discharged by opening the oil drain screw. For countering use a second wrench.
Fig. C.3-2: Oil drain screw
Oil drain pump
If discharging of the oil is not possible, we recommend the employment of a hand pump, which can be attached to the oil drain hose.
Afterwards the oil drain screw is closed again.
Fig. C.3-3: Oil drain pump
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17
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Maintenance Instructions
Oil filter change
The oil filter can be loosen with an oil filter strap.
Fig. C.3-4: Oil filter
Oil filter gasket
Before the insertation of the new oil filter the gasket should be coated with something oil.
Tighten the oil filter only by hand.
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Fig. C.3-5: Oil filter
Open the oil filler neck
After opening the cap of the oil filler neck the new oil is refilled.
Please wait instant, before measure the oil level, the oil must set off in the sump.
Fig. C.3-6: Oil filler neck
AGT-DC_11000_48V_PMS_eng.R01 - Chapter C: Maintenance Instructions Page 71
Maintenance Instructions
Oil dipstick
With the help of the engine oil dipstick the oil level is to examined. The prescribed filling level may not exceed the „Max“ marking.
Fischer Panda recommends 2/3 oil level.
Fig. C.3-7: Oil dipstick
C.4 Ventilating 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 ventilated 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“. Functional components must illuminate.
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).
Fig. C.4-1: Failure bypass switch
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Maintenance Instructions
18.12.08
3. After the fuel pump has been running 3 to 4 minutes because the failure bypass switch has been pushed down the ventilation 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 ventilation screw can be screwed in again.
Now stop pushing the failure bypass switch.
10
Fig. C.4-2: Ventilation screw - fuel solenoid valve
4. Now the unit can be started by pushing the "START"-button. The unit should start after a short while.
5. Should the unit not start the pipe union nuts of the injection nozzles has to be loosen and try again to start the unit.
After the unit has started the pipe union nut has to be tightened again.
6. Main power switch "OFF".
17
Fig. C.4-3: Injection nozzle
C.4.1 Replace the fuel filter
The replace of the filter depends on the contamination of the fuel, should take place at least all 300 operation hours.
Before the replace 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.
Fig. C.4-1: Fuel filter
AGT-DC_11000_48V_PMS_eng.R01 - Chapter C: Maintenance Instructions Page 73
C.4.2 Checking the water separator in the fuel supply
The pre-filter with water separator has a cock at its lower surface, with this cock the downward sunk water can be discharged.
This is simply possible, water is heavier due to its density than the Diesel.
Fig. C.4-1: External fuel filter with water separator
C.5 Replace the air filter
Open the air suction housing by loosen the two snap fastenings and remove the cover.
Maintenance Instructions
Fig. C.5-1: Open air suction housing
Remove the main element with a light turning movement completely from the inner support pipe.
Clean the main element, by blowing out the main element with dry compressed air
(max. 5 bar) or replacing at the latest after one year.
Installation in reverse order.
Fig. C.5-2: Remove main element
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Maintenance Instructions
C.6 Ventilating of the coolant circuit / freshwater
Special notes for the ventilation of the cooling system
If the cooling water is drained or if other air should have arrived into the cooling system, it is necessary to ventilate the cooling system. This ventilation procedure must be repeated several times:
ATTENTION ! Before opening the venilation points the generator must be stagnant !!!
Pay attention that the external coolant expansion tank is connected with the generator by the two intended connection points.
Further it should be guatanteed that the expansion tank is attached in sufficient height (600mm) over the level of the generator exhaust elbow union.
Fig. C.6-1: External coolant expansion tank
Open ventilation screw at the cooling water pump.
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10
Fig. C.6-2: Ventilation screw - water pump
Open venlation screw at the thermostat housing.
10
Fig. C.6-3: Ventilation screw - thermostat housing
AGT-DC_11000_48V_PMS_eng.R01 - Chapter C: Maintenance Instructions Page 75
Maintenance Instructions
Now the cooling water is only filled over the external expansion tank. This is connected by 2 hoses with the genset.
The external expansion tank should be filled in the cold condition only up to maximally
20%. It is very important that a large extension space over the cooling water level remains.
Repeat this procedure several times.
If no change of the cooling water level can be determined, the generator is started for 5 minutes.
Afterwards repeat the ventilation two - three times.
It is meaningful to repeat the ventilation procedure also after some days again to guarantee that in the system remained bubbles are removed.
The ventilation screw over the housing of the cooling water pump may be opened under no circumstances, while the generator runs. If this happens inadvertently, through the opening air is sucked in. A very complex ventilation of the entire system is necessary thereafter.
Fig. C.6-4: entilation screw - water pump
C.6.1 Draining the coolant
In principle only describes here, how the cooling water of the raw water cycle can be drained. The mixture of the fresh water circuit should not be drained in principle. See measures for the preparation of the winter storage.
The simplest and cleanest method consists of the fact to bring the external vent valve below the generator level and hold over a collecting basin. Open the valve now, the water from the raw water circuit flows downward into the container.
C.7
Replace the v-belt
for the internal cooling water pump
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.
Page 76 AGT-DC_11000_48V_PMS_eng.R01 - Chapter C: Maintenance Instructions 18.12.08
Maintenance Instructions
Loosen the fixing screw above the alternator.
Fig. C.7-1: Fixing screw - DC-alternator
Loosen the fixing screw below the alternator only a little bit.
13
12
Fig. C.7-2: Fixing screw - DC-alternator
Press the alternator to the direction of the thermostat housing.
Now the v-belt can be changed (type: XPZ
850-2).
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Fig. C.7-3: V-belt
AGT-DC_11000_48V_PMS_eng.R01 - Chapter C: Maintenance Instructions Page 77
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.
Fig. C.7-4: V-belt
C.8 The raw water circuit
C.8.1 Clean raw water filter
The raw water filter should be released regularly from arrears. In each case the water cock must be closed before. It is mostly sufficient to beat the filter punnet.
If water should seep through the cover of the raw water filter, this may be sealed in no case with adhesive or sealant. Rather must be searched for the cause for the leakage. In the simplest case the sealing ring between caps and filter holders must be exchanged.
Fig. C.8.1-1: Raw water filter
Page 78 AGT-DC_11000_48V_PMS_eng.R01 - Chapter C: Maintenance Instructions
Maintenance Instructions
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Maintenance Instructions
C.8.2 Causes with frequent impeller waste
The impeller of the cooling water pump must be regarded as wearing part. The life span of the impeller can be extremely different and exclusively depends on the operating conditions. The cooling water pumps of the PANDA generators are laid out in such a way that the number of revolutions of the pump lies low compared with other gensets. This is for the life span of the pump a positive effect.
Unfavorably affects the life span of the impeller, if the cooling water sucking in way is relatively long or the supply is handicapped, so that the cooling water sucking in range develops a negative pressure. This can reduce first of all the power of the cooling water pump extremely that the wings of the impeller are exposed to very strong loads. This can shorten the life span extremely.
Further the operation of the impeller pump loaded in waters with a high portion of suspended matters. The use of the impeller pump is particularly critical in coral waterbodies. Cases are wellknown, which a impeller pump had so strongly run after 100 hours already that the lip seal on the wave was ground in. In these cases sharp crystal parts of the coral sand assess in the rubber seal and affect like an abrasive the high-grade steel shank of the impeller pump.
If the generator were mounted over the water level it is particularly unfavorable for the impeller pump. After the first start some seconds will pass by, until the impeller can suck in cooling water.
This short unlubricated operation time damages the impeller. The increased wear can lead after short time to the loss. (see special notes: "Effects on the impeller pump, if the generator is mounted over the waterline")
C.8.3 Replace the impeller
Close the raw water stop cock.
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Fig. C.8.3-1: Raw water stop cock
AGT-DC_11000_48V_PMS_eng.R01 - Chapter C: Maintenance Instructions Page 79
Raw water pump on the front side of the genset.
Fig. C.8.3-2: Raw water pump
Remove the cover of the raw water pump by loosen the screws from the housing..
Fig. C.8.3-3: Raw water pump
Mark the impeller, to make sure that these is used in the correct position at re-installation.
Pull to the impeller with a multigrip pliers of the wave.
Fig. C.8.3-4: Impeller
Page 80 AGT-DC_11000_48V_PMS_eng.R01 - Chapter C: Maintenance Instructions
Maintenance Instructions
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Maintenance Instructions
Check to the impeller for damage and replace it if necessary.
Before the reinsertion into the housing the impeller should have been lubricated with glycerin or with a non-mineral oil based lubricant e.g. silicone spray.
Fig. C.8.3-5: Impeller
The impeller is attached to the pump wave
(if the old impeller is used, pay attention to the before attached marking).
.
Fastening the cover and use a new seal.
Fig. C.8.3-6: Gasket
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AGT-DC_11000_48V_PMS_eng.R01 - Chapter C: Maintenance Instructions Page 81
Maintenance Instructions
C.9 Additional maintenance
Furthermore in addition to the standards checks according to the manual following points of the generator have to be checked:
• automatic shut down of the generator in case off high heating temperature
This shall be done by disconnecting the thermo-switch of the heat sink. Next to the rectifier you will find a 2-pole connector. If you disconnect this connector from the opposite socket, the generator shall shut down – or, when the generator is not running you will get a signal on the panel.
Fig. C.9-1: Rectifier
Temperatures of the rectifier and heating
• Apply a thermocouple meter to the heat sink and the copper bars and monitor the maximum temperatures of the rectifier.
• With the help of the infrared thermometer you can check all the temperatures on the rectifier.
Check all the cable connections of the DC- wiring. The easiest is to touch them carefully with your finger. If they are getting warm or getting hot, these connections are poor and shall be replaced.
The temperature of the heat sink shall never exceed 95°C.
The temperature of the copper bars shall never exceed 120°C
Ensure, that a fuse next to the battery is installed in the battery line for the generator output cable.
Ensure that a battery switch is installed in the battery line. Never leave the generator behind without the cover mounted over the heat sink and capsule not closed.
Remind the customer
• to run the generator only with closed capsule.
• not to run the generator unattended
• to ask for regular service
Page 82 AGT-DC_11000_48V_PMS_eng.R01 - Chapter C: Maintenance Instructions 18.12.08
Maintenance Instructions
C.10 Conservation at longer operation interruption
C.10.1Measures on preparation of the winter storage
1. Rinse raw water circuit with an anti-freeze solution, even if this contains a corrosion protection means. The raw water inlet must be removed at the water cock. Over a hose connector the anti-freeze protection mixture is to be sucked in from a container. The leaked cooling water with the exhaust is to be led back into the sucking in container. The circuit must be kept upright some minutes to guaranteed that the anti-freeze protection mixture reaches all ranges of the cooling system.
2. The concentration of the anti-freeze mixture in the internal cooling circuit must be checked with a suitable measuring instrument. The concentration must be furnished according to the lowest temperatures which can be expected.
3. Clean raw water filter and check seal.
4. Check water cock for practicability. And spray with a corrosion protection oil from the inside or lubricate with acidless grease.
5. Check all hoses and hose connectors for good condition. The rubber hoses are very sensitive to enviromental influences. They can age fast with dry air, in environment of light oil and fuel steams and increased temperature. The hoses must be checked regularly for elasticity. There are operating situations, which the hoses must be renewed once in the year.
6. Check the hose connectors at all raw water valves doubly and if possible protect them with double hose clamps.
7. Dismount the impeller of the cooling water pump and check for wear. The impeller may not remain in the pump. It must be greased with vaseline and be kept at a dark place. It can be reintragrated in the spring again into the pump, if it is in good condition. The impeller is a wearing part, it is recommended to renew it always in the spring, independently how many operating hours the genset ran.
8. Control of the vent valve at the raw water inlet. If the generator is installed below the waterline, always a vent valve is necessary. The vent valve must be checked also during the season regularly. In the winter storage the vent valve should always be disassembled, checked and greased. Hardens or got parts dirty are to be replaced.
9. Check water lock: If the generator were rinsed with an anti-freeze mixture, the antifreeze mixture can leave in the water lock. If the generator were rinsed with fresh water, the water in the water lock must be drained. Otherwise the danger exists that the collector is blown up and destroyed by ice.
10.Check the exhaust/water separator on leakage and if the hose connectors at the lower surface of the separation unit are in normal condition. (with extremely sulfureous fuels it is possible that also high-grade steel tube ends are attacked.)
11. Check all construction units at the generator inside the sound cover for leakages. If there are traces of humidity in the sound cover, the cover must be dried. Further the cause for the wetness must be surched and eliminated.
12.During the winter storage the upper section of the sound cover must be taken off, in order to avoid condensed moisture formation, if traces of humidity remain in the sound cover inside casing by leakages in the raw water circuit.
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AGT-DC_11000_48V_PMS_eng.R01 - Chapter C: Maintenance Instructions Page 83
Maintenance Instructions
C.10.1Measures on preparation of the winter storage
13.The generator housing and the housing of the engine should be sprayed with a corrosion protection oil before the winter storage. This procedure is recommended also in the season. This procedure can avoid that arising and humidity marks on the surface of the aluminum construction units be noticed too late.
14.Disconnect the starter battery (positive and negative pole).
15.Lubricate the spindle for the number of revolutions adjustment device with a special lubricant
(Antiseize grease).
16.Check cooling water connection block at the generator housing on traces of corrosion and if necessary renew. (only such traces are to be considered, which refer to clear "blossoming" of the material. If the surface is only grey coated, this is only an indication for the fact that aluminum came into contact with condensed moisture.)
17.Use of a air dehumidifier. The best way to protect a yacht in the winter storage against damage by humidity is, to places a air dehumidifier inside the ship and locks all hatches. The devices have a hygrometer, which switches the device off, if the humidity is under the adjusted value. There is no better method, in order to protect pads, cable, electronics, wood, engines etc. optimally against any rotting by humidity.
C.10.2Initiation at spring
• Before the first start turn the engine once with the hand, in order to eliminate necessary existing corrosion beginnings in the bushing. If necessarily carry out normal engine inspection.
• Change engine oil and engine oil filters.
• Reintegrate the impeller of the cooling water pump and check pump for leakage.
• Charge starter battery of the generator, connect cables and check battery voltage.
• Start generator and check the basic adjustments of the generator such as voltage, speed regulation etc..
• Check all switching off devices for function by operational procedures.
Fischer Panda does not take over adhesion for possible damages!
Page 84 AGT-DC_11000_48V_PMS_eng.R01 - Chapter C: Maintenance Instructions 18.12.08
Maintenance Instructions
C.11 Replace the water pump
1. Unscrew the water pump mounting screws (2), and remove the water pump (1) from the gear case cover. Use a spanner size 10mm.
When reassembling
• Apply liquid-type gasket (Three Bond 1215 or its equivalent) to both sides of the new water pump gasket.
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1. Water pump body 2. Hexagon head screw
Fig. C.11-1: Water pump
AGT-DC_11000_48V_PMS_eng.R01 - Chapter C: Maintenance Instructions Page 85
C.12 Replace the valve cover gasket
1. Remove the valve cover cap nuts (3). Use a spanner size 10mm.
2. Remove the valve cover (1).
3. Check to see that the valve cover gasket (2) is defective.
4. Replace the valve cover gasket (3) with a new one.
5. Install the valve cover (1), using care not to damage the o-ring.
6. Tighten the valve cover cap nuts (3). Tighten torque: 3,9 to 5,9Nm.
Maintenance Instructions
1. Valve cover
2. Valve cover gasket
3. Hexagon cap nut
Fig. C.12-1: Valve cover
Page 86 AGT-DC_11000_48V_PMS_eng.R01 - Chapter C: Maintenance Instructions 18.12.08
Maintenance Instructions
C.12.1Adjustment of the valve clearance
Valve Clearance
Important: Valve clearance must be checked and adjusted when engine is cold.
1. Remove the head cover
2. Align the „1TC“ mark on the flywheel and projection (1) on the housing so that the No. 1 piston comes to the compensation or overlap top dead center.
3. Check the following valve clearance marked with „O“ using a feeler gauge.
4. If the clearance does not compare with the factory specification, adjust with the adjusting screw.
Valce clearance Factory spec.
0.1,45 to 0.185 mm
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1. Projection
2. TC Mark Line
3. Valce Clearance
Fig. C.12.1-1: Valve Clearance
Note:
• The „TC“ marking on the flywheel is just for No. 1 cylinder. There is no „TC“ marking for the other cylinders.
• No. 1 piston comes to the T.D.C. position when the „TC“ marking is aligned with the projection in the window on flywheel-housing. Turn the flywheel 15° (0.26 rad.) clockwise and counterclockwise to see if the piston is at the compression top dead center or the overlap position. Now referring to the table below, readjust the valve clearance. (The piston is at the top dead center when both the IN. and EX. valve do not move; it is at the overlap position when both the valves move.)
• Finally turn the flywheel 360° (6.28 rad.) to ali gne the „TC“ marking and the projection perfectly.
Adjust all the other valve clearances as required.
• After turning the flywheel counterclockwise twice or three times, recheck the valve clearance.
• After adjusting the valve clearance, firmly tighten the lock nut of the adjusting screw.
AGT-DC_11000_48V_PMS_eng.R01 - Chapter C: Maintenance Instructions Page 87
Cylinder No.
Valve arrangement
Adjustable cylinder
Location of piston
When No. 1 piston is compression dead center top
1st
2nd
3rd
4th
When No. 1 piston is overlap position
1st
2nd
3rd
4th
2 cylinder
IN.
EX.
O
O
O
O
3 cylinder
IN.
EX.
O
O
O
O
O
O
O
O
O
O
O
O
4 cylinder
IN.
EX.
O
O
O
O
Maintenance Instructions
Page 88 AGT-DC_11000_48V_PMS_eng.R01 - Chapter C: Maintenance Instructions 18.12.08
Generator Failure
D. Generator Failure
ATTENTION! Before working on the System read the section “Safety Precautions,” on page 10.
D.1 Overloading the generator
Please ensure that the genset is not overloaded. An overload in the long term can harm the engine. In addition the exhaust gases are soot-blackened (environment).
The full rated output of the generator is primarily intended for brief use.
80% of the nominal load are calculated as constant load should be in the interest of a long life span of the engine.
D.2 Starting problems
D.2.1 Fuel solenoid valve and stop solenoid
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.
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AGT-DC_11000_48V_PMS_eng.R01 - Chapter D: Generator Failure Page 89
01. Fuel solenoid valve
02. Fuel injector pipe
03. Ventilation screw
Stop solenoid for engine stop
Fig. D.2.1-1: Fuel solenoid valve
02
01
03
Generator Failure
Fig. D.2.1-2: Stop solenoid
Page 90 AGT-DC_11000_48V_PMS_eng.R01 - Chapter D: Generator Failure 18.12.08
Generator Failure
D.2.2 VCS does not work - See VCS datasheed for details
For start problems one chief cause is that the VCS doen not work. Check:
Is the shunt connection ok? Check polatrity!
Is the main supply connection ok? Check polatrity!
Does DP+ (VCS ON) lie on clamp 6 of the plug with 6 pins?
Checking the fuse on the VCS printed circuit board.
D.2.3 Dirty fuel filter
If the fuel filter is dirty change the filter element.
For replacing the filter element see
section C.4.1, “Replace the fuel filter” on page 73.
01. Filter element
This protects the injection pump. No water will go thru the filter. If water reaches the filter it will block the fuel flow even if the filter looks clean
01
Fig. D.2.3-1: Fuel filter
D.2.4 Fuse on control panel board
It is possible, that the fuse on the control panel board is defective. Change the fuse if it is defective.
01. fuse on the control panel board
(630mA, slow to blow)
01
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Fig. D.2.4-1: AGT control panel back side
AGT-DC_11000_48V_PMS_eng.R01 - Chapter D: Generator Failure Page 91
D.2.5 Failure bypass switch
ATTENTION:
If the generator switches itself off at operation for temperature reasons, it must be examined immediately, which the cause is. That can be an error at the cooling system, drive belt or any error in the range of the outside cooling system. With cooling water loss: Errors locate and cooling water refill.
After the error was repaired, the lying error message (e.g. by temperature rise) can be bridged with failure bypass switch. As long as the switch is held down, the error messages are switched off. The generator can be started then over the remote control panel. If the generator switched off by temperature rise, the operating temperature can be lowered in this way by a short running time
(natural without load), so that the error message releasing switches decreases/goes back again into the starting position.
01. Failure bypass switch
Generator Failure
01
Fig. D.2.5-1: Failure bypass switch
D.2.6 Troubleshooting table
For Troubleshooting see section F.2, “Troubleshooting” on page 96.
Page 92 AGT-DC_11000_48V_PMS_eng.R01 - Chapter D: Generator Failure 18.12.08
Tables
F. Tables
F.1
Technical data
F.1.1 Technical data engine
Model
Type
No. cylinders
Bore [mm]
Stroke [mm]
Total displacement [ccm]
Combustion chamber
SAE NET intermittent (SAE J1349) at 3600rpm [kW]
SAE NET continuous (SAE J1349) at 3600rpm [kW]
Maximum bare speed [rpm]
Minumum bare idling speed [rpm]
Order of firing
Direction of rotation
Injection pump
Injection pressure
Injection timing (before T.D.C)
Compression ratio
Fuel
Lubrication (API classification)
Dimension (length x width x height) [mm]
Dry weight (BB spec.) [kg]
Starting system
Valve clearance (engine cold) [mm]
Cylinder head cover screw torque [Nm]
Lubrication oil capacity [l] (oil pan)
Fuel consumption a
[l]
Oil consumption
Permissible max. permanent tilt of engine
Kubota D 902
Vertical, water-cooled, 4-cycle diesel engine
3
72
73,6
898
Spherical type (E-TVCS)
17,5
15,2
3850
900 to 1000
1-2-3
Counter-clockwise (viewed from flywheel side)
Bosch MD type mini pump
13,73 MPa, 1991 psi (140kgf/cm²)
20°
24 : 1
Diesle fuel No. 2-D above CF grade
467 x 421 x 544
72
Cell starter (with glow plug)
0,145 to 0,185
37,3 to 42,2
3,7
1,1 - 3,0 max. 1% of fuel consumption a) 25° acr oss the longitudinal axis b) 20° in the longitudinal direction
Table 1: Technical data engine a. 0,35l/kW electrical power, the randomized values between 30% and 80% of the power rating.
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AGT-DC_11000_48V_PMS_eng.R01 - Chapter F: Tables Page 93
F.1.2 Technical data generator
Generator
Generator type
Winding type
Wiring mode
Protection mode
Insulation class
Nominal voltage
Frequency
Nominal speed
Max. current
Apparent power
Real power
Power factor
Table 2: Technical data generator
AGT-DC 11000 PMS
PM-Synchronous Generator
AGT
3~
IP 44
H
56,7 V
426 Hz
-> 3200 rpm
187 A
10,6 kVA
10,6 kW
1,0 for 48V battery system
Tables
Page 94 AGT-DC_11000_48V_PMS_eng.R01 - Chapter F: Tables 18.12.08
Tables
Generatortype
Panda PMS AGT-DC
11000
Ø Cooling water conduit
Fresh water Raw water
[mm]
25
[mm]
25
Ø Exhaust con-
Table 3: Diameter of conduits
duit
[mm]
40
Ø Fuel conduit
Supply Return
[mm]
8
[mm]
8
6
10
16
25
1
1,5
2,5
4
35
50
70
95
120
Wiring.
single phase, not tin-plated, PVC-isolated.
nominal wire cross-section
[mm²]
54
73
98
129
19
24
32
42
158
198
245
292
344
allowed conrinuous current (reference point) a at +30°C [A] at +50°C [A]
38,3
51,8
69,6
91,6
13,5
17,0
22,7
29,8
112
140
174
207
244
Table 4: Cable cross-section a. DIN VDE 0298, part 4.
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AGT-DC_11000_48V_PMS_eng.R01 - Chapter F: Tables Page 95
F.2
Troubleshooting
GENERATOR OUTPUT VOLTAGE TOO LOW
If the generator delivers less than 24V current ("undervoltage"), there can be various reasons for this:
Cause
Generator is overloaded.
Solution
Reduce the electrical load. (Switch off load)
Motor is not reaching the rated rpm.
Actuator is not in maximum position.
VCS-voltage controler defective or wrong adjusted.
Refer to "motor faults" section.
Check actuator resp. renew.
Check resp. renew.
GENERATOR VOLTAGE TOO HIGH (MORE THAN 24V)
The following reasons may be the cause, if the generator delivers more than 24V ("overvoltage"):
Cause
The engine is running at the wrong speed.
Solution
Check the speed of the motor with a rev or frequency counter, set the correct speed.
VCS-voltage controler defective or wrong adjusted.
Actuator defective.
Check resp. renew.
Check resp. renew.
GENERATOR VOLTAGE FLUCTUATES
Cause
1. Fault or defect on the load side.
2. A motor fault.
Solution
1. Check if the power requirement of the load fluctuates.
2. See "Motor running irregularly".
MOTOR DOES NOT TURN OVER WHEN STARTING
Cause
Battery main switch is switched off.
Battery voltage not sufficient.
Starting current fault.
Solution
Check the position of the battery main switch, if necessary switch on..
Check that connection is firm and whether corrosion has occurred..
The voltage of full batteries fall to a maximum of 11V.
The wiring is severed if the voltage does not drop. The battery is discharged if the voltage drops further.
Tables
Page 96 AGT-DC_11000_48V_PMS_eng.R01 - Chapter F: Tables 18.12.08
Tables
MOTOR TURNS OVER BUT DOES NOT START
Cause
Stop solenoid valve not opening.
Fuel pump does not operate.
Lack of fuel.
Glow-plugs not working correctly.
Too much air in fuel lines.
Fuel filter blocked.
Low compression pressure.
Solution
Check wire connections and circuitry to solenoid valve.
(ref. DC wiring diagram: Relay K2, Fuse)
Check fuel-filter and pump: clean if necessary.
Check fuel supply.
Check glow plugs and heating time.
Test fuel system for leakage. Bleed air from fuel system
(refer to section "Air-bleeding of the Fuel System").
Replace fuel filter.
See Kubota motor-manual.
MOTOR DOES NOT TURN OVER AT THE NORMAL SPEED DURING THE STARTING PROCESS
Cause Solution
Starter battery voltage insufficient.
Damaged bearing(s) piston (seized).
Check battery.
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.
MOTOR RUNS IRREGULARLY
Cause
Faulty centrifugal injector governor.
Too much air in fuel lines.
Solution
Have the centrifugal governor inspected by a Kubota-
Service technician.
Bleed air from fuel system.
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AGT-DC_11000_48V_PMS_eng.R01 - Chapter F: Tables Page 97
DROP IN THE SPEED OF THE MOTOR
Cause
Too much oil.
Lack of fuel.
Lack of intake air.
Generator overloaded by too many load.
Generator overloaded by over-energizing.
Defective generator (windings, bearings, or other).
Damaged engine.
Solution
Drain oil.
Check fuel supply system:
- fuel filter, renew if necessary
- check fuel pump
- check fuel lines (bleed if necessary)
Check air intake paths.
Check and clean air filter (and intake muffler if installed).
Reduce the electrical load (switch off load).
Check that the proper capacitor type is installed and that they are connected correctly.
Generator must be sent to manufacturer for repair of damaged bearings or winding.
Repair of bearing damage, etc., by Kubota-Service.
MOTOR SWITCHES ITSELF OFF
Cause Solution
Fuel solenoid valve or throttle shut solenoid is not switching off.
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
Check fuel supply system.
Lack of fuel.
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).
Check oil-level and if necessary top up.
Check motor's oil-pressure and have repaired by
Kubota-Service if necessary.
Tables
Page 98 AGT-DC_11000_48V_PMS_eng.R01 - Chapter F: Tables 18.12.08
Tables
SOOTY, BLACK EXHAUST
Cause
Generator is overloaded.
Insufficient intake air.
Fuel injector nozzles faulty.
Valve clearance incorrect.
Poor fuel quality.
Poor combustion.
Low compression pressure.
Solution
Check electrical load and switch off unnecessary load.
Check intake air filter; clean if necessary.
Replace injector nozzles.
Readjust valve clearance to correct value (refer to
Kubota-manual).
Use better quality diesel (recommended: 2-D Diesel).
Incorrect AFR (air/fuel ratio) due to motor timing adjustment. Have motor serviced by Kubota.
See Kubota motor manual.
GENERATOR MUST BE SHUT OFF IMMEDIATELY IF:
Cause
- motor rpm suddenly rises or drops
- unusual noise comes from genset
- exhaust colour suddenly becomes dark
- motor overheats
- oil pressure drops, oil light suddenly flashes
Solution
Refer to respective section of manual and if necessary, have repaired by Kubota-Service, or Panda representative.
TROUBLESHOOTING VCS SYSTEM
Cause
Actuator does not move.
Solution
Check voltage supply and wire connections to actuator.
Motor connected?
Check connection to VCS.
Actuator sets throttle too high or too low.
Check that the wires to the actuator are connected properly (±).
Check 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.
Loosen the connecting rods motor from the injection pump regulator and turn screw to a max. voltage of 33V.
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AGT-DC_11000_48V_PMS_eng.R01 - Chapter F: Tables Page 99
F.3
Engine oil specification
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 quality.
Examples for diesel engine oil:
API CG Engine oil for highest demands, turbo-tested above 25°C
0°C to 25°C below 0°C
Engine oil types
SAE30 or SAE10W-30; SAE10W-40
SAE20 or SAE10W-30; SAE10W-40
SAE10W or SAE10W-30; SAE10W-40
Tables
Page 100 AGT-DC_11000_48V_PMS_eng.R01 - Chapter F: Tables 18.12.08
Tables
F.4
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.
Fischer Panda recommend to use the product: GLYSANTIN PROTECT PLUS/G 48.
Engine coolant automotive industry Product description
Product name GLYSANTIN ® PROTECT PLUS / G48
Chemical nature
Physical form
Monoethylenglycol with inhibitors
Liquid
Chemical and physical properties
Reserve alkalinity of 10ml
Density, 20°C
ASTM D 1121
DIN 51 757 procedure 4
13 – 15 ml HCl 01 mol/l
Water content pH-value undiluted
DIN 51 777 part 1
1,121 – 1,123 g/cm
3 max. 3,5 %
7,1 – 7,3
Water/antifreeze
70:30
65:35
60:40
55:45
50:50
Coolant mixture ratio
Temperature
-20°C
-25°C
-30°C
-35°C
-40°C
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AGT-DC_11000_48V_PMS_eng.R01 - Chapter F: Tables Page 101
F.5
Dimensions
Tables
Page 102 AGT-DC_11000_48V_PMS_eng.R01 - Chapter F: Tables
Fig. F.5-1: Dimensions
18.12.08
Panel AGT Control Manual
Art Nr. 21..02.02.003H
Art.Nr. 21.02.02.006H
Fischer Panda GmbH
Aktuell:
Replace
Revision
Revision status
Document
Panel AGT Control_Kunde_eng.R03 vom 18.12.08
Panda AGT Control_Manual.R02
Page
Hardware and Software revision
After turning on the panel the welcome screen will show the software revision. The hardware revision is printed on the reverse side of the panel
Attention: Please note the safety remarks in your generator manual
104
General operation
A. General operation
A.1 Panel AGT Control 145x100mm
01
02
03 04
05
06
07
08
09 10
01. LED for temp. green/red
1
02. LED for oil pressure green/red
1
03. LED for fault green/red
1
04. LED for mode Mode green/yellow
2
05. Screen
06. Button „ON/OFF“
07. Button „down“
08. Button „Enter“
09. Button „up“
3
3
10. Button generator „start/stop
1
LED green: normal running mode , LED red: fault
2
Mode LED green: Manuel mode, Mode LED yellow: Atention automatic mode
3
Selectfunction for menue
Fig. A.1-1: Front Panel 100x145
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Panel AGT Control_Kunde_eng.R03 - Kapitel A: General operation Seite 105
A.2 Reverse Side
02
03
05
06
01
04
General operation
01. Clamp 1-9
02. Clamp 10-16
03. Clamp 17-22
04. Fuse 1,6A slow to blow
05. Battery for real time clock
06. Connector for Master-/Slave-Adapter
Fig. A.2-1: Panel Reverse Side
Seite 106 Panel AGT Control_Kunde_eng.R03 - Kapitel A: General operation 18.12.08
General operation
A.3 Running modes - Automatic mode, manual mode and power save mode
Switch on the Panel by pressing the „ON/OFF“ button.
Advice: If the panel is switched on by an external signal (clamp 18 High(+Vbat), the panel can also only be switched off by this external signal. In order to ensure a safe emergency shutdown function, a 2pole emergency shutdown (clamp 1 „VBat+“ and clamp 18 „Extern On“) is necessary.
A.3.1 Manual Mode
The Panel is ALWAYS in the manual mode, after it had been switched on (key 6 Page 105.
Manual Modus -->LED „Mode“ lights green
• Menu is activ.
• Generator can be started and stopped with the „start/stop“ button.
• After the standby time the screen will turn dark.
• After the power save time the display switches in the power save mode.
• To switch into the automatic mode press the „down“-button. The sreen will display the new mode and the mode
LED turns into yellow.
The Panel can be switched off by pressing the „ON/OFF“ button. The running generator will also stop.
A.3.2 Automatic Mode
Automatic Modus -->LED „Mode“ lights yellow ==> CAUTION!!! SAFETY INSTRUCTIONS
PLEASE CONSIDER, THAT AN AUTOMATIC START IS POSSIBLE AT ANY TIME (FOR EXEMPLE
BY THE BATTERY VOLTAGE CONTROL OR BY AN EXTERNAL SIGNAL). THEREFORE, DISCONNECT
THE BATTERIES BEFORE WORKING ON THE GENERATOR.
• Menu is active
• The starting requirements will be requested and carried out.
• After the standby time the screen will turn dark.
• After the power save time the display switches in the power save mode.
• To switch into the automatic mode press the „down“-button. The sreen will display the new mode and the mode
LED turns into yellow.
The Panel can be switched off by pressing the „ON/OFF“ button. The running generator will also stop.
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Panel AGT Control_Kunde_eng .R03 - Kapitel A: General operation Seite 107
General operation
A.3.3 Standby Modus
The display will turn dark after the standby time (only when the generator is not running!), in order to save electric power (both automatic and manual mode).
The standby time and the intensity of the LED standby light is adjustable in the menu.
All buttons are active. Pressing a button (for example „Start“) will start an action and the display changes either to the „automatic mode“ or to „manual mode“ .
The panel can be switched off by pressing the „ON/OFF“ button.
A.3.4 Power Save Modus
After the power save time, which can be adjusted by the Fischer Panda Distributor, the panel will automatically switch into the Power save mode. The panel will be reactivated by pressing the "ENTER"-button for 1 sec.
• Screen is dark.
If the panel switches from the automatic mode to the Power save mode, the mode LED will blink yellow. The panel returns to the automatic mode by a starting request (battery voltage control or external signal).
If the panel switch from the manual mode to the power save mode, the mode LED will blink green. By pressing the "Start/Stop" button, the panel changes from the power save mode back to the manual mode, and the starting/ stopping procedure will be activated.
If the panel changes from an emergency mode to the power safe mode, the fault LED will blink red and the mode
LED will blink according to the mode yellow or green.
The panel can be switched off by pressing the „ON/OFF“ button.
Seite 108 Panel AGT Control_Kunde_eng.R03 - Kapitel A: General operation 18.12.08
General operation
A.4 Starting and Stopping the generator
A.4.1 Starting the generator in the „Manual mode“
1. Open the fuel valve (if necessary).
2. If necessary, close the main battery switch and open the sea lock (Marine version).
3. Press the „ON/OFF“-button (switch on the panel), or awaken the panel from the power save mode by pressing the „Enter“-button.
Optional „ON“ with : +12V on Clamp 18
5.) Press the „Start/Stop“-button - the panel will switch to the manual mode and the generator will automatically be started. The panel initiates following steps pre glow
1 start of the generator runnning the generator
Mode LED is green => „Manual mode““
Errors are recorded and evaluated only in the "run mode" (generator is running). The display always shows the first arisen error. All other errors are stored in the error log and can be looked up and analysed in the menu "error log".
1
The glow time can be interupted by pressing the enter button (for example, when the engine is already warmed up).
ATTENTION: If there is difficulty in starting - close the seacock ( Panda Marine Generators only)
If the generator engine does not start immediately and further start attempts are necessary, then the seacock MUST be closed (i.e. for ventilating the fuel lines etc.) The cooling water impeller pump turns automatically and draws cooling water as long as the motor is turning. If the diesel motor is running, the cooling water is blown out by the exhaust system gases. The cooling water cannot be pressed through the exhaust as long as the diesel motor does not run at sufficient speed. This leads to severe motor damage.
Open the seavalve as soon as the generator is started.
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Panel AGT Control_Kunde_eng .R03 - Kapitel A: General operation Seite 109
General operation
A.4.2 Starting the generator in the „Automatic Mode“
1. Open the fuel valve (if necessary)
2. If necessary, close the main battery switch and open the sea lock (Marine version).
3. Press the „ON/OFF“-button (switch on the panel)
(Optional external „ON“ : +12V on Clamp 18)
4. The panel automatically switches to the „manual mode“. For changing into the „automatic mode“, press the arrow key and acknowledge the choise. In the automatic mode, the starting procedure will be activated, if a starting request is made (for example by the battery voltage control clamp 14 or by an external clamp).
- pre glow
1
(0 - 15 sec, according to adjustment) ( when required, pre-glow is active after the start)
- starting phase
- recognizing the generator
- runnning the generator
LED shines yellow constantly => „Automatic Mode““
Automatic starting of the generator is at any time possible
Errors are recorded and evaluated only in the "run mode" (generator is running). The display always shows the first arisen error. All other errors are stored in the error log and can be looked up and analysed in the menu "error log". Status indications are always displayed according to conditions.
5. Durch drücken der „Start/Stop“-Taste bei stehendem Generator wechselt das Panel in den Manuell Modus und der Startvorgang wird aktiviert. Bei laufendem Generator wechselt das Panel in den Manuell Modus und der
Generator wird gestoppt.
6. By pressing the "START/STOP" button when the generator is not running, the panel will switch to the manual mode and the starting procedure will be activated. By pressing the "START/STOP" button when the generator is running, the panel will switch to the manual mode and the generator will be stopped.
1
The glow time can be interrupted by pressing the enter button (for example, when the engine is already warmed up).
Seite 110 Panel AGT Control_Kunde_eng.R03 - Kapitel A: General operation 18.12.08
General operation
A.4.3 Stopping the generator
1. In the "manual mode" the generator can be stopped either by pressing the "Start/Stop" button or by switching off the remote control panel.
2. In the „automatic mode“ the generator will be stopped by an external stop requirement (e.g. from the battery voltage control or an external signal). The generator can be stopped by pressing the "start/stop" button. The panel will then switch to the manual mode.
(the panel can be switched off by "clamp open" or by „0V“ on clamp 18. The generator will also be stopped. This is of cause only possible, if the panel was switched on by clamp 18).
3. After a longer period of non-use time, the battery main switch should be disconnected and the fuel valve and the sea valve (if necessary) should be closed (position 0 = off).
A.5 Menutable Adjustments
The menutable is accessed as follows:
1. Switch on the panel by pressing the "ON/OFF" key (key 06 - Page 105)
2. Switch to the menu by pressing the "Enter" key (key 08 - Page 105)
3. Select a menu option by pressing the "arrow up / arrow down" keys (keys 7+9 - Page 105)
(flashing line = current selection)
4. Confirm the selection by pressing the "Enter" key (key 08 - Page 105)
The values are stopped as follows:
Change the values by pressing the "arrow up/arrow down" keys (key 7+9 - Page 105)
Confirm the input by pressing the "Enter" key (key 08 - Page 105)
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Panel AGT Control_Kunde_eng .R03 - Kapitel A: General operation Seite 111
A.5.1 Menu tree
General operation
Fig. A.5.1-1: Menu tree
Seite 112 Panel AGT Control_Kunde_eng.R03 - Kapitel A: General operation 18.12.08
General operation
A.5.11Explanation of the menu table
System Parameter
-In the system parameters, all settings can be made, which are important for the user concerning the display
System Parameter - Light
- Setting of the general background light of the display in the operating mode of the panel
Minimum value 0% - maximum value 100% - default value 100%
System Parameter - Contrast
- Setting of the contrast of the display in the operation mode and standby mode of the panel
Minimum value 0% - maximum value 100% - default value 75%
System Parameter - Standby time
- Setting of the time span, until the panel switches into the standby mode. Each pressing of the button causes a reset of the timer
Minimum value 0 seconds - maximum value 30 seconds - default value 20 seconds
System Parameter - Standby Light
- Setting of the general background lighting of the display in the standby mode of the panel
Minimum value 0% - maximum value 100% - default value 50%
System Parameter - Power Save Time
Setting of the time span, until the panel switches into the power save mode. Each pressing of the button causes a reset of the timer.
Minimum value 0sec - maximum value 240 seconds - default value 240 seconds
System Parameter - LED Light
Setting of the LED brightness in the operating mode of the panel
Minimum value 0% - maximum value 100% - default value 75%
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Panel AGT Control_Kunde_eng .R03 - Kapitel A: General operation Seite 113
General operation
Systemparameter - LED-Lighting Standby
Setting of the LED brightness in the standby mode of the panel
Minimum value 0% - maximum value 100% - default value 15%
System Parameter - Language Setting
Setting of the display language
German or English - Standard English
Error Log
In the error log the error messages occurred during starting / operating the generator are stored and can be looked up belatedly. The error log also stores every reset of the countdown time of a delayed error.
Clock Set
- Setting of the system time
A.6 Error Message
The AGT Control Panel are pre-installed in such a way, that a max. operation reliability is ensured. That means,
The AGT Control Panel displays the error messages in different ways.
- appropriate LED changes from green on red (e.g. oil-press)
- general fault LED changes from green on red
- display of the error in the operating mode of the display (see …) - only if the error is set to "display only"
- display changes to delayed error display (see …) - only if the error is set to "delayed"
- display changes to the error display - only if the error is set to "emergency stop".
The appropriate settings can only be made by Fischer Panda or an authorized Fischer Panda Service Point.
For standard configuration see section A.6.5, “Error Messages,” on page 116.
Seite 114 Panel AGT Control_Kunde_eng.R03 - Kapitel A: General operation 18.12.08
General operation
A.6.1 Type of Error „Emergency Stop“
The report for this error is activated.
Fault-LED changes to red (at temperature errors or oil pressure errors the appropriate error LED )
The display changes to error display
The generator stops immediately
The external error output will be switched for approx. 5 sec. (clamp 21)
The setting "emergency stop" ensures highest security to avoid consequential damages for the generator.
A.6.2 Type of Error „Delayed“
The report for this error is activated.
- Fault LED changes to red (at temperature errors or oil pressure errosr the appropriate fault LED)
- Display changes to "delayed errors" display and starts a countdown
- Generator stops after the countdown
- External error output will be swiched.
Vehicles with Diesel Electric Drive Systems are relayed on the driving power for safe manoeuvring. If an emergency shut-down cuts off the drive (i.e. in order to protect the generator against damage), this can lead to a high danger situation for ship, crew and passengers. With the "delayed" error, the driver has the possibility to reach a safe area. A possible considerable damage to the generator is in this situation accepted by the driver.
Resetting the countdown will be reported in the error log and leads to a loss of warranty. Therefore, only use the resetting in emergency situations.
A.6.3 Type of Error „Display only“
The report for this error is activated.
- Fault-LED changes to red (at temperature error or oil pressure error the appropriate fault LED)
- Display of the error in the operating mode of the display
- Generator does not stop
- External error output will be switched.
Only for errors which do not affect the system security.
18.12.08
Panel AGT Control_Kunde_eng .R03 - Kapitel A: General operation Seite 115
General operation
A.6.4 Type of Error „Deactivated“
The report for this error is deactivated.
- Fault-LED does not change to red (at temperature error or oil pressure error the appropriate fault LED)
- No display of the error
- Generator does not stop
All error types, which are not needed in the generator / drive configuration can be deactivated.
A.6.5 Error Messages
The following errors can be displayed:
Oil error (oil pressure error)
possible settings: deactivated - display only - delayed - emergency stop
Standard: emergency stop
Temp error (temperature error)
possible settings: deaktivated - display only - delayed - emergency stop
Standard: emergency stop
Waterflow error
possible settings: deactivated - display only - delayed - emergency stop
Standard: deactivated
Prop drive error
possible settings: deaktivated - display only - delayed - emergency stop
Standard: deactivated
Attention!! Different configuration can lead to a warrenty loss.
(e.g. oil error are deactivated)
Seite 116 Panel AGT Control_Kunde_eng.R03 - Kapitel A: General operation 18.12.08
General operation
A.7 Installation of the AGT Control Panels
A.8 Clamps of the AGT Control Panel
Connect the wires of the connection cable with the clamp of the AGT control according to its no.
16
17
13
14
15
4
5
1
2
Clamp Name of clamp
Vbat (operation voltage)
GND (Ground)
3 T-Fail (temperature error)
Antrieb-Fail (drive error)
Oil-Fail (oilpressure error)
6
7
8
9
10
11
12
18.12.08
Gen-AC-1 (generator frequency)
Gen-AC-2(generator frequency)
Heat (pre-glow)
DC Supply fuel system
Start(starter)
VCS on
Vbat-F-S
(switched operation voltage))
E
E
E
E
E
E
E
A
A
A
A
A
GND (Ground)
Auto-Start-BW(battery voltage control start)
E
GND(Ground)
Auto-Start-Ex.(external start)
E
Gen-Run (generator is running) A
Function
operation voltage + (Automotive) operation voltage - (Automotive) to GND: temperature OK open: temperature error to GND: drive OK open: drive error or invers to GND: oil pressure OK open: oil pressure error frequency of the generators phases der Generator-Phasen connection 1
1 frequency of the generators phases der Generator-Phasen connection 2
1
Application
Standard²
Standard²
Standard²
Optional³
Standard²
Standard²
Standard² to Vbat-F-S
*5
: pre-glow on (Fused a. switched) open (with free wheeling diode): pre-glow off free wheeling diode = protection diode (inverse voltage) to Vbat-F-S
*5
: fuel system on (Fused a. switched) open (with free wheeling diode):fuel system off free wheeling diode = protection diode (inverse voltage) to Vbat-F-S
*5
: starter on (Fused a. switched) open (with free wheeling diode): starter off free wheeling diode = protection diode (inverse voltage) to Vbat-F-S
*5
: VCS on (Fused a. switched) open (with free wheeling diode): VCS off free wheeling diode = protection diode (inverse voltage) connection for external units which should be switched on and off by the panel to Vbat-F-S: units on (Fused a. switched) open (mit Freilaufdiode): units off free wheeling diode = protection diode (inverse voltage)
GND to clamp 14 to GND (clamp 14): Generator on open: Generator off
GND to clamp 16 to GND (clamp 16): Generator on open: Generator off
Standard²
Standard²
Standard²
Optional³
Optional³
Standard²
Standard²
Standard²
Standard²
Generator runs in normal mode
Fig. A.8-1: Clamps
Option³
Panel AGT Control_Kunde_eng .R03 - Kapitel A: General operation Seite 117
General operation
18
19
20
Panel-On (external panel switch on)
BW-OK(failure battery voltage control)
VCS-OK
E
E
E
In = +12/24VDC (+/- tolerance battery voltage):
Panel switched on, FlipFlop ON/OFF reset
In = open or 0V: Panel switched off to GND: no errors open: no mesurement voltage or over voltage or reset not possible to GND : VCS on and no voltage error loged: open: VCS off or voltqage error loged
21 alarm/error out A to Vbat-F-S: Alarm on (Fused a. switched) open (with free-wheeling diode): Alarm off
Free wheeling diode = protection diode (inverse voltage)
22 Water-Fail (water error) E to GND : Temperature OK open: cooling water temperature error
Fig. A.8-1: Clamps
1
Protection of the measurement connection - at voltages >48V with voltage devider RE 9908
² Must be connected for the standard operation.
³ Can be connected optional. This function is activated.
4
This function is in preparation. Not available yet
Optional³
NA Optional
4
NA Optional
4
Optional³
Optional³
A.9 Master-Slave Operation (In Preparation - available 11/2008)
Two AGT Control Panels can be connected in connection with the master slave adapter. This means that one panel has the functions system control, display and input, while the other panel has the functions display and input. A standard AGT control panel can be connected with the master slave adapter. The slave panel needs special software. With the master panel, it is possible to connect up to two slave panels in series. With the first and the last panel of the serial, the jumper J1 must be closed (as a finish resistor).
A.9.1 Master-Slave- Adapter
The Master-Slave Adapter consists of the master Slave plate and appropriate mounting material
Der Master-Slave Adapter iis identical with the master panel and with the Slave panel.
A.9.2 Connection of the Master-Slave Adapter
In preparation
A.9.3 Installation of the Master Panel - Slave Panel
In Preparation
For connection of the Master Slave Adapter, a 6x0,5mm² screemed cable is necessary. Max. lenght 50m.
(4x Signal +1xVbat +1xGND)
Seite 118 Panel AGT Control_Kunde_eng.R03 - Kapitel A: General operation 18.12.08
General operation
A.9.4 Clamps of the Master-Slave Adapter
Master-Slave Conenction, Clamp X1 (reference point: Master)
Clamp
23
24
25
26
GND
RX/TX
RX/TX
GND
Signal Description
Ground
Transmitter / receive path A 24
Transmitter / receive path B 25
Ground (also apply the shield here onesided)
Fig. A.9-1: Clamps Master Slave Adapter
23
24
At the slave, connect with
25
26
18.12.08
Panel AGT Control_Kunde_eng .R03 - Kapitel A: General operation Seite 119
A.9.5 Systemparameter Setting
For recording your preferential settings.
General operation
Fig. A.9.5-1: Systemparameter settings
Seite 120 Panel AGT Control_Kunde_eng.R03 - Kapitel A: General operation 18.12.08
.R03Installation/Tech. documentation
B. .R03Installation/Tech. documentation
B.1 Clamps
9
10
5
6
7
8
11
1
2
Clamp
Vbat (12V)
GND
Clamp name
3 temperature error
4 drive error oil pressure error
Generator-frequency
Generator-frequency pre glow fuel pump starterr
VCS on
12 switched service voltage
16
17
13
14
15
18
GND to 14
Battery monitor start
GND to 16 external start
Generator is running
Panel external turn on
19 battery monitor error
20
Clamp
VCS-OK
Clamp name
18.12.08
E
E
E
A
E
A
A
A
E
E
E
E
E
A
A
E
Funktion
Battery voltage + (12V-Automotive)
Battery voltage - (12V-Automotive) toGND : temperature OK open: temperature error to GND : drive OK open: drive errorr to GND: oil pressure OK open: oil pressure error frequency of the generator phase connection 1 frequency of the generator phase connection 2 to Vbat-F-S : pre glow on open (with free wheeling diode): pre heat off to Vbat-F-S: fuel pump on open (eith free wheeling diode): fuel pump off to Vbat-F-S: starter on open (with free wheeling diode) starter off to Vbat-F-S: VCS on open (with free wheeling diode): VCS off connection for external units which should be switchedb on and off by the panel.
to Vbat-F-S: units on open (with free wheeling diode): units off
GND to Clamp 14 to GND : Generator on open : Generator soll off
GND to clamp 16 to GND generator on open: generator off
used as
Standard
Standard
Standard
Option
Standard
Standard
Standard
Standard
Standard
Standard
Option
Option
Standard
Standard
Standard
Standard generator runs in normal mode in = +12/24VDC (+/- Toleranz Batterievoltage): panel turn on, FlipFlop ON/OFF reset in = open or 0V panel turn off to GND : no errors open: no mesurement voltage or over voltage or reset not possible
Option
Option
Option to GND : VCS on and no voltage error loged open: VCS off or voltqage error loged
Funktion
Fig. B.1-1: Clamps
Option
used as
Panel AGT Control_Kunde_eng.R03 - Chapter B: .R03Installation/Tech. documentation Page 121
21
22 alarm/error out cooling water temp. error
A
E to Vbat-F-S : Alarm on open (eith free wheeling diode): Alarm off to GND : Temperature OK open: cooling water temperature error
Fig. B.1-1: Clamps
.R03Installation/Tech. documentation
Option
Option
Page 122 Panel AGT Control_Kunde_eng.R03 - Chapter B: .R03Installation/Tech. documentation 18.12.08
Installation
C. Installation
C.1 Wiring diagram Panda AGT Control Panel
>) ut np (i r
) + -> le
) ro
ND nt
) + t pu
G co
-> y
<t ut (O t er pu tt pu In
N RU
In ba
( e
( ON r to
OK ur
S il l ne ra ne
Pa
Ge
VC fa
+) >
+) > -
ut ut tp tp Ou ou (
( ON at Vb
S VC x
W
-E
-B
)
) ->
-> +-
(+
(
-S rt
6 ta
1 rt ta
4 1
On
-F t
Sat
VC
Vb to
D
Au
GN to Au
D GN ar St to
-S
-S to
>)
>
-+
--
-2
-1
+ (
(
AC
AC at il at il il
D GN
Fa
Vb
Fa
Fa nn-
Ge
Ge
He
FP
OK
K m on l n ru
S
-O
VC
BW ne Pa n Ge il Fa ar Al
2 L ng nu an sp ss Me
1 L ng nu an sp ss Me
WH
GN
GN
WH
L2 e
L1 e ag lt ag lt vo vo t en t en em ur em ur as me as me
4
1
1:
1: ye bu rd vt
18.12.08
+
Fig. C.1-1: Wiring diagram
Panel AGT Control_Kunde_eng.R03 - Chapter C: Installation Page 123
C.2 Technical Data AGT Control Panel
Panel Version
Max. Current Consumption
Standby Mode
Energy Save Mode
Temperature Area
Operation / Storage
Max. load of the outputs
UV consistency at field service
Umax
Umin
Unom
Imax
Fuse
Panel AGT Control 12VDC
190mA
75mA
20-35mA
Panel AGT Control 24VDC
290mA
95mA
23-30mA
(-20) - 70°C / (-30) - 80°C
(pre-glow phase might be necessary)
1,2A for all together
34,9V(Panel switches off automatically at 35VDC)
9V
12-14,4 VDC 24-28VDC
1,6A ( = Fuse)
1,6A delay
Fig. C.2-1: Technical Data AGT Control
C.3 Technical Data Master-Slave Adapter
in Preparation
Installation
Page 124 Panel AGT Control_Kunde_eng.R03 - Chapter C: Installation 18.12.08
Measurements
D. Measurements
D.1 Hole Pattern 145x100mm
6 13
,5 69
,5 66
3
4x
20
3 10
5 14
5 14
3 10
18.12.08
6 13
Fig. D.1-1: Hole Pattern 145x100mm
Panel AGT Control_Kunde_eng .R02 - Chapter D: Measurements Page 125
Measurements
D.2 Hole Pattern 130x120mm
5 ,7 52
0
8
12
10
5 ,2 55
2,5 10
3
4x
7,5
0 12
8 10
2,5 10
Fig. D.2-1: Hole Pattern 130x120mm
Page 126 Panel AGT Control_Kunde_eng.R02 - Chapter D: Measurements 18.12.08
VCS-AGT-U/I
A. VCS-AGT-U/I
Fischer Panda Datasheet
A.1 VCS-AGT-U/I Versions
Art. Nr.:
F1RORE9627-012-212
F1RORE9627-024-212
F1RORE9627-036
F1RORE9627-048
F1RORE9627-072-212
F1RORE9627-080-212 auf Anfrage / on request auf Anfrage / on request
F1RORE9627-120
F1RORE9627-144
F1RORE9627-180 auf Anfrage / on request auf Anfrage / on request auf Anfrage / on request
A.2 Voltage control system
Set point
120V
144V
180V
300V
320V
336V
12V
24V
36V
48V
72V
80V
96V
115V
Art. Name
VCS-AGT-U/I 12V= @60mV
VCS-AGT-U/I 24V= @60mV
VCS-AGT-U/I 36V= @60mV
VCS-AGT-U/I 48V= @60mV
VCS-AGT-U/I 72V= @60mV
VCS-AGT-U/I 80V= @60mV
VCS-AGT-U/I 96V= @60mV
VCS-AGT-U/I 115V= @60mV
VCS-AGT-U/I 120V= @60mV
VCS-AGT-U/I 144V= @60mV
VCS-AGT-U/I 180V= @60mV
VCS-AGT-U/I 300V= @60mV
VCS-AGT-U/I 320V= @60mV
VCS-AGT-U/I 336V= @60mV
1
1. Terminals 7+8
2. Potentiometer for the charging voltage
Page 127 - Chapter A: VCS-AGT-U/I
3. Terminals 1-6
4. Programming
Fig. A.2-1: VCS view
2
3
4
VCS-AGT-UI_eng.fm
Fischer Panda Datasheet
VCS-AGT-U/I
2
1
1. Terminals 9+10 2. Potentiometer for the charging current
Fig. A.2-2: VCS view
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.
6
7
4
5
8
9
2
3
No.
Short mane
1 + Actuaror
- Actuator
+12V
0V
AC Controllamp
VCS on
Mesurement voltage +
Mesurement voltage -
Mesurement current +
10 Mesurement current -
I
I
I
I
I
I
O
I
O
IN/OUT
O
Function
Out (+) for actuator
Out (-) for actuator
Operation voltage(+); 12V-Automotive
Operation voltage(-); 12V-Automotive to 0V - Optional
12V: VCS is on / open : VCS is off
Mesurement voltage (+) from the generator
Mesurement voltage (-) from the generator
Mesurement current (+) from the generator
Mesurement voltage (-) from the generator
Fig. A.2-3: Terminals of the VCS
The potentiometer next to clamp 7/8 is needed for adustment of the measurement voltage and should be done by an service technican only.
The potentiometer next to clamp 9/10 is needed for adustment of the measurement current and should be done by an service technican only.
Page 128 - Chapter A: VCS-AGT-U/I VCS-AGT-UI_eng.fm
VCS-AGT-U/I
Fischer Panda Datasheet
A.2.1 Gerneral working of the VCS
When the VCS is active (+12V on clamp 6) the VCS controls the actuator to reach the exact voltage.
The mesurement voltage is taken from the generator by an shunt which has 60mV nominal.
A.2.2 Safety instructions for the voltage control
• A broken cable in the mesurement line will be notice by the VCS and the generator will slow down and stop.
• A short circiut in the mesurement line or a wrong pol connection is not noticed by the VCS (its like that there is no voltage). The voltage control in this vase ist out of funktion. It is necessary at the installation to check the right working of the VCS and a second overvoltage protection must be installed.
• For the mesurement voltage a shieldet cable is needet, it must be less than 3 mtr long. The shield should be connected to ground at one side.
Note the safety instruction in the generator manual!
Please Note!
• Run the generator with closed sound cover only
• Recommend: install a smoke connection.
• Ask for regular service
VCS-AGT-UI_eng.fm
Chapter A: VCS-AGT-U/I - Page 129
Fischer Panda Datasheet
VCS-AGT-U/I
Intentionally Blank
Page 130 - Chapter A: VCS-AGT-U/I VCS-AGT-UI_eng.fm
Battery monitor in DIN-tracks housing (RE9517)
Fischer Panda Datenblatt/Datasheet
A.
Battery monitor in DIN-tracks housing (RE9517)
Art Nr.
Bez.
see technical data
Battery monitor
Actual:
Replace:
Replaced by:
Document
Rev.2.0_05.06.2007
Rev.1.0_24.02.2004
--------------------------
Hardware
Rev.1.2_24.02.2004
Rev.1.2_24.02.2004
--------------------------
Software
?
?
--------------------------
A.1 Safety instructions
See the safety instruction of your Generator and all other parts of your system
Electrical power: DANGER TO LIVE!
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.
Anleitung_RE9517_eng.fm
Kapitel/Chapter A: Battery monitor in DIN-tracks housing (RE9517) - Seite/Page 131
Battery monitor in DIN-tracks housing (RE9517)
Fischer Panda Datenblatt/Datasheet
A.2 Brief description
Automatic monitoring of a battery voltage. If the adjusted threshold for battery undervoltage is fallen below, then (e.g.
over the AGT panel RE9513) a battery charge generator is started. If the adjusted threshold for charge voltage is crossed, then the generator - at expiration of an adjustable deceleration time - is stopped.
A.3 Function
Battery undervoltage, charge voltage and delay time can be stopped over potentiometers. If battery undervoltage was recognized, this is indicated over an LED. Threshold excesses and falling below must line up min. 40s, so that a shifting process can be released. The battery monitor supplies itself from the battery which can be supervised. The exit is electrically isolated by an opto coupler from this electric circuit. As output logic element the output transistor of the optocoupler is used. Thus the output signal is polarized and the exit must be attached correctly. A wrong polarity of the exit can lead to the destruction of the battery guard, as well as attached devices!
A.4 Technical data and settings
The battery monitor is setup for a definied voltage. (i.e. 24V or 36V). It is not possible to change these voltage.
Art. No.
F1RORE9517-012
F1RORE9517-024
F1RORE9517-036
F1RORE9517-048
Art. Name
Battery monitor typ RE9517 12V-DC
Battery monitor typ RE9517 24V-DC
Battery monitor typ RE9517 36V-DC
Battery monitor typ RE9517 48V-DC
Nominal
Voltage
12 Volt
24 Volt
36 Volt
48 Volt
F1RORE9517-072
F1RORE9517-080
Battery monitor typ RE9517 72V-DC
Battery monitor typ RE9517 80V-DC
72 Volt
80 Volt
F1RORE9517-120 Battery monitor typ RE9517 120V-DC 120 Volt
F1RORE9517-144 Battery monitor typ RE9517 144V-DC
• charging rate : max 7mADC
144 Volt
Mesuring Voltage
cont./short time
Clamp1(+) Clamp2(-)
25V DC / 27V DC
32V DC / 35V DC
56V DC / 60V DC
86V DC / 95V DC
110V DC / 120V DC
• output (clamp 7 = positive [+], clamp 8 = negative [-])
• max operation voltage: 35VDC
• max backward voltage: -4VDC
• max operation current: 10mADC
• output is electrically isolated from the measuring input
• setting ranges:
• charge conclusion voltage: 2.25V - 2.42V per cell
• battery base voltage: 1.83V - 2.04V per cell
• tolerance of the range limits: ± 2,5%
• tolerance of the operation points: ± 1%
Seite/Page 132 - Kapitel/Chapter A: Battery monitor in DIN-tracks housing (RE9517) Anleitung_RE9517_eng.fm
Battery monitor in DIN-tracks housing (RE9517)
Fischer Panda Datenblatt/Datasheet
• charge conclusion delay time: 10min - 2h
• tolerance of the delay time: ± 20%
The adjusted value for charge conclusion voltage can be based on the clamp 3 against clamp 2 (minus). The adjusted value for battery undervoltage can be based on the clamp 4 against clamp 2 (minus). In each case the operation voltage per cell is measured. Absolute operation voltage can be determined, by multiplying measured voltage with the number of cells. For the measurement use only a multimeter with an impedance
≥
10MOhm, since otherwise substantial measuring errors arise.
Direction of rotation of the trimmers: Turn in the clockwise direction = larger value
By a drilling below clamp 1 is accessible with a small screwdriver a tracer, which makes it possible, for test purposes, to switch between the two switching status back and forth. This functioned however only if the battery voltage is within the adjusted borders. Outside of the limit values the battery guard cannot be affected by the tracer.
Connction examples: Connection to AGT-Panel
Output +
Battery monitor
clamp 7
AGT-Panel
clamp 14
Output clamp 8 clamp 13
The cable connection between battery monitor and control panel must be implemented as twisted or shielded cable.
A.5 Additional products
Relay switch RE0003 for Batterymonitor Fischer Panda Art.No.: F1RORE0003
Fig. A.5-1: Relay switch for battery monitor
Ad-on for the Batterymonitor RE9517 (with transistor out) to get a relay switch.
If the Batterymonitor recognice Bat-Low (LED turn on) the Relay switch close. For additional information see
RE0003 Datasheet.
Anleitung_RE9517_eng.fm
Kapitel/Chapter A: Battery monitor in DIN-tracks housing (RE9517) - Seite/Page 133
Battery monitor in DIN-tracks housing (RE9517)
Fischer Panda Datenblatt/Datasheet
Fig. A.5-2: Wiring diagram
Seite/Page 134 - Kapitel/Chapter A: Battery monitor in DIN-tracks housing (RE9517) Anleitung_RE9517_eng.fm
Impellerfilter
A. Impellerfilter
Fischer Panda Datasheet
Aktuell:
Replace:
Dokument
R2 04.05.07
V1 12.04.07
Art Nr.
.
Bez.
31.06.03.003P
Impellerfilter for Marine Panda P6, P8, P9, P10, P12 and
P14
since March 2007
Hardware
12.04.07
Software
--------------------------
--------------------------
Tested for a flow rate up to 22l/min
31.06.03.003P_Kunde_Impellersieb_Panda_6,8,9,10,12,14_PMS_eng.fm
Kapitel A: Impellerfilter - Page/Seite 135
Impellerfilter
Fischer Panda Datasheet
A.1 General
Starting with March 2007 the Fischer Panda generators type 6, 8, 9, 10, 12 and 14 has got an extra impellerfilter.
A.2 How it works
When the impeller breaks, pieces of rubber will penetrate into the cooling system. This pieces can stock in the pipes with lower diameter (such as the heat exchanger) and reduce the cooling water flow. Expensive reconstruction and cleaning of the raw water circle is necessary.
The Fischer Panda impellerfilter hold this pieces of rubber back, so they can be easely removed. The flow through diameter of the cooling water is expanded in the impellerfilter, in emergency situation (like heavy sea) it is possible to change only the impeller itself and clean the impellerfilter afterwards at a better time. an emergency stop of the generator in fact of a to low cooling water flow and an overheating will be nearly banned. The impellefilter must be cleaned after each impeller break. If you are not sure that every piece of rubber is removed at the cleaning we recommend to change the impellerfilter.
A.3 Cleaning and replacement of the impellerfilter
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.
Note the safety instruction in the generator manual.
Seawater valve must be shut.
Open the generator sound cover like it is explained in the generator manual!
ATTENTION!!! Parts of the generator and the cooling water may be hot after operation
!!!DANGER!!!
Page/Seite 136 - Kapitel A: Impellerfilter 31.06.03.003P_Kunde_Impellersieb_Panda_6,8,9,10,12,14_PMS_eng.fm
Impellerfilter
Fischer Panda Datasheet
Impellerfilter.
The impellerfilter is mounted at the right front motorbase.
Loose holding screw.
Loose the holding srew two turns.
Srew M6 (*SW 10)
*SW 10 = wrench size 10mm
Fig. A.3-1: Impellerfilter
Fig. A.3-2: Holding screw
First hose clamp.
Loose the front hose clamp.
Use a screwdriver, or better a wrench SW 7mm.
31.06.03.003P_Kunde_Impellersieb_Panda_6,8,9,10,12,14_PMS_eng.fm
Fig. A.3-3: First hose clamp
Kapitel A: Impellerfilter - Page/Seite 137
Fischer Panda Datasheet
Second hose clamp.
Loose the second hose clamp.
Use a srew driver, or better a wrench SW 7mm.
Fig. A.3-4: Second hose clamp
Remove the cooling water hose.
remove the first cooling water hose.
Some raw water may flow out of the hose or the impellerfilter.
The hose can be closed with the cap you get together with the impellerfilter spare part pack.
Remove the holding srew.
Remove the impellerfilter holding screw.
Fig. A.3-5: cooling hose
Impellerfilter
Page/Seite 138 - Kapitel A: Impellerfilter
Fig. A.3-6: Holding screw
31.06.03.003P_Kunde_Impellersieb_Panda_6,8,9,10,12,14_PMS_eng.fm
Impellerfilter
Fischer Panda Datasheet
Pull the Impellerfilter out of the capsule.
The second cooling water hose can be removed within these procedure.
Some raw water may flow out of the hose or the impellerfilter.
The hose can be closed with the cap you get together with the impellerfilter spare part pack.
Fig. A.3-7: Remove Impellerfilter
Clening of the impellerfilter with water
The best cleanind will be to flush the filter against the flow direction.
Fig. A.3-8: Cleaning with water
Option: Cleaning of the impellerfilter with air pressure.
Fig. A.3-9: Cleaning with air
Replace the cleaned/new filter in reverse procedure.
31.06.03.003P_Kunde_Impellersieb_Panda_6,8,9,10,12,14_PMS_eng.fm
Kapitel A: Impellerfilter - Page/Seite 139
Fischer Panda Datasheet
A.4 Spare part kit
Fischer Panda Art Nr. 21.03.02.005S
Impellerfilter Art. No. 31.06.03.003P
Screw M6x10 Art. No. G3A20093306010 with spring ring Art.No. G3A20012706 cap 19mm (2x) Art.No. PMGPN610U19
Impellerfilter
Fig. A.4-1: Spare part kit
Page/Seite 140 - Kapitel A: Impellerfilter 31.06.03.003P_Kunde_Impellersieb_Panda_6,8,9,10,12,14_PMS_eng.fm
Impellerfilter
A.5 Dimensions
Fischer Panda Datasheet
31.06.03.003P_Kunde_Impellersieb_Panda_6,8,9,10,12,14_PMS_eng.fm
Fig. A.5-1: Dimensions
Kapitel A: Impellerfilter - Page/Seite 141
Fischer Panda Datasheet
Impellerfilter
Intentionally Blank
Page/Seite 142 - Kapitel A: Impellerfilter 31.06.03.003P_Kunde_Impellersieb_Panda_6,8,9,10,12,14_PMS_eng.fm
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Key features
Super silent technology
100% water-cooled
Patented VCS (voltage control system)
Compact and space-saving
Powerful and efficient
Marine application
Frequently asked questions
The generator is 100% water-cooled
The generator is equipped with a patented VCS (voltage control system) that ensures excellent voltage stability.
The dimensions of the generator can be found in the table of contents.
The installation instructions are provided in this manual.
The instructions for starting and stopping the generator are described in this manual.
The maintenance instructions are provided in this manual.
The troubleshooting table is provided in this manual.
