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Installation Instructions

Panda PMS AGT-DC 4000 - Chapter D: Installation Instructions Page 63

D.8.2 Installation Panda AGT 24V-system

All electrical safety installations have to be made on board.

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1. Generator
2. Battery bank 24V
3. Battery monitor
4. Fuel pump
5. Remote control panel

6. Voltage control VCS
7. Starter battery 12V
8. Fuse
9. Battery switch

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Summary of Contents for Panda AGT-DC 4000 PMS

Page 1: ...Marine Generator Panda AGT DC 4000 PMS 12V 24V 4kW Icemaster Fischer Panda Installation manual Installation maintenance and troubleshooting...

Page 2: ...uperiority in efficiency also ensures a fuel saving to the same extent The 100 water cooled Panda Aggregate are currently manufactured in the performance range from 2 to 100 kW in various versions Fas...

Page 3: ...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...

Page 4: ...ccessible a power relay must be used instead of the main switch which can be served manually which can be served then if necessary from different places The switches for the power relay are to mark ac...

Page 5: ...or A battery must always be connected to the inverter as a capacity Recommended capacity at 12V 240Ah at 24V 120Ah The screws at the electric rectifier may be pulled tight only with a torque wrench To...

Page 6: ...it 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 po...

Page 7: ...fuel supply 14 B 4 1 De aerating the fuel system 14 B 4 2 Exchange the air filter 16 B 5 De aerating of the coolant circuit freshwater 17 B 6 Exchange of the toothed belt for the raw water pump 18 B...

Page 8: ...g system 47 D 5 Watercooled Exhaust System 48 D 5 1 Installation of the standard exhaust system 48 D 5 2 Exhaust water separator 49 D 5 3 Installation exhaust water separator 50 D 6 Fuel System Instal...

Page 9: ...Panda PMS AGT DC 4000 Table of Contents Page 3 F 3 Types of coil VIII F 4 Inspection checklist for services IX F 5 Engine oil X F 6 Coolant specifications XI F 7 Measurements XII...

Page 10: ...Page 4 Panda PMS AGT DC 4000 Table of Contents...

Page 11: ...k 3 Coil temperature 4 Oil pressure The fault is transmitted if one of these switches measures a value that exceeds the required value all switches are openers The current is switched off by the main...

Page 12: ...stream fed here tears off and the exhaust connection heats up immediately extremely fast since the water cooling is missing The thermo switch supervises a functioning raw water cycle Fig A 2 Thermo s...

Page 13: ...f if the oil pressure drops under a certain value Fig A 6 Oil pressure switch A 1 1 Regulation of the generator voltage by the VCS The output voltage of the generator is permanently measured by the VC...

Page 14: ...the continuous load operation does not release superelevated temperatures of the engine also with extreme conditions It is to be considered that the exhaust gas values in the full load operation becom...

Page 15: ...case in the sound cover at both ends with a connecting nipple by a hose end Both hose ends must led out from the sound cover to a point which is at least for 600mm over the waterline if possible in th...

Page 16: ...han 5 seconds the impeller must exchanged he sucks in air before raw water reaches the impeller see picture below and the impeller then wears strongly In this case the impeller loses his effect and ra...

Page 17: ...st with dry air in which environment of muted oil and fuel steams and increased temperature The hoses must be checked regularly for elasticity There are operating situations at which the hoses must be...

Page 18: ...e an oil drain hose is lead through the sound cover Oil drain screw The oil can be discharged by opening the oil drain screw For countering use a second wrench Oil drain pump If discharging of the oil...

Page 19: ...hours Open the oil filler neck After opening the cap of the oil filler neck the new oil is refilled Please wait instant before measure the oil level the oil must set off in the sump Oil dipstick With...

Page 20: ...ter is heavier due to its density than the Diesel B 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 starter motor starts operat...

Page 21: ...otor 3 Switch the panel ON 4 Press START button The fuel pump runs audible 5 Switch the panel OFF 6 Switch the panel ON 7 Press again the START button This procedure must be repeated several times unt...

Page 22: ...e 16 Panda PMS AGT DC 4000 Chapter B Maintenance Instructions B 4 2 Exchange the air filter Open the air suctin housing by loosen the six hexagon head screws on the frame cover Change the air filter m...

Page 23: ...ling water pump Fill in cooling water into the cooling water filler neck If it is to be recognized that the cooling water level does not fall anymore with cold cooling water the cooling water levelmu...

Page 24: ...ime because the air in the sound insulated capsule can be relative warm and dry The toothed belt must be controlled in a very short time interval It can be happen to change the toothed belt after some...

Page 25: ...ter The raw water filter should be released regularly from arrears In each case the water cock must be closed before It is mostly sufficient to beat the filter punnet If water should seep through the...

Page 26: ...of the impeller are exposed to very strong loads This can shorten the life span extremely Further the operation of the impeller pump loaded in waters with a high portion of suspended mat ters The use...

Page 27: ...e 21 Raw water pump on the front side of the genset Remove the cover of the raw water pump by loosen the wing screws from the hou sing Pull to the impeller with a multigrip pliers of the wave Mark the...

Page 28: ...lace it if necessary Before the reinsertion into the housing the impeller should have been lubricated with glycerin or with a non mineral oil based lubricant e g silicone spray The impeller is attache...

Page 29: ...opposite socket the gene rator shall shut down or when the generator is not running you will get a signal on the panel Temperatures of the rectifier and heating Apply a thermocouple meter to the heat...

Page 30: ...or output cable Ensure that a battery switch is installed in the battery line Never leave the generator behind wit hout the cover mounted over the heat sink and capsule not closed Remind the customer...

Page 31: ...clamps 7 Dismount the impeller of the cooling water pump and check for wear The impeller may not remain in the pump It must be greased with vaseline and be kept at a dark place It can be reintragrate...

Page 32: ...all hatches The devices have a hygrometer which switches the device off if the humidity is under the adjusted value There is no better method in order to protect pads cable electronics wood engines e...

Page 33: ...eriods only A high peak current is required to start many electrical devices especially electric motors and compressors from a still stand state In order to prolong the genset s life expectancy the no...

Page 34: ...be fixed to this point This delimitation serves for the protection of the generator so that it is not overloaded 01 Actuator 02 Spiral thread spindle 03 Ajusting nuts for min speed 04 Spindle nut wit...

Page 35: ...This has the consecu ence that the rev spindle can not be turned to all positions faultless Therefore the voltage of the generator is regulated not good or sometimes not at all If you notice that the...

Page 36: ...r 3 Turn the actuator by hand and check if the spindle turns back by the motor 4 If the motor react on the turn by manual strongly the motor can normally hold with the fingers the drive will be workin...

Page 37: ...Charge current must be 10 A at U UNenn Upper suspension point 7 Connect the load 8 Turn the actuator by hand gradually the insertable load up to the upper susoension point Charge current must not lay...

Page 38: ...ity between the individual windings connections If continuity is detected for any of the combinations the generator must be sent to the factory for inspection and repair If this is not possible the st...

Page 39: ...her you should get a reading of 0 00Ohm When you isolate the probes the reading will be Overflow Please do this tests to check your meter Measure of the resistance within the individual windings The v...

Page 40: ...uring instrument is necessary which mea sures the inductance of a coil Inductance is measured in the same way as the ohmic resistance i e the coils are compared The value is indicated in mH milli Henr...

Page 41: ...s C 5 1 VCS does not work For start problems one chief cause is that the VCS doen not work Check Is the voltage sense connecttion ok Check polatrity Is the shunt connection ok Check pola trity Is the...

Page 42: ...is nevertheless essential to bleed the system as follows prior to the first operation as all hoses are empty 1 Put a container under the fuel return pipe to catch running out fuel to catch 2 Take off...

Page 43: ...a few seconds before the motor comes to a full halt If the generator fails to start runs rough does not reach the proper RPM or does not stop pro perly the first item to suspect in most cases is the...

Page 44: ...Generator Failure Page 38 Panda PMS AGT DC 4000 Chapter C Generator Failure...

Page 45: ...t obtains by compound these surfaces by ribs Also break throughs should be sawed which inter rupt the surface Disguising the surrounding walls with a heavy layer e g lead plus foam mate rial improves...

Page 46: ...o the appropriate regulati ons The supplied cables are rated for ambient temperatures up to 70 C 160 F If the cables are required to meet higher temperature requirements they must be run through condu...

Page 47: ...ge iv 1 3 4 5 6 7 8 9 10 11 2 11 1 Passage for battery cable 2 Passage for battery cable 3 Raw water inltake 4 Cable for remote control panel 5 Cable for VCS 6 Cable for fuel pump 7 Cable for voltage...

Page 48: ...n to induce more water intake for cooling For Panda generators the thru vessel inlet should NOT point in the sailing direction When sailing at higher speeds more water will be forced into the inlet th...

Page 49: ...ine this problem can be limited a little It is very important to change the impeller every few month When starting the generator you should pay attention and listen when raw water comes out from the e...

Page 50: ...cover to one point if possible 600mm over the waterlinee in the midship line The valve is connected at the highest place with the two hose ends If the valve is blocked the cooling water pipe cannot be...

Page 51: ...to be undertaken a Open the cooling water cap on the coo ling water tank b Open the ventilation valve 2 Filling the cooling water circle a Fill in the prepared mixture cooling water with anti freeze p...

Page 52: ...ing water exit Then the clo sure screw must be closed immediately Turn on only lightly to treat the thread Pay attention that the external cooling water expansion tank is filled with enough cooling wa...

Page 53: ...ing water pump Feel the cooling water return pipe either at the outlet of the water cooled exhaust elbow union or at the side where this pipe entry at the heat exchanger The temperature difference bet...

Page 54: ...m 1 6 Panda 14000 and above approx 50mm The water lock must be installed at the lowest point of the exhaust system An optional noise insulated water lock can also be installed The exhaust hose descend...

Page 55: ...goose neck and the water separation With this exhaust water separator the cooling water is derived over a separate pipe Thereby the exhaust noises at the exterior of the yacht are strongly decreased...

Page 56: ...under the water line If the thru hull exhaust outlet has to be mounted far from the generator an exhaust water separa tor must definitely be installed The sea water from the separator must then run a...

Page 57: ...da PMS AGT DC 4000 Chapter D Installation Instructions Page 51 Example of an unfavorable installation water lock not deeply enough under the hights level of the generator distance water lock to exhaus...

Page 58: ...o not connect the generator fuel supply lines with any other fuel lines of other diesel systems The following items need to be installed Fuel supply pump 12V DC Pre filter with water separator not par...

Page 59: ...he tank in order to prevent fuel running back into the tank after the motor has been switched off which can lead to enormous problems if the generator is switched off for a long period Non return Valv...

Page 60: ...r with water separator must be installed outside of the sound cover in the fuel system line is not included in delivery D 7 Generator DC System Installation D 7 1 Connection of the 12V starter battery...

Page 61: ...C system F2 Fuse 10A for AC system K1 Starter motor relay K2 Pre glow relay glow plug K3 Fuel pump relay D 7 3 Terminal block AGT 4000 24V The Panda generators are equipped with various DC relays whic...

Page 62: ...re numbered from 1 to 11 and the 12th core is coloured yellow green The con trol cables are securely connected to the genset On the back of the control panel there are terminals numbered from 1 12 Con...

Page 63: ...itches to manual mode i e automatic cut off requirements are not carried out Switch pressure in manual mode If the generator starts automatically the generator continues to run and the panel switches...

Page 64: ...ge 1 7 Input generator voltage 2 8 Output pre glow 9 Output fuel pump 10 Output starter motor 11 Output VCS ON voltage control for VCS 12 Output operating voltage maximum permissible load 0 2A 9 Termi...

Page 65: ...tage exceeds 60 Volts The panel must be mounted that the voltage carrying points can not touched This is also the case during testing 1 Operating and starting the Generator will works with the Control...

Page 66: ...erator after a adjusted time of one minute if there is the voltage drops down in a adjustable level to reload the batteries On the panel at the terminal 15 and 16 is the allocation for extern switches...

Page 67: ...peed sensor tip should be aligned with the tip of a gear rim and screwed in until it touches the tip of the tooth ATTENTION Ensure that when inserting the sensor that the sensor tip is not screwed int...

Page 68: ...ure that all electrical installations including all safety systems comply with all required regulations of the regional authorities This includes lightnening conductor personal protection switch etc D...

Page 69: ...Page 63 D 8 2 Installation Panda AGT 24V system All electrical safety installations have to be made on board 1 2 5 6 7 3 4 8 8 8 9 1 Generator 2 Battery bank 24V 3 Battery monitor 4 Fuel pump 5 Remot...

Page 70: ...hould be sized such that the rated current of the generator on each of the individual phases is not excee ded by more than 25 Data for gensets with power output greater than 30kW on request The fuses...

Page 71: ...oltage must be attached directly at the battery and may not attached to the output of the electric rectifier By the voltage drop between generator and battery the accurate voltage can only recieved di...

Page 72: ...fier By the voltage drop between generator and battery the accurate voltage can only recieved direct at the battery A false link can lead to damage the battery 06 03 04 01 05 07 09 02 08 01 Voltage se...

Page 73: ...the protection of the electrical devices is the installation of an external voltage controller with separation contactor We recommend this measure with all reproduction and point out also that the ge...

Page 74: ...possible at many engines by the crank case exhaust A crank damage could cause for example that by overpressure too much oil is pressed into the crank case so that this oil arrives into the sucking in...

Page 75: ...al power kW Continuous power kW Nominal voltage VDC Continuous charging current A Nominal charging current A AGT 2500 12 2 5 2 5 12 180 180 AGT 2500 24 2 5 2 5 24 90 90 AGT 4000 12 4 3 2 12 220 280 AG...

Page 76: ...single phase not tin plated PVC isolated nominal wire cross section mm allowed conrinuous current reference point a a DIN VDE 0298 part 4 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...

Page 77: ...e is running at the wrong speed Check the speed of the motor with a rev or frequency counter set the correct speed VCS voltage controler defective or wrong adjusted Check resp renew Actuator defective...

Page 78: ...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 Kub...

Page 79: ...manufacturer for repair of damaged bearings or winding Damaged engine Repair of bearing damage etc by Kubota Service MOTOR SWITCHES ITSELF OFF Cause Solution Fuel solenoid valve or throttle shut solen...

Page 80: ...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 respecti...

Page 81: ...e volume 309cm3 max Power DIN 6270 NB at 3000rpm 5 1kW Rated speed 50 Hz 3000rpm Idle speed running a a progressive speed by VCS 2900rpm Valve clearance engine cold 0 16 0 20mm Cylinder head torque 58...

Page 82: ...Tables Page VIII Panda PMS AGT DC 4000 Chapter F Tables F 3 Types of coil HP3 delta connection HP3 star connection...

Page 83: ...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...

Page 84: ...number refers to the fluidity with heat Complete yearly oils have usually SAE 10W 40 SAE 15W 40 etc Quality of oil The quality of an engine oil is specified by the API standard American Petroleum Ins...

Page 85: ...OTECT PLUS G 48 Engine coolant automotive industry Product description Product name GLYSANTIN PROTECT PLUS G48 Chemical nature Monoethylenglycol with inhibitors Physical form Liquid Chemical and physi...

Page 86: ...Tables Page XII Panda PMS AGT DC 4000 Chapter F Tables F 7 Measurements...

Page 87: ...pull push or lift the person to safety using a wooden pole rope or some nonconductive material If possible turn off the electrical power Send for help as soon as possible After the injured person is...

Page 88: ...nd lift chin Shout Are you OK Look listen and feel for brea thing for 3 to 5 seconds 6 Give 2 Full Breaths Keep head tilted back Pinch nose shut Seal your lips tight around victim s mouth Give 2 full...

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