Panda 4000i PVMV-N - Ysebaert€¦ · Panda 4000i Generator Permanent-Magnet-Generator Art Nr....

Pan

da_4

000i

_PV

MV

-N_B

ook_

eng.

R03

26.5

.08

Panda 4000i PVMV-N

230V 50Hz 4kW

Fischer Panda GmbH

2

Revision

Document

Akcuell: Panda_4000i_PVMV-N_Book_eng.R03_26.5.08

Replace Panda_4000i_PVMV-N_Book_eng.R02

Revision Page

Panda 4000i

26.5.08 Panda_4000i_PVMV-N_Book_eng.R03 - Chapter A: Panda 4000i - Page 3

A. Panda 4000i

A.1 Components

Panda 4000i Generator

Permanent-Magnet-Generator

Art Nr. C20040BX4SV01

Manual see Page 5

Fig. A.1-1: Panda 4000i generator

Panel Panda iControl with elektronicboard at the generator

Art Nr. 21.02.02.011H (Panel)

Art Nr. 21.02.01.005H (electronic board)

Manual see Page 81

Fig. A.1-2: iControl

Panda PMGi 4000 Inverter AC/AC 3,5 kW230 V / 50 Hz

Art Nr. 21.07.03.003H

Manual see Page 93

Fig. A.1-3: PMGi 4000

Panda 4000i

Page 4 Panda_4000i_PVMV-N_Book_eng.R03 - Chapter A: Panda 4000i 26.5.08

A.2 Range of operation

Reliable power supply

A.2.1 Main features of the Panda 4000i

• Extremely high starting capacity, perfect for a Bauer junior 2.2kW compressor!

• 230 V / 50 Hz system for all your domestic appliances!

• Compact and light, takes up less space!

• Super silent sound insulation capsule!

• Graphical Display, easy to operate!

• Option for reduce speed at lower loads, saves fuel!

• Pure sinus wave, higher frequency and voltage stability!

• Optimized engine rpm (2800 rpm) for a long generator life!

26.5.08 Panda_4000i_PVMV-N_Book_eng.R02 - Table of contents Page 1

Table of contentsPanda 4000i PVMV-N................................. ............................................................................. 1

Super silent technology............................ ............................................................................. 1

Revision........................................... ........................................................................................ 2

A Panda 4000i ...................................... ............................................................................. 3

A.1 Components ..................................... ................................................................................ 3

A.2 Range of operation ............................. .............................................................................. 4

A.2.1 Main features of the Panda 4000i ....................................................................................... 4

Panda 4000i Part 1 Panda 4000i PVMV-N Manual....... ......................................................... 5

Revision........................................... ........................................................................................ 6

Safety first ....................................... ........................................................................................ 8

Tools .............................................. .......................................................................................... 9

Safety Precautions ................................. .............................................................................. 12

A The Panda Generator............................... .................................................................... 15

A.1 Typeplate at the generator ..................... ....................................................................... 15

A.2 Description of the Generator.................... ...................................................................... 16

A.2.1 Front view .......................................................................................................................... 16A.2.2 Rear View .......................................................................................................................... 17A.2.3 Top view ............................................................................................................................ 18A.2.4 Side view right ................................................................................................................... 19A.2.5 Side view left ..................................................................................................................... 20

A.3 Details of function units ...................... .......................................................................... 21

A.3.1 Remote control panel see iControl datasheet ................................................................... 21A.3.2 Components of the cooling system ................................................................................... 21A.3.3 Components of the fuel system ......................................................................................... 26A.3.4 Components of cumbastion Air circle ................................................................................ 29A.3.5 Components of the electrical system ................................................................................ 32A.3.6 Komponents at the oil circle .............................................................................................. 35A.3.7 Thermosensor/switches .................................................................................................... 37A.3.8 External Components ........................................................................................................ 39

A.4 Operation Instructions - see separate control pa nel manual ..................................... 40

A.4.1 Daily routine checks before starting - See iControl manual. ............................................. 40A.4.2 Starting Generator - See iControl manual. ........................................................................ 40A.4.3 Stopping the Generator - See iControl manual. ................................................................ 40

B Installation ...................................... .............................................................................. 41

B.1 Connections of the generator ................... .................................................................... 41

B.1.1 Primary remark .................................................................................................................. 41B.1.2 Connections ....................................................................................................................... 41B.1.3 Installation of the fuel system ............................................................................................ 42B.1.4 The electrical fuel pump .................................................................................................... 42B.1.5 Position of the pre-filter with water separator .................................................................... 42B.1.6 Connection of the fuel lines at the tank ............................................................................. 43

Page 2 Panda_4000i_PVMV-N_Book_eng.R02 - Table of contents 26.5.08

Table of contentsB.1.7 Battery connection ............................................................................................................. 44

B.2 Generator Electric-System-Installation ......... ............................................................... 44

B Panda6000ND_PVK_U_Book_s01645Installation......... .............................................45

B.1 Connection of the external radiator ............ .................................................................. 45

B.2 The Battery Monitor ............................ ............................................................................ 46

B.3 Cooling system ................................. .............................................................................. 46

B.4 Exhaust Installation ........................... ............................................................................. 59

C Mode of Operation of the Generator................ ...........................................................61

C.1 Mode of Operation of Operating Surveillance ..... ......................................................... 61

C.2 Safety instruction ............................. .............................................................................. 61

C.3 Generator Betriebsanleitung .................... ..................................................................... 62

C.3.1 Checks before starting ....................................................................................................... 62C.3.2 Hose elements and rubber formed component in the sound cover ................................... 62

C.4 Oil level ...................................... ...................................................................................... 62

C.4.1 Start of the Generators - see iControl datasaheet ............................................................. 62C.4.2 Stop of the Generators see iControl datasheet ................................................................. 62

D Maintainence...................................... ...........................................................................63

D.1 Check Daily .................................... ................................................................................. 63

D.2 Oil circuit maintenance ........................ .......................................................................... 63

D.3 Execution of an oil change ..................... ....................................................................... 63

D.4 Venting the cooling water circiut .............. .................................................................... 65

D.4.1 De-aerating the fuel system ............................................................................................... 67

D.5 Checking the water separator in the fuel supply ......................................................... 68

D.6 Replacement of the air filter matt ............. ..................................................................... 69

E Generator Tables .................................. ........................................................................71

E.1 Trouble shooting ............................... ............................................................................. 72

E.2 Technical Data Engine .......................... ......................................................................... 75

E.3 Technische Daten Generator ..................... .................................................................... 75

E.4 Types of coil .................................. .................................................................................. 76

E.5 Inspection checklist for services .............. .................................................................... 76

E.6 Engine oil ..................................... .................................................................................... 77

E.7 Coolant specifications ......................... .......................................................................... 78

E.8 Measurements ................................... .............................................................................. 79

Panda 4000i - Part 2 Panel Panda iControl Manual... .........................................................81

Current revision status............................ .............................................................................82

A , Panda iControl .................................. ..........................................................................83

26.5.08 Panda_4000i_PVMV-N_Book_eng.R02 - Table of contents Page 3

Table of contentsA.1 Safety instructions ............................ ............................................................................. 84

A.2 Connection of the iControl ...................... ....................................................................... 84

A.3 Buttons and display of the iControl ............. ................................................................. 85

A.4 Engine control .................................. ............................................................................... 86

A.5 Operation manual ............................... ............................................................................ 86

A.5.1 Daily routine checks before starting ................................................................................... 86A.5.2 General .............................................................................................................................. 87A.5.3 Long time run of the generator .......................................................................................... 88A.5.4 Start of the generator ........................................................................................................ 88A.5.5 Stop of the generator ......................................................................................................... 88A.5.6 Automatic start .................................................................................................................. 89A.5.7 Additional information ........................................................................................................ 89

A.6 Error warnings ................................. ............................................................................... 89

A.7 Errors ......................................... ...................................................................................... 90

A.8 Electronic board ............................... .............................................................................. 91

A.8.1 Location at the Panda 4000i PMS ..................................................................................... 91

A.9 Technical data ................................. ............................................................................... 91

A.9.1 Intended use ...................................................................................................................... 91A.9.2 Dimensions ........................................................................................................................ 92

Panda 4000i - Part 3 PMGi 4000 Manual .............. ............................................................... 93

Current revision status ............................ ............................................................................ 94

A Panda PMGi 4000 .................................. ...................................................................... 95

A.1 Safety instruction ............................. .............................................................................. 96

A.2 Type plate ..................................... ................................................................................... 96

A.3 Front side/connection side ..................... ....................................................................... 97

A.3.1 Socket pins of the PMGi 4000 ........................................................................................... 97

A.4 Back side - Top side ........................... ............................................................................ 98

A.5 Operation manual ............................... ............................................................................ 99

A.5.1 Primary remarks / Winter operation ................................................................................... 99A.5.2 Load at the PMGi .............................................................................................................. 99A.5.3 Automatic start .................................................................................................................. 99

A.6 Status LED´s ................................... ................................................................................ 99

A.7 Cooling of the PMGi ............................ ......................................................................... 100

A.8 Installation of the PMGi ....................... ........................................................................ 100

A.8.1 Electrical connection. ...................................................................................................... 100A.8.2 Installation of the ferrites ................................................................................................. 101

A.9 Technical Data ................................. ............................................................................. 102

A.9.1 General Data ................................................................................................................... 102A.9.2 Generator Spezifikation ................................................................................................... 102A.9.3 PMGi out ......................................................................................................................... 103

A.10 PMGi protections .............................. ............................................................................ 103

A.10.1 Overload - switch point ................................................................................................... 103A.10.2 Short circiut ..................................................................................................................... 104A.10.3 Under voltage and signal ................................................................................................. 104A.10.4 Overheat ......................................................................................................................... 104

A.11 Dimensions ................................... ............................................................................... 105

Page 4 Panda_4000i_PVMV-N_Book_eng.R02 - Table of contents 26.5.08

Table of contentsA.12 Wiring diagram PGMi with 4000i generator ...... .......................................................... 106

A.13 Wiring diagram PGMi - RCD ..................... ................................................................... 107

A.14 Wiring diagram PGMi - isolation control ....... ............................................................. 108

Pan

da_4

000i

_PV

MV

-N_B

ook_

eng.

R03

26.5

.08

Panda AGT 4000i PVMV-N

230V 50Hz - 4kW

Fischer Panda GmbH

Panda 4000i Part 1 Panda 4000i PVMV-N Manual

6

Revision

Document

Actuell: Panda_4000i_PVMV-N_Book_eng.R03_26.5.08

Replace: Panda_4000i_PVMV-N_Book_eng.R01

Revision Page

Picture of the location of the type plate replaced 15

7

Fischer Panda

FISCHER GENERATORS have been manufactured since 1978 and are a well-known brand for first class diesel gene-rators with especially effective sound-insulation.

Fischer has been one of the leading manufacturers in respect of quality and know-how during this period.

FISCHER, as the worldwide manufacturer of modern marine diesel generators, developed the Sailor-Silent series forexample 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 concentrateon 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 shortspace 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 institutesand magazines during the past years. The patented VCS (voltage Control System) means it can meet all demandsincluding motor speed. The start-booster (ASB) means Panda generators meet the highest demands in respect ofvoltage stability and starting values A Panda generator, with the same drive motor, produces 15% more effective outputthan 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 invarious 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 themselvesmany times for many uses, that they meet the demands in quality of yachts and vehicles, and offer space and weightsaving of 50% compared to slow running generators.

In addition to the Panda series, Fischer Panda also supply the super compact high-tech sound-insulated battery char-ging aggregate from the DC/AC Panda AGT series, which is a very interesting solution for the production of mobilepower.

The new HTG-alternators ensure that a charging rate of 285 amps is achieved that was scarcely thought possible forthis compact construction. This alternator replaces a separate shipboard generators (constant 230 volts AC with up to3500 kW from the main machine)

Fischer Panda GmbH, 33104 Paderborn, reserves all rights regarding text and graphics. Details are given to the best of our knowledge. No liability is accepted for correct-ness. Technical modifications for improving the product without previous notice may be undertaken without notice. Before installation, it must be ensured that the Pictures,diagrams and related material are applicable to the aggregate supplied. Enquiries must be made in case o doubt.

Icemaster GmbH Fischer MarineGenerators

Conclusion Fischer - Icemaster GmbH

100 % water cooled Pan-da generators

Panda Vehicle Genera-tors

since 1977

since 1978

since 1988

since 1988

since 1988

8

Safety first

These symbols are used throughout this manual and on labels on the maschine itself to warn of the possibility of per-sonal injutry. Read these instructions carefully. It is essential that you read the instructions and safety regulationsbefore you attempt to assemble or use unit.

This danger symbol refers to toxic danger and draws attention to special warnings,instructions or procedures which, if not strictly observed, may result in severe per-sonal injury or loss of life.

This danger symbol refers to electric danger and draws attention to specialwarnings, instructions or procedures which, if not strictly observed, may result inelectrical shock which will result in severe personal injury or loss of life.

This danger symbol refers to electric danger and draws attention to specialwarnings, instructions or procedures which, if not strictly observed, may result inelectrical shock which will result in severe personal injury or loss of life.

This warning symbol draws attention to special warnings, instructions or procedureswhich, 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 procedureswhich, if not strictly observed, may result in damage or destruction of equipment

9

Tools

This symbols are used throughout this manual to show which tool must be used at maintenance or installation.

Spanners

X = number of spanner

Hook wrench for oil filter

Screw driver, for slotted head screws and for recessed head screws

Multimeter, multimeter with capacitor measuring

Infrared temperature mesuring pistol

Current clamp (DC for syncron generators;AC for asyncron generators)

X

10

Socket wrench set

Hexagon wrench keys

11

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of California to cause cance r,

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 gu ideline 98/37/EG .

The generator is in such a way developed that all assembly groups correspond to the CE guidelines. If machine gui-deline 98/37/EG is applicable, then it is forbidden to bring the generator into operation until it has been determinedthat the system into which the generator is to be installed in also corresponds to the regulations of the machine gui-deline 98/37/EG. This concerns among other things the exhaust system, cooling system and the electrical installa-tion.

The evaluation of the "protection against contact" can only be accomplished in connection with the respectivesystem. Likewise among other things responsibility for correct electrical connections, a safe ground wire connection,foreign body and humidity protection, protection against humidity due to excessive condensation as well as the over-heating through appropriate and inappropriate use in its installed state on the respective machine lies within theresponsibility 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 resultfrom errors in the periphery.

Problems due to errors in the installation can be recognized in the apron.

Technical Support per Internet: [email protected]

12

Safety Precautions

The electrical Installations may only be carried ou t be trained and

tested personnel!

The generator may not be taken into use with the co ver removed.

The rotating parts (belt-pulley, belts, etc) must be covered and protected so that there is no danger to life and body!If a sound insulation cover must be produced at the place of installation, then well-placed signs must show that thegenerator can only be switched on with a closed capsule.All servicing-, maintenance or repair work may only be carried out, when the motor is not running.

Electrical power: DANGER TO LIVE!

Electrical voltages above 48 volts (battery chargers greater than 36 volts) are always dangerous tolife). The rules of the respective regional authority must be adhered to. Only an electrician maycarry out installation of the electrical connections for safety reasons.

ATTENTION!

Do not connect the minus pole of the starter batter y to the ground of the boat because of galvanic rea son.

CAUTION!

Contact of the electrical contacts may be DANGER TO LIVE!

The PMGi cable must be secured at the generator and at the PMGi with appropriate safety devices.

The generator is also include into the CO 2 - fire-extinguishing system.

Measures to the fire protection.

All construction units in the environment of energized parts, which carry more than 50 Amp., must be fire protection-moderately secured.

All junction points at the energized parts must be examined regularly on heating up (infrared thermometers).

13

Safety Instrictions for the Handling with Batteries

These instructions must be noticed additionally to the instructions of the battery manufacturer:

• If the batteries are working, someone should be in your near area to help you in a case of emergency.

• Water and soap must be hold ready if battery acid corrode your skin.

• Wear eye protection and protective clothing. During working with the batteries don´t touch the eyes.

• If you got a acid splash on your skin or clothing grow it with much water and soap out.

• If you got acid in your eyes rinse them immediately with clear water until no cauterization is noticeable. Visit imme-diate a doctor.

• Don´t smoke in the near of the batteries. Avoid naked flames or open fires. In the area of batteries exists danger of explosions.

• Pay attention that no tools fall on the battery poles, if necessary cover them.

• During the installation don´t wear a wrist watch or arm jewels, you can create under these circumstances a battery short-circuit. Burning of the skin could be the result.

• Protect every battery contact against unintentional touch.

• Use only cyclical profoundly dischargeable batteries. Starter batteries are not appropriate. Lead-gel batteries are commended. They are maintenance-free, profoundly dischargeable and not produce gas.

• Do not charge a frozen battery.

• Avoid a batterie short-curcuit.

• Take care of a good ventilation of the battery to drain off developing gas.

• The battery connection terminals must be checked of a tight contact at least before operating.

• The battery connection cable must be carefully mounted and checked about incorrect heating at operation with load. The vibrating devices must be regulary checked about scour points and flaw in the isolation.

14

Blank

The Panda Generator

26.5.08 Panda_4000i_PVMV-N_Book_eng.R03 - Kapitel A: The Panda Generator Seite 15

A. The Panda Generator

A.1 Typeplate at the generator

Fig. A.1-1: Typeplateg

The Panda Generator

Seite 16 Panda_4000i_PVMV-N_Book_eng.R03 - Kapitel A: The Panda Generator 26.5.08

A.2 Description of the Generator

A.2.1 Front view

Fig. A.2.1-1: Frant view

01 02 06

10 11

03 04 05 07 08

12 13 1409

01. Watercooled pre silencer02. Venting screwat the pre silencer03. Combustion air intake04. Air filter housing with filter 05. Protective resistor for thermoswitch 75°C/70°C06. Starter07. Oil pressure switch

08. iControl elektronic board „DO NOT OPEN - Danger to life“

09. Electric fuse (white=25A; green=30A;10. Fuel solonoid11. Oil filler cap12. Oil dip stick13. Ground connection point14. Schalldämmkapsel-Unterteil

The Panda Generator


A.2.2 Rear View

Fig. A.2.2-1: Rear View

12 14

03

2120

050201 04 07

1110 16 17 18 19

06

13 15

08 09

01. Cooling water pump02.. iControl elektronic board „DO NOT OPEN - Danger to

life“03. Generator housing with stator winding04. Generator housing front cover05. Venting screw engine06. Cooling water hose07. Water cooled pre silencer08. Battey connection (-)09. Batterie connection (+)10. Sound cover base part

11. Coolling water in12. Cable to PGMi13. Cable to radiator fan14. Cable to fuel pump15. Cable to remote control panel iControl 16. Fuel out17. Fuel in18. Watercolled exhaust elbow19. Compensator under heat isolation20. Cooling water back flow21. Exhaust out

The Panda Generator


A.2.3 Top view

Fig. A.2.3-1: Top view

04

19

0201

13

14

15 17

05 09 10 12

20 21 22 23

16 18

03 1106 07 08

01. Watercooled pre silencer02. Exhaust out03. Cooling water out04. Compensator under heat isolation05. Cooling water hose06. Watercooled exhaust elbow07. Venting screw exhaust elbow08: Fuel connection09. Generator housing front cover10. Generator housing with stator winding11. Cooling water in12 Cooling water pump

13. Thermo switch 75°C/70°C14. Thermo switch 82°C/77°C15. Thermo switch 98°C/83°C16. Thermo sensor at engine 17. Venting screw enginer18. iControl elektronic board „DO NOT OPEN - Danger to

life“19. Venting screw pre silencer22. Air suction housing23. Ait filter housing24. Protective resistor for thermo switch 75°C/70°C 25. Starter

The Panda Generator


A.2.4 Side view right

Fig. A.2.4-1: Side view right

01

01. Water cooled pre silencerr

The Panda Generator


A.2.5 Side view left

Fig. A.2.5-1: Side view left

02 03 04

05 06

03

01. Cooling water pipe, pump to engine 02. iControl elektronic board „DO NOT OPEN - Danger to

life“03. Type plate at engine EA 300

04. Cooling water pump05. Lead-through for oil drain hose07. Sound cover base part

The Panda Generator


A.3 Details of function units

A.3.1 Remote control panel see iControl datasheet

A.3.2 Components of the cooling system

Expansion tank with filler capintegrated in the Radiator

Radiator

elect. water pump

Engine Kubota EA 300

water cooled exhaust elbow

water cooled pre-silencer

overflow hoseat filler cap

Overpressure valvein the filler cap

´thermo sensorat engine

Thermo sensorat pre-silencer

iControl elektronic board

Thermo switchat pre silencer"82°C fan fast""75°C fan slow"

fan

coldair

hotair

cold side

hotside

coolant

The Panda Generator


Cooling water filler cap at the externalradiator

Sample picture

Fig. A.3.2-1: Cooling water filler cap

Cooling water in

Connect the hose from the externalradiaror here.

Fig. A.3.2-2: Cooling water in

Cooling water pump

The cooling water flows through the pumpto the engine.

Fig. A.3.2-3: Cooling water pump

The Panda Generator


Cooling water connection block

Colling water in at the engine

Fig. A.3.2-4: Water connection block

Venting screw at the engine

The venting screw should not be opened ifthe generaqtor is running. Air will pene-trate the cooling circle.

Fig. A.3.2-5: Venting screw engine

Water out at engine

The cooling water out is at the bottem ofthe engine.t

Fig. A.3.2-6: Cooling water out

The Panda Generator


Water cooled exhaust elbow

The exhaust elbow is cooled by the coo-ling water comming from the engine.

Fig. A.3.2-7: Water cooled exhaust elbow

Venting screw exhaust elbow

The venting screw should not be opened ifthe generaqtor is running. Air will pene-trate the cooling circle.

Fig. A.3.2-8: Venting screw exhaust elbow

KCooling water hose

Cooling water hose from exhasut elbow topre silencer

Fig. A.3.2-9: Cooling water hose

The Panda Generator


Water cooled pre silencer

Fig. A.3.2-10: Water cooled pre silencer

Venting screw pre silencer

De aerating of the cooling system at thsscrew.

Fig. A.3.2-11: Venting screw

Cooling water out

Connect the colling wter hose to the radia-tor here (hot side)

Fig. A.3.2-12: Cooling water out

The Panda Generator


A.3.3 Components of the fuel system

external Tank external elec. fuelpump

fuel stop solonoid

fuel injection nozzle

fuel in

fuel out

air filter housing

engineKubota EA300

exhaust elbow

pre-silencer

glow plug

automatic venting filler cap with strainer

injection pump

Fuel filter +water seperator

fuel in

exhaust out

combustionair in

The Panda Generator


Fuel pump

Fig. A.3.3-1: Fuel pump

Connections for the fuel supply

1. Fuel in

2. Fuel out

Fig. A.3.3-2: Fuel connection

Fuel solonoid

The fuel solonoid open automaticly whenthe start button at the iControl panel ispushed.The solonid is closed when youpress the stop buttton

It will take a few seconds till the generatorstop

If the generator is not starting, or notreach the higher rpm, mainly the fuel solo-noid is out of order.

1) Fuel solonied2) Venting screw at solonoid

Fig. A.3.3-3: Fuel solonoid

1

2

2

1

The Panda Generator


Injection nozzle

Fig. A.3.3-4: Injection nozzle

Glow plug

Fig. A.3.3-5: Glow plug

The Panda Generator


A.3.4 Components of cumbastion Air circle

external Tank external elec. fuelpump

fuel stop solonoid

fuel injection nozzle

fuel in

fuel out

air filter housing

engineKubota EA300

exhaust elbow

pre-silencer

glow plug

automatic venting filler cap with strainer

injection pump

Fuel filter +water seperator

fuel in

exhaust out

combustionair in

The Panda Generator


Air in at the generator cover

Do not cover!

Fig. A.3.4-1: Air in

Air sucction housing

Fig. A.3.4-2: Air sucction housing

Air filter housing with filter matt

Sample picture

Fig. A.3.4-3: Air filetr housing

The Panda Generator


Watercooled exhaust elbow

Fig. A.3.4-4: Exhaust elbow

Compensator under heat isolation

Fig. A.3.4-5: Compensator

Exhaust out

Fig. A.3.4-6: Exhaust out

The Panda Generator


A.3.5 Components of the electrical system

The Panda Generator


Starter battery

1. Connection point (+)

2. Connection point (-)

Fig. A.3.5-1: Starter battery

Electrical connections

1. Cabel to PHGMi

2. Cable to radiator fan

3. Cable to fuel pump

4. Cable to iControl remote control panel

Fig. A.3.5-2: Electrical connection

Starter with solonoid

1. Starter

2. Solonoid

Fig. A.3.5-3: Starter

2 1

1

2

3

4

12

The Panda Generator


Fuses

30 A green for DC supply

25 A white for radiator fan

Fig. A.3.5-4: Fuses

Plug of the aux. winding

Fig. A.3.5-5: Hilfswicklung

Bridge rectifier with capacitator for theaux. winding

1. Bridge rectifier

2. Capacitator

Fig. A.3.5-6: Brückengleichrichter

1

1

1

2

The Panda Generator


A.3.6 Komponents at the oil circle

Oil filler cap

Pleas note the oil spezification

Fig. A.3.6-1: Oil filler cap

oil filler cap

engineKubota EA300

oil strainer

oil dipstick

oil pressure

switch

oil drain hose

iControl electronic board

operator control

oil in

oil out

The Panda Generator


Oil dip stick

When the oil reaches the min level, fill itup to 2/3.

Fig. A.3.6-2: Oil dip stick

Oil drain hose

Open the screw at the end to drain the oil

NOTE! Oil and generator parts may be hotafter operation

Fig. A.3.6-3: Oil drain hose

The Panda Generator


A.3.7 Thermosensor/switches

Thermosensor cylinderhead

Fig. A.3.7-1: Thermosensor cylinderhead

Thermoswitch/Thermosensor pre silencer

At this point the cooling water has normalthe highest temp.

1. Thermosensor

2. 82°C/77°C (Fan fast)

3. 75°C/70°C (Fan slow)

Fig. A.3.7-2: Thermoswitch/sensor

Resistor

01. The resistor is connected in row withthe Thermo switch 75°C/70°C.

Fig. A.3.7-3: Resistor

1

2

3

1

The Panda Generator


Winding- Thermosensor

Another Thermosensor is build into thewinding

Fig. A.3.7-4: Thermosensor winding

Oil pressure switch at the engine

Fig. A.3.7-5: Oil pressure switch

The Panda Generator


A.3.8 External Components

Panel iControl

Fig. A.3.8-1: iControl

Electronic board for iControl mounted at the genera -tor.

For description please see „Panel Manual“

Fig. A.3.8-2: Electronic board

PMGi 4000

The „inverter“ of the Panda 4000i

Fig. A.3.8-3: PMHGi 4000

The Panda Generator


A.4 Operation Instructions - see separate control pa nel manual

A.4.1 Daily routine checks before starting - See iCo ntrol manual.

A.4.2 Starting Generator - See iControl manual.

A.4.3 Stopping the Generator - See iControl manual.

Installation

26.5.08 Panda_4000i_PVMV-N_Book_eng.R03 - Kapitel B: Installation Seite 41

B. Installation

B.1 Connections of the generator

Attention! See the “Safety Precautions” auf Seite 1 2 lesen before installation

B.1.1 Primary remark

• make shure that the engine room is well vemtilated

• Do not cover the Radiator or the generator air intake

• Only trained persons should work at the generator

B.1.2 Connections

Fig. B.1.2-1: Connections

3 7 81 2 4 5 6 9

1. Cooling water in2. Cable to the PGMi3. Cable to the radiator fan4. Cable to the fuel pump5. Cable to the iControl panel6. Fuel out

7. Fuel in8. Cooling water out (hot side)9. Exhaust out10. Starterbatteye (-)11. Starterbattery (+)

Installation

Seite 42 Panda_4000i_PVMV-N_Book_eng.R03 - Kapitel B: Installation 26.5.08

B.1.3 Installation of the fuel system

Additional fuel filters (with water seperator) must be mounted outside the capsule in easily acces-sible 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 connectthe 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 cablefor the fuel pump is already installed on the generator (length 5m).

B.1.4 The electrical fuel pump

Electrical fuel pump

With the Panda generator is usually supp-lied an external, electrical fuel pump (12VDC). The fuel pump must be installedclose at the fuel tank. The electrical con-nections are preloaded at the generatorwith the lead planned.

• • Suction hight of the pump: max. 1,2m at 02, bar

• • Diameter of fuel lines: “Diameter of conduits” on Page 71

B.1.5 Position of the pre-filter with water separato r

Additionally to the standard fine filter a pre-filter with water separator must be installedoutside of the sound cover in the fuelsystem line. (is not included in delivery.)

Installation

26.5.08 Panda_4000i_PVMV-N_Book_eng.R03 - Kapitel B: Installation Seite 43

B.1.6 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, ifthe generfator is mounted higher than the tank, in order to prevent fuel running back into the tankafter the motor has been switched off, which can lead to enormous problems if the generator isswitched 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 afterthe generator has been switched off, if it is not possible to use the return flow pipe as a submergepipe be placing it in the tank. The instructions "Bleeding Air from the Fuel System" must be readafter initial operation or after it has stood still for a long period, in order to preserve the starter bat-tery.

ATTENTION! Non-return valve for the fuel return pip e

If the fuel tank should be installed over the level of the generator (e.g. daily tank), then anon-return valve must be installed into the fuel re turn pipe to guaranteed that through thereturn pipe no fuel is led into the injection pump.

Fig. B.1.6-1: Installation sample

1

4

2

3

1. Generator2. Externer Kraftstofffilter mit Wasserabscheider

3. Rückschlagventil (optional)4. Kraftstofftank

Installation

Seite 44 Panda_4000i_PVMV-N_Book_eng.R03 - Kapitel B: Installation 26.5.08

B.1.7 Battery connection

Fig. B.1.7-1: Installation sample

B.2 Generator Electric-System-Installation

ATTENTION! Before the electrical system is installe d, READ the “Safety Precautions” onPage 12 of this manual FIRST! Be sure that all elect rical installations (including all safetysystems) comply with all required regulations of th e regional authorities. This includeslightnening conductor, personal protection switch e tc.

Required cable cross-sections

The following recommended electrical cable dimensions (cross sections) are the minimum requi-red sizes for a safe installation. (see “Cable cross-section” on Page 71)

1

4

2

3

1. Generator2. Batteryswitsch

3. Fuse4. 12V Starterbattery

Panda6000ND_PVK_U_Book_s01645Installation

26.5.08 Panda6000ND_PVK_U_Book_s01645 - Kapitel B: Panda6000ND_PVK_U_Book_s01645Installation - Seite 45

B. Panda6000ND_PVK_U_Book_s01645Installation

B.1 Connection of the external radiator

Connection of the external radiator - Installation sample

Fig. B.1-1: Installation sample

1

1

1. Generator 2. Radiatorr


Seite 46 Panda6000ND_PVK_U_Book_s01645 - Kapitel B: Panda6000ND_PVK_U_Book_s01645Installation 26.5.08

B.2 The Battery Monitor

For the automatic start of the generator a battery monitor is necessary.

This battery monitor ensures that the unit starts automatically when the battery voltage dropsbelow a pre-set level. If the battery voltage exceeds the adjusted value, then the unit is stoppedautomatically. The two contacts of the battery monitor (7+ & 8 -) must connected with the appro-priate clamps of the iControl Panel (see iControl datasheet)

!! For more information see Battery monitor datasheet

B.3 Cooling system

General instructions

The PANDA vehicle generator is supplied as standard without a radiator. Various radiators areavailable according to the customer’s requirements; these can be chosen according to the appro-priate operating and installation situation. The cooling system can also be assembled togetherwith a normal commercial vehicle radiator.

Determing the size of the radiator

Consideration must be paid to the total heat load when determining the size of the unit. Thisequates to the generator nominal performance without the water-cooled pre-silencer. The heatresistance is 1.8 times the generator nominal capacity, when the water-cooled pre-silencer isused (i.e. Panda 12000 PVMV-N has a total heat capacity of approx. 18kW). The radiator can beserviced by any usual radiator servicing agency. It should, however, be pointed out that the radia-tor possesses high safety levels. Tthe radiator is often manufactured too small. ICEMASTER alsohas various radiators available (for horizontal and vertical installation) as standard generatorcomponents.



Radiator position

The place and fitting position of the radiator must be carefully considered. It is especiallyimportant that the warm air can escape. For this reason, the best place for the radiator is in a ver-tical position on the vehicle roof (if one take into account that an obstruction could arise in narrowentrances).

The manufacturer is only too happy to give suggestions on how to install the radiator. It must,however, be expressively pointed out that all recommendations of this type are not binding . Itcontinually occurs that special influencing factors are not recognised from the start. The customeror the technician making the installation must always take changes to the position or radiator’splace of installation into consideration. The manufacturer cannot accept liability for the recom-mendations given to the best of his knowledge. As a precaution, attention should always be paidthat the air outlet for escaping warm is as large as possible . The vehicle paint sprayer is oftennot in agreement with this, but the person making the installation must make the aim clear. Thefitter must make his position clear.

Radiators which are installed vertically, and the warm air is blown downwards , must be twice thesize of such radiators, by which the warm air rises through its own thermal energy. It must also beconsidered that a build up of heat results through the emission of warm air in the direction of theground, whereby the warm air is once again forced to rise to the area of the radiator. Freely esca-ping warm air cannot be guaranteed in this case. Additional ventilators may be necessary shouldthe warm air need to be channelled through pipes.

It must be ensured that warm air is extracted out of the radiator.

Permitted coolant temperatures

The performance of the radiator must be so measured that the coolant temperature of the Pandagenerator does not exceed more than 70°C. The coola nt intake must be fitted direct to the coolantpump.

There must be a large amount of water circulating to ensure that the difference in temperaturewhen compared to the temperature of the water leaving the generator (full load) does not exceed12°C. The difference may also amount to 17K if a pr e-silencer is installed.

The hoses must be so laid out that knots and other obstructions are avoided. If necessary, theamount of coolant must be measured. As a minimum the following values are necessary:

Essential coolant amounts:

Panda 4500 ............................... min. ca. 10 l/min

Panda 8000 - 9000 ...................approx. 16 bis 22 l/min

Panda 12000 - 14000 ..............approx. 24 bis 28 l/min

Panda 18 - 24 ........................... approx. 32 bis 38 l/min



The greater the amount of coolant circulating, the lower the difference in temperature. If thenecessary cooling performance cannot be achieved, the amount circulating can be increased byadjusting the pulley on the pump and thereby raising the performance.

ATTENTION! The coolant pressure may, however, not exceed 0.7 bar!



Construction and position of the radiator

The radiator can be assembled away from the generator in a well ventilated position. Attentionmust be paid that the radiator emission direction is completely free of obstruction. Turbulence isto be avoided. There is often a clash between the streamline appearance of the chassis and thetechnical requirements.

The radiator can be installed (vertically) or (horizontally). Consideration must be given to the factthat air is drawn in via a fan motor.

The best result is achieved if the radiator is fitted vertically on the vehicle roof.

Possible positioning of the external radiator

Fig. B.3-1: Radiator position sample

Pay attention to the following item at the horizont al assembly of the radiator:

To avoid damages of the fan motor please bore some holes on the backside of the fan (diameterapprox 4mm). Because water can enter the fan (rainwater, condenswater, sweatwater etc.). Thewater can run out through these holes. (see below 02) Generally a fan is a wearing part andshould be changed one time a year.

2

1

3

1. Radiator on the roof2. Radiator vertical

3. Radiator under the vehicle



Fig. B.3-2: water drain holes

Distance from the radiator to the unit

The coolant water pump mounted on the generator is so laid out that a distance of up to 7 mtrslength from the radiator is possible. The hose cross-section must be laid out accordingly. Theminimal internal diameter amounts to 18mm (Panda 4500). A hose must be used for both sides(forward and back flow) which is resilient to pressure and high temperatures (at least 120°C).

Minimum hose diameter for cooling lines:

Panda 04 - 10 kW .................... Ø18mm (¾")

Panda 12 - 20 kW .................... Ø25mm (1")

Panda 25 - 30 kW .................... Ø32mm (1¼")

Panda 40 - 50 kW .................... Ø38mm (1½")

Panda 50 - 60 kW .................... Ø44mm (1¾")

Coolant expansion tank

It is absolutely essential, that a exoansion tank, that can be aerated, is fitted adjacent to the radia-tor. The ventilation pipe should, if possible, be fitted to the radiator’s highest position. For this, apipe with a maximum diameter of 10mm suffices, which must be fed to the expansion tank. A fur-ther pipe, which must be fitted to the floor of the expansion tank, can be fitted to the coolingsystem in any desired place (i.e. T-piece). Frequently a connection is provied on the radiator its-elf. The coolant expansion tank is not normally supplied by ICEMASTER. For this a standardvehicle expansion tank is the most suitable. Vehicle accessory range is the most suitable.

2

1

1. Plug for fan control 2. Bores (diameter 4mm)



Coolant Pump

This Is normally equipped with a independent impeller suction pump. This pump suffices if thecooling water pipes etc equate to the normal standard. ICEMASTER can give no guaranty. Itmust be determined whether the amount of cooling water circulating is sufficient. Considerationmust always be given to the fact that the water flow is supported by an external pump.

Antifreeze

The antifreeze concentration must be regularly checked in the interests of safety. The antifreezesolution supplied from the factory provides protection to -15°C. If lower temperatures are occasio-ned during transportation or storage, then the coolant must be drained. The cooling system is,however, so arranged that the draining of the coolant is only possible in the assembled state,when air under pressure is blown into the system. Air pressure of approx. 0.5b suffices, in orderto blow out the water.

Suction filter as a source of noise

The external suction filter (not included on delivery) must always be used if the generator is to beused in a dust-free environment. This filter is connected by means of a hose with a connectingpiece to the generator housing. The filter can be the source of considerable noise. If this is thecase, an air intake muffler with the appropriate nominal width should be ordered from ICEMA-STER. This is a cylinder, which takes up relatively large amou nt of room (Total length approx700mm, Diameter 100mm).

Vehicle Generator with Centrifugal Coolant Pump

An impeller pump can also be provided if the radiator, for technical reasons, is to be installed rela-tively distant from the radiator and addtionally requires a number of changes to the direction ofthe pipe. This coolant impeller pump is mounted on the generator as an additional pump, and isdriven by pulleys. The pump action is carried out by a "rubber impeller".



ATTENTION! Temperature restriction!

This pump may only be used if it is ensured that the temperature of the coolant entering the pumpdoes not exceed 70°C during continual duty. 75°C is permissible for short periods. These may,however, in no case be for longer periods. If the coolant temperature exceeds the permissiblerate, this can lead to the impeller blades being torn off.The advantage of this impeller pump is thatthis pump, as a "positive displacement pump", is self-suctioning and is therefore very sensitive toair bubbles etc.

Ventilating the cooling system with the aid of a self suction impeller pump is very simple. In somecases the pump is additionally installed for this reason alone. Unfortunately the operating noise ofthese pumps is very loud.

In spite of this attention must be paid that a zone is available at a high point, where the airbubbles in the coolant are able to escape to. As a rule, this is the expansion tank, as long as thisis connected direct to the tank. If the coolant expansion tank is, however, so integrated in thesystem that it cannot be reached by circulating water, then an air release valve must be fitted inthe circulation pipe at a place of your own choice, which can then also be connected to theexpansion tank (see next page).

In case of doubt, you should send a diagram of the required coolant system to ICEMASTER andlet this be checked there.

Installation with special air separator

An "air separator" must be fitted at all critical places in the circulation system, in case a perfectautomatic ventilation on account of obstacles in the pipe passage cannot be achieved. A self-actuating ventilation valve must be fitted to each air separator.

Monitoring the Temperature

You are expressively advised to measure the temperature of the circulating coolant after installa-tion. Two remote thermometers must be used for this. A connection must be fitted to the motorcoolant inlet; the second on the coolant outlet. After a short warming-up period, the generatormust have a load of at least 75% of the nominal capacity placed on it. The coolant circulating is tobe checked. The values must lie within the following limits:

1. Coolant inlet, max 70°C during constant duty at m aximum load

2. Coolant outlet, max 85°C during constant duty

3. Difference of both values: This point is especially important and gives an indication of the coo-lant circulating. The difference should amount to a maximum of 17°C for a water-cooledsystem with an integrated water-cooled pre-silencer, as a rule it should, however, lie between10 - 12°C.

The circulating coolant is not sufficient, if the difference amounts to more than 15°C, and theamount of water circulating must be increased. This can be solved, for example, if the pipe pas-sage is improved or the pulley diameter is reduced. It is absolutely essential to measure the per-formance of the cooling system after installation of the generator. The above named valuesshould be considered as the maximum permissible values. They are also valid for operation athigh temperatures. During constant duty at normal temperatures (20°C), the values should bewell below the above named data.



Installing a Coolant Temperature Display

A remote display unit for coolant temperatures should be installed, when fitting sensitive systems(i.e. Television broadcasting vehicles, ambulances or other vehicles) with sensitive measuringinstruments. In this case a standard coolant display device with remote thermometer can beused. It is absolutely essential that two display instruments are installed:

1. Cooling water inlet

2. Cooling water outlet

It does not matter at which place the measurement is made. T-pieces for hose elements can beobtained from ICEMASTER into which the usual trade sensors can be installed.

Monitoring of temperature:

1. Temperature at the cylinder head

2. Temperature at the manifold

3. Temperature in the generator winding area (only Panda 8000 upwards)

The winding temperature monitor is not fitted with a special display unit. The fuel solenoid valve isswitched on as a circuit breaker for the motor stop solenoid or the fuel pump. If the generatorswitches off because the winding overheats, nothing is displayed. In this case a long period ofwaiting can, in circumstances, be necessary. This can be bridged by using the switch. This mustbe carried out by an electrician who should use the circuit diagram for this. It suffices in this casewhen the plug which leads to the guage wire is opened and both conducters in the plug are brid-ged. This shut down should, however, be a last resort! It is only applicable, if the generator tem-perature exceeds the permissible value on account of inaccessible working conditions. It mustthen be explained which measures are necessary to restore normal operating conditions.

Recording the temperature values

Installation records are delivered with every handbook, which must be completed after installationand returned to the manufacturer (Copy). The generator should be tested at 70% of its maximumperformance. The temperature values must be checked at the maximum possible performance.The external temperature must be taken into consideration when doing this check. The values forT1 (see additional installation record for the vehicle version) may not exceed 85°C, even at highexternal temperatures and maximum load. If necessary the maximum permissible performancemust be reduced (i.e. by the use of fuses).

Connection of the Generator to the Vehicle Cooling System

The Panda can in many cases be connected to the original vehicle system (vehicle-drive motor),without a problem. The amount of time required to do this is minimal, if the vehicle radiator is fit-ted with an electric fan. Should that not be the case, an electric fan is to be additionally placed infront of the radiator, which is monitored by a thermostat. The coolant pipes are connected directlywith the pipes leading from the motor to the radiator. This installation is comparable with theinstallation of an additional hot water heating system, as long as this includes the motor coolingsystem. The manufacturer should be consulted in cases of doubt. The generator can be fitted tothe vehicle cooling system via a heat exchanger, should there be any objections.



Connection of the Generator to the Vehicle Cooling System


Connecting the Generator Cooling System with the Ve hicle Cooling System can bring the following advantages:

1. Pre-warming of the vehicle motor in winter (The generator can also be automatically startedvia a time switch).

2. Exploitation of the generator heat for vehicle heating systems (i.e. buses, conference vehicles,promotion vehicles etc.).

3. Otherwise saves the required space and the cost for an additional generator radiator.

We must, however, point out that connection of the vehicle cooling system to the motor coolingsystem requires a relative amount of experience of vehicle cooling systems. Various require-ments must be considered. For example, it must be considered that the system acts as a"Bypass" when opening the cooling system thermostat. In some cases heating systems are con-nected to the system, which can then also operate as a "Bypass".

No liability is assumed, when a recommendation is made by the generator manufacturer to con-nect the generator to the motor cooling system. The person making the installation must alsoensure in this case that all conditions of this type are considered.

It should also be considered that the vehicle thermostat or the thermo switch must be adjusted tothe starting point for the radiator fan. In certain circumstances it is also essential to use additionalthermostats for switching on the fan, which are installed in the generator’s coolant pipes.

ICEMASTER can accept no liability if the cooling system does not function correctly.

Chassis construction companies and companies manufacturing vehicle assemblies should beaware that there could be problems with the motor or vehicle manufacturer regarding the gua-ranty, if consequential damage occurs to the motor because of coolant pipe leaks. ICEMASTERwill not accept any liability, if further units (i.e. vehicle motor) are damaged, when a part of thegenerator cooling system itself breaks down.

4

6

51 2 3

7

1. Exhaust pipe2. Water-cooled pre-silencer3. Combustion motor4. Coolant expansion tank

5. Vehicle combustion engine6. Vehicle radiator7. Fan for radiator



External radiator should be installed when initiall y being put into operation or after repairs

A ventilating valve is fitted, as a rule, to all units manufactured since the Spring 1995. A hosemust be placed on the connecting nozzle ventilation valve to aerate the unit (nominal width 6-8mm). A transparent hose is recommended, since the ventilation process is easy to observe. Thehose is to be fixed with light hose clips to the connecting nozzle. The hose must be sufficientlylong to be able to feed the other end into the open coolant expansion tank during operation.

The coolant expansion tank is initially filled with coolant. The air valve must be completely openedbefore the following procedure is carried out. You should assure yourself whether the connectingpipe has been connected correctly to the coolant backflow pipe by means of a T-piece. This pipeshould have an internal diameter of 12mm. Since the coolant pipes, for technical reasons, canonly be gradually laid out with difficulty, resistance builds up during refilling, which can only be dis-placed with difficulty by the air in the generator or motor. This process can be made easier by pro-ducing excess pressure by means of the above mentioned ventilation pipe. The process is easedconsiderably, in that a transparent ventilation hose draws in air (this can also be carried out bymouth, if done cautiously). Meanwhile the coolant expansion tank should, at the same time, berefilled with water. The generator can be started as soon as the drawn in water is seen in the ven-tilation pipe (all other measures must, of course, be considered, for example, checking whetherthe motor oil has been topped up etc., as stipulated in the generator operating

instructions).

During the starting process, the coolant expansion tank must be continually refilled with coolantso that no further air can force its way into the system from above. The other end of the ventilationpipe should be laid in the open coolant expansion tank filling opening, so that outflowing coolantruns back into the tank.

During the starting process the open coolant expansion tank must continually be filled with coo-lant so that no further air can force its way into the system. The ventilation pipe should be laid inthe open filler cap of the coolant expansion tank during the starting procedure, so that escapingcoolant runs back into the tank.

Decisive for the success of this procedure is that sufficient water enters to internal coolant pump,so that the coolant pump can function. The coolant pump cannot draw water as long as there isair in the casing.



Installation diagram for vertical radiator


02

07

03

06

05

01 04

09 1108 10

01. External fan control02. Coolant expansion tank03. Ventilation pipe04. Ventilation screw05. Fan for radiator06. Radiator

07. Stop valve for coolant08. Thermoswitch09. Bucket with submerged pump10. Water-cooled pre-silencer11. Internal cooling water pump



Installation diagram for underneath the vehicle


03

07

04

06

05

01

08 09 11 12

02

1013

01. Water-cooled pre-silencer02. Water-cooled exhaust elbow03. Coolant expansion tank04. External fan control05. Dry silencer06. Exhaust outlet07. Pipe with connection for Thermoswitch

08. External cooling water pump09. Stop valve for coolant10. Pipe with connection for Thermoswitch11. Radiator12. Fan for radiator13. Bucket with submerged pump



Installation diagram for radiator on the roof


2

6

3

5

4

1

1. Ventilation pipe2. Radiator (horizontal)3. Coolant expansion tank (integrated)

4. T-piece for Ventilation pipe5. External cooling water pump6. Bucket with submerged pump


Seite 58 Panda6000ND_PVK_U_Book_s01645.R01 - Kapitel B: Panda6000ND_PVK_U_Book_s01645Installation 26.5.08

Installation diagram with special air separator


2

7

6

1

4

5

3

1. Ventilation pipe2. Coolant expansion tank3. T-piece for coolant expabsion tank4. Water-cooled pre-silencer

5. Exhaust output6. Special air separartor7. Radiator



B.4 Exhaust Installation

Exhaust connection for roof outlet


Exhaust connection for mounting below the vehicle


3

2

1

4 5 6 7 8

1. Exhaust port2. Generator3. Roof outlet for exhaust pipe4. Shock absorber

5. External pre-silencer6. Connection pipe7. External silencer8. Exhaust pipe

1 2 3 4 5 6 7 8

1. Generator2. Exhaust port3. Compensator 4. External pre-silencer

5. Shock absorber6. Connection pipe7. External silencer8. Exhaust pipe



Mode of Operation of the Generator

26.5.08 Panda_4000i_PVMV-N_Book_eng.R03 - Kapitel C: Mode of Operation of the Generator Seite 61

C. Mode of Operation of the Generator

C.1 Mode of Operation of Operating Surveillance

Internal monitoring switches

The generator is equipped about failure sensors, which are indicated on the remote control panel,and also about failure switch, which switch-off the generator automatically without indicating afailure in the remote control panel:

The remote control panel supervised the following values. In the case of a disturbance the gene-rator is switched off, in order to avoid damage to the aggregate:

1. Cooling water temperature at engine and exhaust connection

2. Coil temperature

3. Oil pressure

The fault is transmitted, if one of these sensors measures a value that exceeds the requiredvalue. (Fuel magnet valve closes, the fuel suction pump is switched off).

The combustion engine possesses an oil pressure control switch, which switches the engine off ifthe oil pressure drops under a certain value.

Location of the sensors and switches see "A.3.7 Thermosensor/switches” on page 37.

C.2 Safety instruction

Do not run the generator with a open sound cover.

Sofern der Generator ohne Schalldämmgehäuse montiert werden soll, müssen die rotierendenTeile (Riemenscheibe, Keilriemen etc.) so abgedeckt und geschützt werden, daß eine Verlet-zunggefahr ausgeschlossen wird.

Falls vor Ort ein Schalldämmumbau angefertigt wird, muß durch gut sichtbar angebrachte Schil-der darauf hingewiesen werden, daß der Generator nur mit geschlossenem Schalldämmgehäuseeingeschaltet werden darf.

Alle Service-, Wartungs- oder Reparaturarbeiten am Aggregat dürfen nur bei stehendem Motorvorgenommen werden.

Elektrische Spannung LEBENSGEFAHR !

Die elektrischen Spannungen von über 48V sind immer lebensgefährlich. Bei der Installa-tion sind deshalb unbedingt die Vorschriften der je weils regional zuständigen Behörde zubeachten. Die Installation der elektrischen Anschlü sse des Generators darf aus Sicher-heitsgründen nur durch einen Elektrofachmann durchg eführt werden.

Es muß immer die Starterbatterie abgeklemmt werden (zuerst Minus- dann Pluspol), wenn Arbei-ten am Generator oder am elektrischen System des Generators vorgenommen werden, damitder Generator nicht unbeabsichtigt gestartet werden kann.

Mode of Operation of the Generator

Seite 62 Panda_4000i_PVMV-N_Book_eng.R03 - Kapitel C: Mode of Operation of the Generator 26.5.08

C.3 Generator Betriebsanleitung

C.3.1 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

C.3.2 Hose elements and rubber formed component in t he sound cover

Check all hoses and hose connections for good condition. The rubber hoses are very sensitive toenviromental influences. They can season fast with dry air, in which environment of muted oil andfuel 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 mainte-nance activities are to be accomplished for marine aggregates.

C.4 Oil level

The best oil level is 2/3

C.4.1 Start of the Generators - see iControl datasah eet

C.4.2 Stop of the Generators see iControl datasheet

Maintainence

26.5.08 Panda_4000i_PVMV-N_Book_eng.R03 - Kapitel D: Maintainence Seite 63

D. Maintainence

D.1 Check Daily

• Oil level

• Cooling system leaks

• Visual check for any changes, leaks oil drain system, v-belt, cable connections, hose clips, air filter, fuel lines

Maintenance see Table E.5, “Inspection checklist fo r services,” on Page 76.

D.2 Oil circuit maintenance

The first oil change is to be accomplished after a period of operation from 35 to 50 hours. After-wards the oil is to be changed after 100 hours. For this the oil SAE30 for temperatures over 20°Cand SAE20 for temperatures between 5°C and 20°C is to be used. At temperatures under 5°C oilof the viscosity SAE10W or 10W-30 is prescribed.

Type and amount of required oil see:Table E.6, “Engine oil,” on Page 77 and Table 2, “TechnicalData,” on Page 71.

D.3 Execution of an oil change

To drain the oil open the screw at the endof the oil drain hose.

Note! Generator parts and oil may be hotafter operation.

Fig. D.3-1: Oil drain hose

Maintainence

Seite 64 Panda_4000i_PVMV-N_Book_eng.R03 - Kapitel D: Maintainence 26.5.08

IIf it is not possible to drain the oil, use ansiutable oil pump.

Close the screw after draining

Fig. D.3-2: Oilpump

Oil filler cap

Refill the engine with new oil here

Fig. D.3-3: Oil filler cap

Check the oil level with the oil dip stick.

Do not fill the oil over the max. mark.

Fischer Panda recommend 2/3 oil level.

Fig. D.3-4: Oil dip stick

Maintainence


D.4 Venting the cooling water circiut

Special notes:

After draining the coolant or if the system has sucked air in, the circiut must be de aerated.

Open the venting screws only, when the generator is not running. Els air will be sucked in .

NOTE!: Generator parts and cooling water may be hot after operation. !! DANGER TOHEALTH!!

Open the venting screw at the engine.

Wrench size: SW10mm

Fig. D.4-1: Venting screw motor

Open venting screw exhaust elbow

Wrench size: SW10mm

Fig. D.4-2: Venting screw exhaust elbow

Maintainence


Open venting screw pre silencer

Wrench size: SW10mm

Fig. D.4-3: Venting screw pre silencer

Fill the cooling water into the Radiator

Sample picture

Fig. D.4-4: Cooling water filler cap

When the cooling water is filled to the max level and the level do not drop anymore, close the ven-ting screws.

Run the generator for max 60 sec. Stop the generator.

Repeat the filling procedure.

Maintainence


When no change of the cooling water level is mentioned any more, run the generator for 5 minutes.

Check with an IR Thermometer if all hoses and the pre silencer gets warm. If not the cooling waterdoes not circulate and you must repeat the de aerating and filling.

Run the engine for some more time and check if the fan starts running.

Repeat the de aerating after 2-3 days to make shure that every air is out of the system

D.4.1 De-aerating the fuel system

Normally, the fuel system is designed to bleed out air itself i.e. as soon as the electric startermotor starts operation the fuel pump starts working and the fuel system will be de-aerated aftersome time automatically. It is nevertheless essential to bleed the system as follows prior to thefirst operation (as all hoses are empty):

1. Place an container under the fuel outconnection

Fig. D.4-1: Fuel out

2. Disconnect the plug at the starter solo-noid

Fig. D.4-2: Starter solonoidr

3. Switch panel on . (see Fernbedienpanel datasheet)

Fig. D.4-3: Remote Control Panel

Maintainence


4. Push the start button. (The fuel pump start running)

5. Switch panel off

6. Switch panel on

7. Again push the start button

Repeat this procedure, till the fuel runs out of th e Fuel out connection without bubbles.

8. Switch panel off

9. Reconnect the plug at the starrter solonoid.

D.5 Checking the water separator in the fuel supply

The pre-filter with water separator has acock at its lower surface, with this cock thedownward sunk water can be discharged.

This is simply possible, water is heavierdue to its density than the Diesel.

Fig. D.5.0-1: External fuel filter

Maintainence


D.6 Replacement of the air filter matt

Open the air filter housing by removingthe six hexagon screws

Wrench size: SW 8mm

Fig. D.6-1: Air filter housing

Replace the Air filter matt

Close the Air filter housing.

Fig. D.6-2: Air filter matt

Maintainence


Blank

Generator Tables

26.5.08 Panda_4000i_PVMV-N_Book_eng.R03 - Kapitel E: Generator Tables Seite 71

E. Generator Tables

Tabelle 1: Diameter of conduits

Generator type

Ø Cooling water pipeØ Exhaust hose

[mm]

Ø Fuel hose

Fresh water

[mm]

Raw water

[mm]

Supply

[mm]

Return

[mm]

Panda 4000i PMS 20 20 30 8 8

Tabelle 2: Technical Data

TypeNominal power

[kW]Continuous power [kW]

Panda 4000i PMS

4 3,2

Tabelle 3: Cable cross-section

Wiring for vehicle.

single phase, not tin-plated, PVC-isolated.

nominal wire cross-section[mm²]

allowed conrinuous current (reference point) a

at +30°C [A] at +50°C [A]

1 19 13,5

1,5 24 17,0

2,5 32 22,7

4 42 29,8

6 54 38,3

10 73 51,8

16 98 69,6

25 129 91,6

35 158 112

50 198 140

70 245 174

95 292 207

120 344 244

a. DIN VDE 0298, part 4.

Generator Tables

Seite 72 Panda_4000i_PVMV-N_Book_eng.R03 - Kapitel E: Generator Tables 26.5.08

E.1 Trouble shooting

GENERATOR OUTPUT VOLTAGE TOO LOW

If the generator delivers less than 24V current ("undervoltage"), there can be various reasons for this:

Cause Solution

PGMi is overloaded. Reduce the electrical load. (Switch off load)

Motor is not reaching the rated rpm. Refer to "motor faults" section.

MOTOR DOES NOT TURN OVER WHEN STARTING

Cause Solution

Battery main switch is switched off. Check the position of the battery main switch, if neces-sary switch on..

Battery voltage not sufficient. Check that connection is firm and whether corrosionhas occurred..

Starting current fault. The voltage of full batteries fall to a maximum of 11V.The wiring is severed if the voltage does not drop. Thebattery is discharged if the voltage drops further.

MOTOR TURNS OVER BUT DOES NOT START

Cause Solution

Stop solenoid valve not opening. Check wire connections and circuitry to solenoid valve.(ref. DC wiring diagram: Relay K2, Fuse)

Fuel pump does not operate. Check fuel-filter and pump: clean if necessary.

Lack of fuel. Check fuel supply.

Glow-plugs not working correctly. Check glow plugs and heating time.

Too much air in fuel lines. Test fuel system for leakage. Bleed air from fuel system(refer to section "Air-bleeding of the Fuel System").

Fuel filter blocked. Replace fuel filter.

Low compression pressure. See Kubota motor-manual.

Generator Tables


MOTOR DOES NOT TURN OVER AT THE NORMAL SPEED DURING THE STARTING PROCESS

Cause Solution

Starter battery voltage insufficient. Check battery.

Damaged bearing(s) piston (seized). Repairs need to be carried out by Kubota-Service.(refer to Kubota motor-manual)

Cooling water in combustion chamber. 1. Turn generator "OFF" at control panel.

2. Remove the glow plug (see Kubota-manual).

3. Rotate the motor by hand carefully.

4. Check if there is water in the oil and change both oiland filter if necessary.

5. Determine cause for excess water in the combustionchamber. The excess water can be caused by a defec-tive air vent in the cooling water system, which shouldbe checked and cleaned, or replaced if faulty.

MOTOR RUNS IRREGULARLY

Cause Solution

Faulty centrifugal injector governor. Have the centrifugal governor inspected by a Kubota-Service technician.

Too much air in fuel lines. Bleed air from fuel system.

DROP IN THE SPEED OF THE MOTOR

Cause Solution

Too much oil. Drain oil.

Lack of fuel. Check fuel supply system:

- fuel filter, renew if necessary

- check fuel pump

- check fuel lines (bleed if necessary)

Lack of intake air. Check air intake paths.

Check and clean air filter (and intake muffler if instal-led).

Generator overloaded by too many load. Reduce the electrical load (switch off load).

Defective generator (windings, bearings, or other). Generator must be sent to manufacturer for repair ofdamaged bearings or winding.

Damaged engine. Repair of bearing damage, etc., by Kubota-Service.

Generator Tables


MOTOR SWITCHES ITSELF OFF

Cause Solution

Fuel solenoid valve or throttle shut solenoid is not swit-ching off.

Check wire connections to solenoid. Check valvefunctions as in the "Inlet Fuel Solenoid Valve" or in thetrottle shut off solenoid sections. Replace if necessary.

MOTOR STOPS BY ITSELF

Cause Solution

Lack of fuel. Check fuel supply system.

Excess heat in cooling system (thermo switch tripped)-lack of cooling water. Is indicated on the remote controlpanel.

Check cooling water system flow: water pump, inletwater 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 byKubota-Service if necessary.

SOOTY, BLACK EXHAUST

Cause Solution

Generator is overloaded. Check electrical load and switch off unnecessary load.

Insufficient intake air. Check intake air filter; clean if necessary.

Fuel injector nozzles faulty. Replace injector nozzles.

Valve clearance incorrect. Readjust valve clearance to correct value (refer toKubota-manual).

Poor fuel quality. Use better quality diesel (recommended: 2-D Diesel).

Poor combustion. Incorrect AFR (air/fuel ratio) due to motor timing adjust-ment. Have motor serviced by Kubota.

Low compression pressure. See Kubota motor manual.

GENERATOR MUST BE SHUT OFF IMMEDIATELY IF:

Cause Solution

- 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

Refer to respective section of manual and if necessary,have repaired by Kubota-Service, or Panda represen-tative.

Generator Tables


E.2 Technical Data Engine

Panda 4000i PMS

Type EA 300

Govenour --

Cylinder 1

Bore 75mm

Stroke 70mm

Stroke volume 309cm3

max. Power (DIN 6270-NB) at 3000rpm 5,1kW

Rated speed 3000rpm

Idle speed running a 3000rpm

Valve clearance (engine cold) 0,16 - 0,20mm

Cylinder head torque 58,8 - 63,7Nm

Lubrication oil capacity 1,3l

Fuel consumption b approx. 0,42 - 1,12 l

a. progressive speed by VCSb. 0,35l/kW electrical power, the randomized values between 30% and 80% of the nominal power

E.3 Technische Daten Generator

Generator Panda 4000i PVMV-N

Nominal power 4 kW , 50°C

Nominal Voltage 1-500 V

Drehzahl 3000 rpM

Stator Da 240 mm

Stator Di 170 mm

Rotor Lfe 20 mm

Generator Tables


E.4 Types of coil

HP3 delta connection

Fig. E.1: HP3 delta connection

E.5 Inspection checklist for services

Inspection work

1) check 4) change

2) measure 5) sealing

3) clean 6) check isolation

Inspection-Category

A Installation checkD 100 h

E 500 h

B daily F 1000 h

C 35 - 50 h G 5000 h

Inspection-CategoryInspection work

A B C D E F G

01. 5) 5) 5) 5) 5) 5) 4) coolant water hoses

02. 1) 1) 1) 1) 1) 4) 4) raw water pump (impeller)

03. 1) 1) 3) 3) 3) 3) 3) water separator / fuel pre-filter

04. 1) 1) 4) 4) 4) 4) 4) engine oil

05. 3) 3) oil strainer

06. 1) 1) 1) 4) 4) 4) 4) air filter

07. 1) 1) 1) 1) 1) 1) 1) fuel lines (leaks)

08. 1) 1) 1) 4) 4) 4) 4) fine particle fuel filter

09. 1) 1) 1) 1) 1) valve clearance

10. 1) 1) 4) 5) 4) 4) 4) valve cover gasket

11. 1) 1) 1) 1) coolant therm (sensor)

Generator Tables


12. 1) 1) 1) 1) exhaust temp sensor

13. 1) 1) 1) 1) oil pressure sensor

14. 1) 1) 1) 1) 1) 1) belt tension

15. 1) 1) 1) 1) 4) 4) 4) "V" belts

16. 1) 1) Thermostat

17. 1) 1) 1) 1) 1) 1) 1) generator & engine screws

18. 1) 1) 1) 1) 1) 1) 1) unit's base mount screws

19. 6) 6) 6) 6) 6) 6) 6) check electrical cables

20. 1) 1) 1) 1) 1) 1) 1) motor reinforced mountings

21. 1) 1) 1) 1) 1) 1) 1) actuator mounting

22. 1) 1) 1) 1) 1) 1) 1) starter motor mounting screws

23. 1) 1) 1) 1) 1) 1) 1) screws generator-engine

24. 2) 2) 2) 2) 2) 2) input temp of coolant under load

25. 2) 2) 2) 2) 2) 2) outlet temp of coolant under load

26. 4) 4) generator rotor bearing

27. 1) 1) 1) 1) 1) signs of corrosion to generator

28. 1) 1) 1) 1) 1) 1) VCS function test

29. 2) 2) 2) 2) 2) 2) voltage without load

30. 2) 2) 2) 2) 2) 2) voltage under load

31. 2) 2) 2) 2) 2) 2) current under load

32. 2) 2) 2) 2) 2) 2) engine speed (rpm)

33. 1) 4) injector test

34. 1) 1) compression

35. 1) 1) 1) 1) 1) 1) 1) hose clips

36. 1) 1) 1) 1) 1) 1) 1) recifier

37. 1) 1) 1) 1) 1) 1) 1) test cable with temperature tester

E.6 Engine oil

Engine oil classification

Operating range:

The operating range of an engine oil is determined by SAE class. "SAE" is for the union of American engineers(Society of Automotives Engineers). The SAE class of an engine oil only informs over the viscosity of the oil (lar-ger number = more viscous, lower number = more highly liquidly) e.g. to 0W, 10W, 15W, 20, 30, 40. The first num-ber shows the liquid of cold weather, the second number refers to the fluidity with heat. Complete yearly oils haveusually 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 designa-tion is to be found on each engine oil bundle. The first letter is always a C.

API C for diesel engines

The second letter is for the quality of the oil. The more highly the letter in the alphabet, the better the C für Diesel-motoren.

Examples for diesel engine oil:

API CG Engine oil for highest demands, turbo-tested !

Generator Tables


Engine oil types

above 25°C SAE30 or SAE10W-30

SAE10W-40

0°C to 25°C SAE20 or SAE10W-30

SAE10W-40

below 0°C SAE10W or SAE10W-30

SAE10W-40

E.7 Coolant specifications

Use a mixture of water and antifreeze. The antifreeze needs to be suitable for aluminium. The antifreeze concen-tration 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 descript ion

Product name GLYSANTIN ® PROTECT PLUS / G48

Chemical nature Monoethylenglycol with inhibitors

Physical form Liquid

Chemical and physical properties

Reserve alkalinity of 10ml ASTM D 1121 13 – 15 ml HCl 01 mol/l

Density, 20°C DIN 51 757 procedure 4 1,121 – 1,123 g/cm3

Water content DIN 51 777 part 1 max. 3,5 %

pH-value undiluted 7,1 – 7,3

Coolant mixture ratio

Water/antifreeze Temperature

70:30 -20°C

65:35 -25°C

60:40 -30°C

55:45 -35°C

50:50 -40°C

Generator Tables


E.8 Measurements

Fig. E.2: Measruremants

Generator Tables


Blank

Panda iControl

Fischer Panda GmbH

Panda 4000i - Part 2 Panel Panda iControl Manual

82

Current revision status

Document

Actual: Panda_4000i_Panda iControl.R01_26.5.08

Replace:

Revision Page

, Panda iControl

Panel_icontrol_eng.fm Kapitel A: , Panda iControl - Seite 83

Fischer Panda DatasheetA. , Panda iControl

Art Nr. . 21.02.02.01H

Bez. Panda iControl

Document Hardware Software

Actual: R02

Replace: R01

, Panda iControl

Seite 84 - Kapitel A: , Panda iControl Panel_icontrol_eng.fm

Fischer Panda Datasheet

A.1 Safety instructions


The rotating parts (belt-pulley, belts, etc) must be covered and protected so that there is no danger to life andbody!If a sound insulation cover must be produced at the place of installation, then well-placed signs must show thatthe generator can only be switched on with a closed capsule.All servicing-, maintenance or repair work may only be carried out, when the motor is not running.


Electrical voltages above 48 volts (battery chargers greater than 36 volts) are always dangerousto life). The rules of the respective regional authority must be adhered to. Only an electricianmay carry out installation of the electrical connections for safety reasons.

Before start working at the Panda 4000i (service, repair ect), diconnect the starter battery (First minus cable, thenpositive cable), so that the generator cannot be unintentionally started.

A.2 Connection of the iControl

To connect the iConrol use the original prepared cable.

(6 wires shilded)

1. U+ cablecolour „brown“

2. Gnd cablecolour „brown-white“

3. Rzl cablecolour „green“

4. D_A cablecolour „blue“

5. D_B cablecolour „blue-white“

Between clamp RZL(3) und Gnd(2) an automatik startdevice (Battery monitor) can be connected

Note

Regarding to the open electric board the iControl p anel has a protectrive class IP00.

Builded in a control board with a siutable seal (f. e. Sikaflex) IP66 can be reached.

1 3 5

2 4

, Panda iControl



A.3 Buttons and display of the iControl

Warning! At the Electronic bord is an voltage of 45 0 V. Only special trained persons areallowed to open the cover of the Electronic board. !!!DANGER TO LIVE!!!

2

4

1 3

2a2b

2d2c

2e2f

2g

1. Button „on/off“

2. Display

3. Button „enter“

4. Button „start/stop“

2a. Load indication in %2b. Oil pressure indication „OK“ oder „Fault“2c. Engine temp. indication2d. Exhaust elbow temp. indication

2e. Stator Winding temp. indication2f. Engine rpm indication2g. Operation hours

, Panda iControl



A.4 Engine control

The iControl Panel and Electronic Board is for driving the Panda 4000i. Push the „on/off“ button to start thepanel(1). The panel will come up in the „stand by mode“.

„stand by mode“

in the stand by mode the iControl checks the generator

- Display shows welcome screen

- the Led-Light will switch off after 2 min. (energie save)

- push the „enter“ button“ to reset the LED-Light timer

- start the generator with the „start/stop“ button --> „run mode“

- start the generator with the „automatic start“ option --> „run mode“

„run mode“

Generator was started with the “start/stop“ button or with the „automatic start option“

- Display light is on

- Display shows generator data

- stop the generator with the „start/stop“ button --> „standby mode“

- stop the generator with the „automatic start“ option --> „standby mode“

A.5 Operation manual

A.5.1 Daily routine checks before starting

1. Oil Level Control (ideal level: 2/3).

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 level, if the level drops min. mark.

2. State of Cooling Water.

The external compensation tank should be filled up to a 1/3 level 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.(if necessary)

For safety reasons, the seacock should be closed after the generator is switched off for a longer time. It should be re-opened before

starting the generator.

4. Check Raw water Filter.

, Panda iControl


Fischer Panda DatasheetThe raw water filter must be regularly checked and cleaned. The impeller fatigue increases, if residual affects the raw water intake.

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 cas-

ing 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 Load.

For the automatic option make shure that the load is connected to the PMGi only, when the nominal output of

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).

Attention! Make sure that the PMGi is connected wit h the generator. Never connect or dis-connect the PMGi when the generator is running. Thi s will destroy the PMGi. (it may burnor explode)

A.5.2 General

Very low Temperatures

The generator is disigned to start at temperatures up to -20 ° C. Please make sure, that the fuel is siutable foryour temperature range.

The electronic of the iControl changes the pre-glow time at the generator start according to the actual generatortemperature. The normal time at a cold engine is 8 sec. The pre-glow times rises at temperatures below 8 ° C anddrops (down to 0 sec.) at temperatures over 40°C.

Tips regarding Starter Battery

Fischer Panda recommends the use of a normal starter battery. If a genset is required for extreme winter conditi-ons, then the starter battery capacity should be doubled. It is recommended to charge the starter battery regularlyby a suitable battery-charging device (i.e., at least every 2 months). A correctly charged starter battery is neces-sary especially for low temperatures.

, Panda iControl


Fischer Panda Datasheet Engine Oil at winter conditions.

Make sure using a siutable engine oil at winter conditions.

Do not use start help sprays or similar.

A.5.3 Long time run of the generator

Make sure the PMGi is not overloaded. The PMGi will switch off in this case.

We recommend to calculate the normal load should be at 80 % of the nominal load of the generator and PMGi.Normel load is in this case the load you need for a very long period. Nearly 100 % of the nominal power of thegenerator and PMGi can be used for 2-3 hours without any problems.

A.5.4 Start of the generator

1. Open the fuel valve (if necessary)

2. Close the battery switch (if necessary)

3. Push "on/off" button (turn iControl on).

Panel comes up with „Welcome“ screen

4. Push the „start/stop“ button to switch from „Welcome“ to the „Main“ screen

Screen switch to „Main“ screen

5. Push „start/stop“ button

The Engine pre-glow and start. It is not allowed to run the starter motor for more than 10 sec. If the generator does not start within this

time, the start is blocked for 20 sec.

Please check if the fuel is present at the generator, before you try to start the generator again. (and if the fuel is siutable for the tempe-

rature range)

6. Switch on the load when the nominal output of 230 V / 50 Hz is reached at the PMGi. See “Automatic start” onpage 89.

A.5.5 Stop of the generator

1. At higher temperatures (over 25 ° C) the generato r should run 5 min. after the load has been switched off inorder to cool down)

2. Push the „start/stop“ button to switch off the generator.

3. Close additional switches (battry, fuel ect.).

4. Push the „on/off“ button to turn off the iControl“.

, Panda iControl



following warnigs are displayed

A.5.6 Automatic start

The iControl has an „automatic start“ option at clamp Rzl and Gnd. Close the connection of these clamps to startthe generator. Open it to stop the generator.

If you use this option make sure that the load is connected to the PMGi after the output has reached the nominal230 V / 50 Hz and not to overload the PMGi (some electronic devices - such like air conditions - need an higherstarting current. You may use a relay which connects the load at 230 V.

To activate the automatic start:

1. Turn the panel on („on/off“ button)

2. Switch to „Main“screen („start/stop“ button)

3. Activate automatic start („enter“ button)

To deactivate the automatic start, press the „enter“button again or switch the panel off with the „on/off“button

A.5.7 Additional information

1. The revision of the hard and software is stored in the electronic memory and can be read out by the servicetechnican.

2. If the iControl is in the stand by mode and the battery voltage drops under 12.1 V for more than 2 min., theiControl shut the system off to prevent the battery for total discharge..

A.6 Error warnings

Error warnings are shown in the display. The screen switch from the temperature to „High“.

Engine temp. > 75 °C

Exhaust temp. > 70 °C

winding temp. > 120 °C

, Panda iControl


Fischer Panda Datasheet Example for the warning on the display

(Winding temp. „HIGH“„

A.7 Errors

The least 5 errors are stored in the electronic memory and can be read out by the service technican..

Push the „enter“ button to quitt errors which has stopped the generator

Unexpected stop Generator stops during operation or RPM droped under 1100 RPM (Fuel low, overloadect.)

Fault: Oilpress Oilpressure to low

Fault: Winding Winding temp. over 135°C

Fault: Exhaust Exhaust tem over> 75°C (PMS version) or>100°C(vehicles versions)

Fault: Cyl. Head Cylinder head temp. over >90°C (PMS version) or >95°C (vehicles versions)

Starting Fail Generator do not start after 10 sec.

Tab. 1: Fault table

Example for an error display after the generatorwas stopped.

(Oil Pressure failed)

, Panda iControl



A.8 Electronic board

The iControl panel has an electronic board which is mounted at the Generator. This board controls all generatorfunctions.

The bord is in a box and contains self healing fuses and relais.

For safety reasons it is not allowed to open the box of the electronic board.Inside there are up to 450 V AC. !!!DANGER TO LIFE“„“.

Only special trained persons are allowed to change the board in case of anerror.

A.8.1 Location at the Panda 4000i PMS

Electronic board at the Panda 4000i PMS

A.9 Technical data

A.9.1 Intended use

The Panda iControl is a part of the Panda 4000i. It is not allowed to use the iControl at other generators or appli-cations.

The iControl must be connected with the electronic board at the generator.

Attention! See also the safety instructions in the generator and the PMGi manual. Therules of the respective regional authority must be adhered to. Only an electrician maycarry out installation of the electrical connection s for safety reasons.

, Panda iControl



A.9.2 Dimensions

PMGi 4000

Fischer Panda GmbH

Panda 4000i - Part 3 PMGi 4000 Manual

94

Current revision status

Document

Actual: Panda_4000i_PMGi_4000.R01_26.5.08

Replace:

Revision Page

Panda PMGi 4000

PGMi_eng.fm Chapter A: Panda PMGi 4000 - Page 95

Fischer Panda DatasheetA. Panda PMGi 4000

Art Nr. . 21.07.03.003H

Bez. Panda PMGi 4000

Document Hardware Software

Actual: R03

Replace: R02

Panda PMGi 4000

Page 96 - Chapter A: Panda PMGi 4000 PGMi_eng.fm


A.1 Safety instruction


The rotating parts (belt-pulley, belts, etc) must be covered and protected so that there is no danger to life andbody!If a sound insulation cover must be produced at the place of installation, then well-placed signs must show thatthe generator can only be switched on with a closed capsule.All servicing-, maintenance or repair work may only be carried out, when the motor is not running.


Electrical voltages above 48 volts (battery chargers greater than 36 volts) are always dangerousto life). The rules of the respective regional authority must be adhered to. Only an electricianmay carry out installation of the electrical connections for safety reasons.

Before start working at the Panda 4000i (service, repair ect), diconnect the starter battery (Firstminus cable, then positive cable). This avoid unexpected start of the generator.

A.2 Type plate

1. Location of the type plate

1

Panda PMGi 4000



A.3 Front side/connection side

To connect the PMGi 4000 use the prepared cable with the 4pin plug and connect to socket 3 (PMGi in-450V/400Hz)

Connect your termination box with the socket 1. Use a 3pinplug (230V/50Hz AC - PMGi out)

Do not cover the Air out grille (2)

A.3.1 Socket pins of the PMGi 4000

Socket 1 - 230V / 50Hz AC - PMGi out

1. Ground (cabel green/yellow)

2. Neutral (cabel blue)

3. Live (cabel brown)

.Socket 3 - PMGi in

1. Ground

2-4. Phase 1-3

Attention! Connecting one of the three Phase with t heearth pin will destroy the PGMi

1 3

2

Panda PMGi 4000



A.4 Back side - Top side

Inside of the PMGi a fan is mounted. The air holes and air grille should not be covered.

01. Air holes - 02. Status LED

Attention! Inside of the PMGi are up to 550 V AC. T he cover of the PMGi should only beopened by special trained persons !!! Danger for Li ve“

Attention!

Make sure that the connection between the generater and the PMGi is secured. Neverconnect or disconnect the PMGi while the generator is running. This will destroy the PMGi(it may burn or explode).

1

2

Panda PMGi 4000



A.5 Operation manual

A.5.1 Primary remarks / Winter operation

The PGMi can operate in the range of -20°C to +40°C

A.5.2 Load at the PMGi

Do not overload the PMGi. It will go on error.

A.5.3 Automatic start

The generator can start (depending on the remote control panel) by an external signal (atomatic start)

If you use this option make sure that the load is connected to the PMGi after the output has reached the nominal230V/50Hz and not to overload the PMGi (some electronic devices, such like air conditions, need an higher startcurrent). May use a relay which connect the load at 230V.

A.6 Status LED´s

When the PMGi is mounted on the right way, vertical with the lectric connection down. The LED´s from left to rightare:

Red - Yellow - Green

LED - Red Red LED lights together with the green LED for the very first seconds (about 5 sec) after therunning of the engine. During this time no output is provided by the PMGi.

Red LED starts to blink when an overload condition is reched. During this time the green LEDcontiniues to light.

When an overload condition stays for too much time the red LED stops blinking and stays per-manently switched on, while the green LED switch off.

LED-Yellow Yellow LED lights together with the green LED when the output voltage becomes less than thenominal voltage.

LED-Green Green LED permanently lights alone when the PMGi output is available and it value stays inthe spacification

Panda PMGi 4000



A.7 Cooling of the PMGi

Inside of the PMGi a fan is mounted

Do not cover the air holes and grille.

The heat sink and the fan of the PMHGi may become dirty as a consequence of tzhe use of the generator, and sothe unit can loose a part of their heat transfer carateristic. Every 6 months it is necessary to visual inspect the heatsinks and clean it with compressed air. At every Generator service the fan of the PMGi should be cleaned by thespecial trained person.

A.8 Installation of the PMGi

The PMGi must be mounted vertical, with the electrical connection down. So you can read the writing on thePMGi.

The surface where the PMGi is mounted should be smoothed and support the heat transfer. The Air holes and Airgrille must be not covered and enough cooling air must be pleasant at any time for the PMGi.

To mount the PMGi use the vour fixing holes diameter 6,5mm. See “Dimensions” on page 105.

Note! See the safety instruction in your Generator and iControl Manual.

The rules of the respective regional authority must be adhered to. Only an electrician may carryout installation of the electrical connections for safety reasons.

A.8.1 Electrical connection.

Only special trained persons are allowed to make the electrical connection.

When an extension cable is required, be sure to use a though rubber sheated flexible and fireproof cable. Limitlength of extension cables depends on the voltage drop along the cable. This drop must be less than 2,5% valueof the nominal output voltage.

Pay attention to the right pin assignment. See “Socket pins of the PMGi 4000” on page 97.

Panda PMGi 4000



A.8.2 Installation of the ferrites

.Ferrit to clip on the cable

.Ferrit to clip on the cable

cip the ferrit on thr cable which is going from thePMGi to your electrical cabinet. The ferrit should beas close to the PMGi as possible. Secure the ferritwith teh cable straps.

.Ferritring

Insert the cable comming from the generator about 10cm through thering.

Turn it back and insert it through again. (second time)

Turn it back and insert it through again. (Third time)

The ferrit should be as close to the PMGi as possible. Secure the ferritwith teh cable straps or heat shrinkable tube.

Mount the plug on the cable.

.Ferritring

Insert the cable comming from the generator about 10cm through thering.

Turn it back and insert it through again. (second time)

Turn it back and insert it through again. (Third time)

The ferrit should be as close to the PMGi as possible. Secure the ferritwith teh cable straps or heat shrinkable tube.

Mount the plug on the cable.

Panda PMGi 4000



A.9 Technical Data

A.9.1 General Data

PMGi is part of the 4000i. It´s not allowed to be used with other generators or aplications.

Storage temperature PMGi -20°C to +55°C

Working temperature PMGi Minimum: -20°C

Maximum: +40°C

Maximale internel temperature ofthe PMGi: +70°C

A.9.2 Generator Spezifikation

PMG Generator out 3 Phasig

Voltage Phase minimum 250V AC Maximum 550V AC

Frequency minimum 250 Hz Maximum 650 Hz

Panda PMGi 4000



Voltage:

A.9.3 PMGi out

Nominal Voltage NOV AC 230V VAC +/- 5% without load

Regulation R 5%

Stability (short term (30sec)) D s 5%

Stability (Long term (4h)) D l 5%

Voltage offset V offset +-5V -20°C bis +40°C

Current Current Nominal @230Veff. 17.4 A

Current Maximum @230Veff. 19.5 A

Power Nominal power 4,3 kVA

Long term 4,0 kVA

Frequency Nominal Frequency 50 Hz +/-2%

Regulation 4%

Stability (short term (30sec)) 3%

Stability (Long term (4h)) 3%

A.10 PMGi protections

A.10.1 Overload - switch point

Output type Max. current Comments

230VAC 20.0A +/- 0.5A When protection takes place the engine must be swit-ched off and all apliances detached

Panda PMGi 4000



To operate the short circiut protection a fuse must be put in series with the live wire. The minimum requested featurefor this fuse are the following.

A.10.2Short circiut

Rated current 1.2 1.5 2.75 4.0 10.0

16A >1h <30min 5msto 150ms 2ms to 15ms <2ms

A.10.3Under voltage and signal

Output type Min Voltage Comments

230VAC 219VAC+/-5%

190VAC+/-5%

150VAC+/-5%

Yellow LED ON

Unit trips without overload

Unit trips on overload conditions only

Input Min Voltage Comments

250VAC+/-5% Yellow LED ON

Unit trips without overload

Unit trips on overload conditions only

A.10.4 Overheat

Output type Max. temperature

at cooling plate

Kommentare

AC 70°C +/- 5°C When protection takes place the engin e must be swit-ched off. Detach all the appliances and wait for co oling down of the PGMi

Note! The electrical Data refer to the system runni ng in accordance with all the limits defi-ned in the „General Specification“ table.

Panda PMGi 4000



A.11 Dimensions

Panda PMGi 4000



A.12 Wiring diagram PGMi with 4000i generator

230V output

AC IN

AC Out

Panda PMGi 4000

L1

L2

L3

PE

L1

PE

N1

23

-X

Panda 4000i Generator

Inverter

Achtung!

Stecker niemals unter Spannung

stecken oder aufschalten!

Warnung!

Do not plug or switch on

with voltage on!

Stecker/plug 4p

Art 34.05.08.019H

+34.05.08.017H

Stecker/plug 3p

Art 34.05.08.018H

+34.05.08.016H

PMGI Converter mit Panda 4000i Generator

PMGI Converter with Panda 4000i Generator

Panda PMGi 4000



A.13 Wiring diagram PGMi - RCD

01

23

45

67

89

Datum

Bearb.

Gepr.

Norm

Urspr.

Ers.d

Ers.f

Blatt 1

Bl.

= +

von 1

Zust.

Änderung

Datum

Name

Zeichnungsnummer:

D-33104 Paderborn

Otto-Hahn-Str. 32-34

www.fischerpanda.de

+49(0)5254/9202-0

Projektnummer:

Fischer Panda

Generatoren

Fischer Panda GmbH

Bröckling

070104_00_00

---

070104_00_00

connectionplan - PMGi Out - RCD

PMGi - Out

L1

NNL

-1X4

Powerline Out

PE

PE

24A

30mA

-1F4

14.05.2008

14.05.2008

Panda PMGi 4000



A.14 Wiring diagram PGMi - isolation control

01

23

45

67

89

Datum

Bearb.

Gepr.

Norm

Urspr.

Ers.d

Ers.f

Blatt 1

Bl.

= +

von 1

Zust.

Änderung

Datum

Name

Zeichnungsnummer:

D-33104 Paderborn

Otto-Hahn-Str. 32-34

www.fischerpanda.de

+49(0)5254/9202-0

Projektnummer:

Fischer Panda

Generatoren

Fischer Panda GmbH

Bröckling

070105_00_00

connectionplan - PMGi Out - Isolation control

PMGi - Out

Powerline Out

L1

N

PE

+/L

L-1X2

1 2

3 4

5 6

-1Q6

NPE

Bender

IR420 / IR425

11

12

22

24

14

21

isolation control

E

KE

A1

A2

L1

L2

T/R

-1A5

4kW

A1

A2

-1Q6

GND

14.05.2008

14.05.2008

Date post:	12-Apr-2018
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