Marine Generator Manual Panda 5000i.Neo PMS Super silent technology 230 V 50 Hz 5 kVA 120 V 60 Hz 5 kVA 110 V 60 Hz 5 kVA Panda_5000i.Neo_PMS_eng.R03 13.4.
Current revision status Document Actual: Panda_5000i.Neo_PMS_eng.R03_13.4.17 Replace: Panda_5000i.Neo_PMS_eng.R02 Revision Page 120 V 60 Hz eingepflegt 110 V 60 Hz eingepflegt R03 Erstellt durch / created by Fischer Panda GmbH - Leiter Technische Dokumentation Otto-Hahn-Str. 32-34 33104 Paderborn - Germany Tel.: +49 (0) 5254-9202-0 email: info@fischerpanda.de web: www.fischerpanda.
Inhalt / Contens Marine Generator Manual ............................................................................................................................ ....... 1 Current revision status................................................................................................................................ ....... 2 3 General Instructions and Regulations .................................................................................................. ..... 10 3.1 Safety first!.........
Inhalt / Contens 6 Panda 5000i PMS generator .................................................................................................................. ..... 33 6.1 Type plate at the generator ............................................................................................................. .... 33 6.1.1 6.1.2 6.1.3 6.1.4 Right Side View .............................................................................................................. .... Left Side View ...................
Inhalt / Contens 7.9.1 7.9.2 7.9.3 The following items need to be installed: ........................................................................ .... 61 Connection of the fuel lines at the tank .......................................................................... .... 62 Position of the pre-filter with water separator ................................................................. .... 63 7.11 Generator DC system installation ....................................................................
Inhalt / Contens 9.5 Fuel ................................................................................................................................................. .... 86 9.6 Coolant specifications ..................................................................................................................... .... 86 9.6.1 Coolant mixture ratio ....................................................................................................... .... 87 10 Inverter Panda PMGi 5000 .......
Inhalt / Contens 12.4.1 12.4.3 12.4.4 12.4.5 12.4.6 12.4.7 12.4.8 12.4.9 12.3.3.5 Panda i-Generator with electro-magnet Clutch (optional) ................................ .. 12.3.3.7 Autostart mode................................................................................................. .. Set-up menu ................................................................................................................... .. The configuration menu ("config") ................................................
Inhalt / Contens Seite/Page 8 Inhalt/Contens 13.4.
Dear Customer, Thank you for purchasing a Fischer Panda Generator and choosing Fischer Panda as your partner for mobile power on board. With your generator, you now have the means to produce your own power – wherever you are - and experience even greater independence. Not only do you have a Fischer Panda generator on board, you also have worldwide support from the Fischer Panda Team. Please take the time to read this and find how we can support you further.
General Instructions and Regulations 3. General Instructions and Regulations 3.1 Safety first! These symbols are used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury of lethal danger during certain maintenance work or operations. Read these instructions carefully. Can cause acute or chronic health impairments or death even in very small quantities if inhaled, swallowed, or absorbed through the skin.
General Instructions and Regulations General warning of a hazard area WARNING: General warning Can cause acute or chronic health impairments or death even in very small quantities if inhaled or ingested. WARNING: Danger due to inhalation and/or ingestion Warning of live parts that may cause electric shock upon contact. Especially dangerous for persons with heart problems or pacemakers. WARNING: Risk of electric shock upon contact Danger of injury due to being pulled into equipment.
General Instructions and Regulations Wearing the applicable snugly fitting protective clothing provides protection from hazards and can prevent damage to your health. MANDATORY INSTRUCTION: Wear snugly fitting protective clothing (PPE). Wearing hearing protection provides protection from acute and gradual hearing loss. MANDATORY INSTRUCTION: Wear hearing protection (PPE). Wearing safety goggles protects the eyes from damage. Optical spectacles are not a replacement for the corresponding safety goggles.
General Instructions and Regulations Socket wrench set Hexagon socket wrench set Clamp-on ammeter (DC for synchronous generators; AC for asynchronous generators) Torque wrench 13.4.
General Instructions and Regulations 3.3 Manufacturer declaration in accordance with the Machinery Directive 2006/42/EC Manufacturer declaration in accordance with the Machinery Directive 2006/42/EC The generator was designed in such a way that all assemblies correspond with the CE guidelines.
General Instructions and Regulations 3.5 Safety Instructions - Safety First! 3.5.1 Safe operation Careful handling of the equipment is the best insurance against an accident. Read the manual diligently, and make sure you understand it before starting up the equipment. All operators, regardless of their experience level, shall read this manual and additional pertinent manuals before commissioning the equipment or installing an attachment.
General Instructions and Regulations 3.5.5 Safe handling of fuels and lubricants Keep fuels and lubricants away from naked fire. Before filling up the tank and/or applying lubricant, always shut down the generator and secure it against accidental start-up. Do not smoke and avoid naked flame and sparking near fuels and the generator. Fuel is highly flammable and may explode under certain conditions. Refuel in well-ventilated open spaces only. If fuel/lubricant was spilled, eliminate fluids immediately.
General Instructions and Regulations 3.5.7 Safety precautions against burns and battery explosions The generator and its cooling agents and lubricants as well as the fuel can get hot while the generator is operated. Use caution around hot components such as parts containing exhaust fumes, radiator, hoses, and engine block during operation and after the generator was shut down. The cooling system may be pressurised. Open the cooling system only after letting the engine and the coolant cool down.
General Instructions and Regulations 3.5.10 Implementation of safety inspections and maintenance Disconnect the battery from the engine before performing service work. Affix a sign to the control panel both the main and the corresponding slave panel - with the instruction “DO NOT START UP MAINTENANCE IN PROGRESS“ to prevent unintentional start-up. To prevent sparking due to accidental short-circuiting, always remove the earthing cable (-) first and reconnect it last.
General Instructions and Regulations 3.6.1.1 Protective conductor and potential equalisation: Electric voltage above 50 V may be life-threatening. Fort this reason systems are grounded with a protective conductor. In connection with a RCD the current supply will be disconnected in case of a failure. Appropriate safety precautions like the RCD and corresponding fuses have to be provided by the customer to guarantee a save operation of the generator. 3.6.1.
General Instructions and Regulations 3.6.1.5 Safety instructions concerning cables Cable types It is recommended to use cables that are in compliance with the standard UL 1426 (BC-5W2) with type 3 (ABYC section E-11). Cable cross-section The cable shall be selected taking into account the amperage, cable type, and conductor length (from the positive power source connection to the electrical device and back to the negative power source connection).
In case of Emergency First Aid / Im Notfall Erste Hilfe 4. In case of Emergency First Aid / Im Notfall - Erste Hilfe First Aid in case of accidents by electrical shocks 5 Safety steps to follow if someone is the victim of electrical shock Do not touch the injured person while the generator is running. 1 Switch off the generator immediately. 12 13 If you cannot switch off the generator, pull, push, or lift the person to safety using a wooden pole, rope or some nonconducting material.
In case of Emergency First Aid / Im Notfall Erste Hilfe 4.1 WHEN AN ADULT STOPS BREATHING DO NOT attempt to perform the rescue breathing techniques provided on this page, unless certified. Performance of these techniques by uncertified personnel could result in further injury or death to the victim. Warning: 1 Does the Person Respond? Tap or gently shake victim. Shout, “Are you OK?“ 2 Shout, “Help!“ Call people who can phone for help. 3 Roll Person onto Back.
Basics 5. Basics 5.1 Intended use of the machine The Fischer Panda generator is made to produce electrical energy out of diesel fuel. The diesel fuel is converted to mechanical energy by the diesel engine. This mechanical energy drives the generator. In the genset, the mechanical energy is converted to electrical energy. This process is controlled by (sometimes external) components, the remote control panel and the voltage control system.
Basics 5.2.3 User Users are persons, established by the operator/owner, to operate the generator. The operator/owner has to ensure that the user has read and understood the manual and that all hazard notes and safety instructions are respected. The user must be instructed by the operator/owner regarding his activity at the generator, especially concerning the maintenance. 5.3 Components of the i-system 1. Panda i-generator Fig. 5.3-1: Panda i generator Permanent magnet generator 2.
Basics 3. Panda PMGi inverter AC/AC 4. Fischer Panda manual Fig. 5.3-3: PMGi inverter Fig. 5.3-4: Manual The Fischer Panda manual contains the following components: • Transparent sheet with general information, guarantee conditions, installation inspection, and service list.
Basics 5.4.2 Fischer Panda transport box with metal tab closure 1. Bend up the metal tab closures on the transport box lid 2. Remove the cover 3. Remove the loose 4. Bend open the metal tab closures at the bottom of the transport box 5. Remove the sidewalls 6. Open the generator attachment 5.5 Opening the GFK sound insulation capsule GFK sound insulation capsule with lash closures Fig. 5.
Basics • For loading/unloading, an adequate industrial truck shall be used. • Depending on the transport distance (e.g. air cargo), the generator fluids (coolant, engine oil, fuel) may have to be drained. The corresponding instructions and warnings must be fitted to the transport packaging. 5.6.2 Loading/unloading of the generator For loading/unloading the generator, appropriate ring eye bolts shall be installed in the holes in the support rails.
Basics Modern starter batteries are typically maintenance-free. Deep discharge will damage the battery and can render it unusable. Keep battery clean and dry. Clean battery poles (+ and -) and terminals regularly and coat with acid-free and acidresistant grease. During assembly, ensure good contact of the terminal connections. General limits for lead-acid batteries: 2.1 V / cell corresponds with full battery (charged). 1.95 V / cell corresponds with empty battery - recharge.
Basics • Drain diesel from tank and refill with a protective mixture (90 % diesel and 10 % preservative oil) (level to full). Crank engine without start. • Dismount V-belt as specified, wrap and store in a dry location. Protect against UV radiation. Cover alternator apertures. Attention! Cleaning fluids and preservatives must not enter the alternator. Risk of destroying the alternator. • Clean engine as per manufacturer's instructions. • Spray engine parts and V-belt disks with preservative.
Basics engine during the downtime. The control unit must be marked accordingly with a note specifying “NO COOLING WATER“. • Drain engine oil as specified. Refill engine with preservative oil to the max. level on the oil dipstick. • Drain diesel from tank and refill with a protective mixture (90 % diesel and 10 % preservative oil) (level to full). Crank engine without start. • Dismount V-belt as specified, wrap and store in a dry location. Protect against UV radiation. • Disconnect battery.
Basics seconds. Repeat this procedure 2 times. • Perform visual check of the generator similar to initial commissioning and start up generator. Fischer Panda recommends: Note: After extended downtimes, a full 150 h inspection as per the inspection list should be performed. 13.4.
Basics Leere Seite / Intentionally blank Seite/Page 32 Kapitel/Chapter 5: Basics 13.4.
Panda 5000i PMS generator 6. Panda 5000i PMS generator 6.1 Type plate at the generator Fig. 6.1-1: Type plate Fig. 6.1-2: Discription type plate 13.4.
Panda 5000i PMS generator Description of the Generator 6.1.1 Right Side View Fig. 6.1.1-1: Right side view 10 09 08 01 11 02 07 03 04 05 01) 02) 03) 04) 05) 06) Actuator (servo) Raw water pump Oil pressure switch Oil filter Oil drain hose Dip stick Seite/Page 34 - Kaptitel/Chapter 6: Panda 5000i PMS generator 06 07) 08) 09) 10) 11) Housing with iControl electronic board (DO NOT OPEN) Air filter housing Lifting eye Oil filler cap Injection pump 13.4.
Panda 5000i PMS generator 6.1.2 Left Side View Fig. 6.1.2-1: Left side view 09 08 07 01 12 02 03 04 01) 02) 03) 04) 05) 13.4.
Panda 5000i PMS generator 6.1.3 Front View Fig. 6.1.
Panda 5000i PMS generator 6.1.4 Back View Fig. 6.1.4-1: Back side view 01 02 10 03 04 09 08 05 01) 02) 03) 04) 05) 13.4.
Panda 5000i PMS generator 6.2 Details of function units 6.2.1 The Panda iControl2 panel The "Panda iControl2 panel" control panel is the control and display unit for the Panda iControl2 control system and represents the interface between the user and the Panda iControl2 controller. The integrated display serves to present the most important data of the system as well as warnings and error messages. The control panel is equipped with four buttons for operating the Panda iControl2 controller: Fig. 6.2.
Panda 5000i PMS generator 6.2.2 Components of the Cooling System Fig. 6.2.2-1: Cooling System 13.4.
Panda 5000i PMS generator 6.2.3 Components of the Fuel System Fig. 6.2.3-1: Components of the Fuel System Seite/Page 40 - Kaptitel/Chapter 6: Panda 5000i PMS generator 13.4.
Panda 5000i PMS generator 6.2.4 Components of the Electrical System Fig. 6.2.4-1: Components of the Electrical System 13.4.
Panda 5000i PMS generator 6.2.5 Components of the Oil Circuit Fig. 6.2.5-1: Components of the Oil Circuit 6.2.6 Sensors and switches for operating surveillance Thermo-sensor at engine Fig. 6.2.6-1: Thermo.sensor at engine The thermo-sensor at the engine is used for monitoring the engine temperature. Seite/Page 42 - Kaptitel/Chapter 6: Panda 5000i PMS generator 13.4.
Panda 5000i PMS generator Thermo-switch at exhaust connection Fig. 6.2.6-2: TThermo-switch at exhaust connection If the impeller pump drops out and delivers no more seawater, the exhaust connection becomes extremely hot. Thermo-sensor coil Fig. 6.2.6-3: Thermo-switch coil One thermo sensor is located in the stator winding 1 Oil pressure switch Fig. 6.2.6-4: Oil pressure switch In order to be able to monitor the lubricating oil system, an oil pressure switch is built into the system. 13.4.
Panda 5000i PMS generator 6.3 Operation Instructions - see separate iControl panel manual 6.3.1 Daily routine checks before starting - See iControl manual. 6.3.2 Starting Generator - See iControl manual. 6.3.3 Stopping the Generator - See iControl manual. Seite/Page 44 - Kaptitel/Chapter 6: Panda 5000i PMS generator 13.4.
Installation Instructions 7. Installation Instructions All connections (hoses, wires etc.) and installation instructions are designed and suited for “standard” installation situations. Attention!: Adapt system correctly.
Installation Instructions Oil and fuel vapours can ignite at contact with ignition sources. Therefore: Warning!: Danger of fire • No open flames during work on the generator. • Do not smoke. • Remove oil and fuel residues from the generator and floor. Contact with engine oil, antifreeze and fuel can result in damage to health. Therefore: Danger!: Danger of poisoning • Avoid skin contact with engine oil, fuel and antifreeze. • Remove oil and fuel splashes and antifreeze from the skin immediately.
Installation Instructions 7.2 Place of installation 7.2.1 Preliminary remark • There must be sufficient fresh air supply for the combustion air. • It has to be ensured that the cooling air supply from underneath or sidewise is sufficient. • During operation the sea cock has to be opened. • The generator may only be opened by a technical trained person. • The generator may only be operated by a trained person. 7.2.
Installation Instructions 7.2.3 Advice for optimal sound insulation The convenient base consists of a stable framework, on which the generator is fastened by means of shockmounts. Since the aggregate is „free“ downwards, the combustion air can be sucked in unhindered. In addition the vibrations are void which would arise with a closed capsule base. 7.3 Fig. 7.2.3-1: Generator base Generator Connections All electrical wires are connected within the capsule tightly to the motor and the generator.
Installation Instructions Fig. 7.3-2: Connection at the Generator - sample 1 2 3 1. Cable Power out to PMGi inverter 2. Cable Control to PMGi inverter 7.4 3. Cable for remote control panel Installation of the cooling system - raw water 7.4.1 General information The genset should have its own raw water (coolant water) inlet and should not be connected to any other engine systems. Ensure that the following installation instructions are complied with: 7.4.
Installation Instructions rate see section 9.2, “Technical data,” on page 118. 7.4.4 Generator installation above waterline The Panda is equipped with a water intake pump mounted on the motor. Since the intake pump is an impeller pump there are wearing parts which are likely to require replacement after a period of time. Ensure that the genset is installed so that the intake pump can be easily accessed.
Installation Instructions Fig. 7.4.5-2: Rubber hose for vent valve - example The rubber hose for the external vent valve will be cut... ...and bend upwards. Fig. 7.4.5-3: Split rubber hose for vent valve Both hose ends will be extended respectively with a hose and connected with a vent valve 600 mm over the waterline. Example 7.4.5.1 Raw water installation scheme Fig. 7.4.5.1-1: Raw water installation schema 13.4.
Installation Instructions 7.4.6 First filling and ventilation of the internal cooling water circuit The expansion tank is supplied with a pressure relief valve in the cap with 500 mbar. It is possible when operating the generator hot cooling water can leak here if there is an overpressure. When working always wear protective clothing and ensure an adequate installation location. ATTENTION!: Risk of scalding. 1. Fill up the external cooling water expansion tank with coolant. Fig. 7.4.
Installation Instructions stood still for a long time. During the ventilating process repeated checks must be made to check the cooling water is indeed circulating. If there are air bubbles in the internal cooling water pump, it is possible that the cooling water is not circulating. The generator will heat up very quickly and switch off, because of overheating. ATTENTION: Check circulation 7.4.6.
Installation Instructions 7.5 Installation of the water cooled exhaust system 7.5.1 Installation of the standard exhaust system The generator exhaust system must remain completely independent and separate from the exhaust system of any other unit(s) on board. The water lock must be installed at the lowest point of the exhaust system. An optional noise insulated water lock can also be installed. The exhaust hose descends from the capsule to the water lock.
Installation Instructions Thereby, the position of the generator and the waterlock, as well as the arrangement of the cooling water and exhaust hoses play the decisive role. If the waterlock is arranged in an unfavourable position, the cooling water flowing back in the exhaust hose can rise so high, that it reaches the exhaust stack. Since at least one discharge valve is always open when the engine is shut off, the sea water has free access to the combustion chamber.
Installation Instructions The deeper the waterlock is located underneath the generator, the better the protection from entering water into the combustion chamber. The picture below shows that the distance between the critical point at the exhaust elbow and the maximum permissible water level in the exhaust hose is stated with 600 mm. This distance should be understood as a minimum distance. 7.6.
Installation Instructions In Fig. 7.6.3.1-1, the waterlock is mounted in center underneath the generator. Fig. 7.6.3.1-1: Ideal position of the waterlock When the ship tilts, the position of the waterlock related to the critical point at the exhaust hose, changes only slightly. Tilted position 15 degrees - Fig. 7.6.3.1-2 Fig. 7.6.3.1-2: Tilted position 15 degrees The distance from the exhaust elbow to the hydrostatic head has derated to 540 mm. Tilted position 30 degrees - Fig. 7.6.3.1-3 Fig. 7.6.3.
Installation Instructions Summary: The preset minimum height of 600 mm must be regarded unconditionally and is only valid if the waterlock is mounted in its ideal position in center underneath the generator. A higher position is highly recommended if it has to be reckoned with tilted positions of 45 degrees. 7.6.3.
Installation Instructions B) Installation distance between waterlock and the generator’s center line 1000 mm Installation distance between waterlock and the generator’s center line 1000 mm Tilted position 30 degrees - Fig. 7.6.3.2-4 Fig. 7.6.3.2-3: waterlock, 1000 mm next to center line Fig. 7.6.3.2-4: Tilted position 30 degrees The water level and the critical point at the exhaust elbow are at the same level now.
Installation Instructions Fig. 7.7.0-1: Installation Scheme exhaust / water separator 7.8 Installation exhaust water separator If the exhaust water separator was sufficiently highly installed, a goose neck is no longer necessary. The exhaust/ water separator fulfils the same function. If the „Super silent“ exhaust system were installed correctly, the generator will not disturb your boat neighbour. The exhaust noise should be nearly inaudible.
Installation Instructions Fig. 7.8.0-1: Example for an unfavourable Installation Example of an unfavourable installation: - Water lock not far enough below the lowest level of the generator - Distance water lock to gooseneck too large 7.9 Fuel system installation 7.9.
Installation Instructions Fig. 7.9.1-2: Fuel system - schema 6 3 5 4 1 2 1. Fuel tank 2. External fuel pump 3. External fuel prefilter with water separator 4. Non return valve 5. External fuel fine filter 6. Generator External fine filter Fig. 7.9-3: externer Feinfilter At generators with FP 320, Kubota EA 300 or Farymann engines, the fine filter is delivered with the generator. This fine filter should be installed in the fuel feed line next to the generator. 7.9.
Installation Instructions period, in order to preserve the starter battery. Non-return valve for the fuel return pipe ATTENTION! If the fuel tank should be installed over the level of the generator (e.g. daily tank), then a non-return valve must be installed into the fuel return pipe to guarantee that through the return pipe no fuel is led into the injection pump. 7.9.
Installation Instructions 7.10 Ventilating the fuel system Normally, the fuel system is designed to ventilate air itself i.e. as soon as the electric starter motor starts operation the fuel pump starts working and the fuel system will be de-aerated after some time automatically. It is nevertheless essential to ventilate the system as follows prior to the first operation (as all hoses are empty): Start the fuel pump The external fuel pump can be started manual by an option in the iControl2 panel.
Installation Instructions Make sure that the voltage of the starter battery fits to the start system voltage ATTENTION! f.e. 12 V starter battery for a 12 V start system f.e. 24 V starter battery for a 24 V start system (2x12 V batteries in a row) To avoid large voltage drops the battery should be installed as near as possible to the generator. The positive terminal of the battery is attached at the red cable, the negative pole at the blue cable.
Installation Instructions Positive battery cable Fig. 7.11.1-2: Positive Battery Cable The positive (+) battery cable is connected directly to the solenoid switch of the starter. Negative battery cable Fig. 7.11.1-3: Negative Battery Cable The negative (-) battery cable is connected to the engine foot. Note! The battery negative pole may not be connected with the boat ground. Fig. 7.11.1-4: Connection starterbattery 12V - schema 1. Generator 2.
Installation Instructions 7.11.2 Connection of the remote control panel - See Panda iControl panel manual 7.11.3 Installation of the iControl panel - See iControl Manual 7.12 Generator AC System Installation Before the electrical system is installed, READ the SAFETY INSTRUCTIONS of this manual FIRST! Be sure that all electrical installations (including all safety systems) comply with all required regulations of the regional authorities. This includes lightening conductor, personal protection switch etc.
Installation Instructions Fig. 7.12-1: Electrical installation - example 1 1 3 2 4 1. Generator 2. Electrical fuel pump DC 3. PMGi 5000 inverter 4. iControl panel 5. Starter battery DC 7.12.1 Installation PMGi inverter - See separate PMGi 5000 inverter manual All electrical safety installations have to be made on board. 7.12.2 Power source selector A power source selector switch must be installed between the PMGi power out and the ship's electrical supply system.
Installation Instructions 3-Way Cam Switch Fig. 7.12.2-1: 3-Way Cam Switch A 3-way cam switch should be used. This switch basic positions: „Shore power“ - „OFF“ - „Generator“. If an (DC-AC) inverter is used, a fourth position will be required. 0. OFF I. Generator II. Shore power connection III. Inverter The cam-type switch must have 2 poles, so that „MP“ and „phase“ can be switched off.
Installation Instructions 7.13 Checking and filling of the oil circuit Check oil and fill the oil circuit as described in the service chapter. 7.14 Isolation test After installation, before bringing into service and handover of the generator to the customer, an isolation test has to be accomplished as follows: ATTENTION! 1. Switch off all electrical load. 2. Start the generator. 3.
Maintenance Instructions 8. Maintenance Instructions 8.1 Personal requirements All maintenance work - if not specially marked - can be made by the trained persons. Further maintenance work must only be made by Technical personel or Fischer Panda service points. 8.2 Personal requirements All maintenance, if not special marked, can be done by the trained persons. Further maintenance must be done by technical personal or Fischer Panda service points. 8.
Maintenance Instructions Oil and fuel vapours can ignite on contact with ignition sources. Therefore: Warning!: Danger of fire • No open flames during work on the generator. • Do not smoke. • Remove oil and fuel residues from the generator and floor. Contact with engine oil, antifreeze and fuel can result in damage to health. Therefor: Danger!: Danger of poisoning • Avoid skin contact with engine oil, fuel and antifreeze. • Remove oil and fuel splashes and antifreeze from the skin immediately.
Maintenance Instructions Observe the instructions from your battery manufacturer. 8.4 Environmental protection Danger to the environment due to mishandling! Environmental protection. Significant environmental damage can occur, particularly for incorrect disposal, if environmentally hazardous operating materials are mishandled. Therefore: • Always observe the instructions mentioned below. • Take immediate action if environmentally hazardous materials reach the environment.
Maintenance Instructions 8.5.2 Checks before each start • Oil level • Leaks in the Cooling system • Visual check for any changes, leaks in the oil drain system, v-belt, cable connections, hose clips, air filter, fuel lines 8.6 Maintenance interval For the maintenance interval, please see the „General information for PMS generators“ which are attached to this manual. At generator with dynamic operation hours (f.e. Generators with iControl2 system) the maintenance interval can may be extended.
Maintenance Instructions • Open the generator casing. • Screw the oil dipstick out of the check rail. • Clean oil dipstick. • Put the oil dipstick back into the check rail, do not screw it in and wait for 10 seconds. Fig. 8.8-1: Oil dipstick • Pull the oil dipstick out of the check rail and read off the oil-level at the lower end of the stick. Oil dipstick FP320 Engine Fig. 8.8-2: Oil dipstick The oil-level is to be checked by means of the oil dipstick.
Maintenance Instructions 5. Wipe off the oil dipstick and put it into the check rail. 6. Pull the oil dipstick out of the check rail and check the oil-level. See section 8.8, “Checking oil-level,” on page 74. If oil-level is still too low (under 2/3): repeat steps 4-6. 8.8.2 After the oil level check and refilling the oil • Screw the oil dipstick back into the check rail. • Close the oil filling cap. • Remove potential oil stains and splashes from the generator and surroundings.
Maintenance Instructions 2. Loosen oil filling cap Fig. 8.9-1: Oil filling cap Unscrew the oil filling cap. This is necessary, because otherwise a vacuum will form and the oil can not completely drain off. 3. Open oil drain screw. Fig. 8.9-2: Oil drain hose Unscrew the oil drain screw by means of the open-ended wrench from the oil drain hose (rotating direction left). Use a second open-ended wrench to lock. Make sure to do this over the container. Use spanner size 17 mm. 4. Discharge used oil.
Maintenance Instructions Fill the engine oil into the engine via feed hopper. Check oil-level after every 0,75 litres with the oil dipstick. 9. Check proper filling level. See section 8.8, “Checking oil-level,” on page 74. When the proper filling level is reached, screw in the oil cap again. Run the engine for 10 minutes and then turn it off. Check the oil-level once more after several minutes with the oil dipstick. If it is too low, refill some oil. 10.
Maintenance Instructions 8.11 Checking the water separator in the fuel supply The pre-filter with water separator has a cock underneath, by which means the water can be drained. Fig. 8.11-1: Pre-filter with water separator This water sinks to the bottom, due to the difference in the densities of water and fuel. Water is heavier than the diesel Sample picture 8.11.
Maintenance Instructions 1. Put a container under the fuel return pipe to catch running out fuel to catch. Fig. 8.11.2-1: Fuel return pippe 2. Switch the panel „ON“. 3. Activate the the fuel pump prime function in the panel menue. 4. Let the pump run till the fuel runs bleed free out of the return line. (about three times activation of the fuel pump prime function) This procedure must be repeated several times, until fuel (nonporously) withdraws perfectly at the fuel return pipe. Fig. 8.11.
Maintenance Instructions Remove the air filter. Fig. 8.11.3-2: Air filter Clean the air filter housing. Replace the air filter and close the cover again. 8.12 De-aerating of the coolant circuit / freshwater The Panda 5000i PMS is self de-aerating. 8.13 The raw water circuit 8.13.1 Clean raw water filter The raw water filter should be released regularly from arrears. In each case the water cock must be closed before. It is mostly sufficient to beat the filter punnet.
Maintenance Instructions can shorten the life span extremely. Further the operation of the impeller pump loaded in waters with a high portion of suspended matters. The use of the impeller pump is particularly critical in coral waterbodies. Cases are well-known, which a impeller pump had so strongly run after 100 hours already that the lip seal on the wave was ground in.
Maintenance Instructions Remove the cover of the raw water pump by loosen the wing screws from the housing. Pull to the impeller with a multigrip pliers of the wave. Fig. 8.13.3-3: Raw water pump Fig. 8.13.3-4: Impeller Mark the impeller, to make sure that these is used in the correct position at re-installation. Check to the impeller for damage and replace it if necessary. Fig. 8.13.
Maintenance Instructions Seite/Page 84 - Kaptitel/Chapter 8: Maintenance Instructions 13.4.
Generator Tables 9. Generator Tables 9.1 Diameter of conduits Fig. 9.1-1: Diameter of conduits Generator type Panda 5000i PMS 9.2 Ø Cooling water pipe Ø Cooling water pipe external expansion tank Raw water [mm] Feed /Bleeding [mm] 12 10/8 Ø Exhaust hose [mm] 40 Ø Fuel hose Supply [mm] Return [mm] 8 8 Technical Data Fig. 9.
Generator Tables 9.3 Types of coil HP3 delta connection 9.4 Fig. 9.3-1: HP3 delta connection Engine oil 9.4.1 Engine oil classification Full mineral engine oil SAE15W-40 ACEA A3/B3 Fischer Panda recommend Castrol GTX 9.5 Fuel Use a clean Diesel fuel oil according to DIN590:1999 or better. For Generators with common rail or particle filter use DIN590:2009 or better. Do not use alternative fuel, because its quality is unknown or it may be inferior in quality.
Generator Tables 9.6.1 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 13.4.
Generator Tables Seite/Page 88 - Kaptitel/Chapter 9: Generator Tables 13.4.
Inverter Panda PMGi 5000 10. Inverter Panda PMGi 5000 Art Nr. Bez. Document Actual: R03 Replace: R02 13.4.
Inverter Panda PMGi 5000 10.1 Safety instruction The generator may not be taken into use with the cover 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 the 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.
Inverter Panda PMGi 5000 Fig. 10.2-2: Type plate 230 V 50 Hz version Fig. 10.2-3: Type plate 110 V 60 Hz version 13.4.
Inverter Panda PMGi 5000 10.3 Front side/connection side To connect the PMGi 5000 use the prepared cable with the 4pin plug and connect to socket 3 (PMGi in-450 V/400 Hz) Fig. 10.3-1: Connection side 230 V Version 3 Connect your termination box with the socket 1. Do not cover the Air out grille (2) 1 1. Socket for Load 2. Air out grille 3. Socket for generator connection 4 4. FP- Bus socket connection to generator 2 Seite/Page 92 - Kaptitel/Chapter 10: Inverter Panda PMGi 5000 13.4.
Inverter Panda PMGi 5000 Fig. 10.3-2: Connection side 110V and 120 V Version 3 1 4 2 10.3.1 Socket pins of the PMGi 5000 Socket 1 - 230 V / 50 Hz AC - PMGi out Fig. 10.3-1: Socket 1 1. Ground (cable green/yellow) 2. Live (cable brown) 3 1 3. Neutral (cable blue) Connecting the Phase with the earth pin will destroy the PGMi 13.4.
Inverter Panda PMGi 5000 10.4 Back side - Top side Fig. 10.4-1: Back side 1 Inside of the PMGi a fan is mounted. The air holes and air grille should not be covered. 1. Air holes Inside of the PMGi are up to 550 VAC. The cover of the PMGi should only be opened by special trained persons! !Danger for Live! Attention! Make sure that the connection between the generator and the PMGi is secured. Never connect or disconnect the PMGi while the generator is running.
Inverter Panda PMGi 5000 10.5 Settings for the use of iGenerators with power inverter For the use of power inverter with the PMGi, the settings of the power inverter must be modified. ATTENTION: Wrong settings can destroy the PMGi Wrong settings can damage or destroy the PMGi. The settings for the Victron power inverter must be adapted for the power inverters of other brands. 10.5.1 Settings in the Victron VE Configure II Software - General Fig. 10.5.
Inverter Panda PMGi 5000 10.5.2 Settings in the Victron VE Configure II Software - Inverter Fig. 10.5.2-1: Settings in the Victron VE configure II Software 10.5.2.1 Assist current boost factor To reduce the action of the power inverter on the iGenerator, the Assist current boost factor must be reduced from 2.0 to 1.3. Wrong settings will cause bad rpm control of the generator. Seite/Page 96 - Kaptitel/Chapter 10: Inverter Panda PMGi 5000 13.4.
Inverter Panda PMGi 5000 10.6 Operation manual 10.6.1 Primary remarks / Winter operation The PMGi can operate in the range of -20 °C to +40 °C. 10.6.2 Load at the PMGi Do not overload the PMGi. It will go on error. 10.6.
Inverter Panda PMGi 5000 10.9 Installation of the PMGi The PMGi must be mounted vertical, with the electrical connection down. So you can read the writing on the PMGi. The surface where the PMGi is mounted should be smoothed and support the heat transfer. The Air holes and Air grille must be not covered and enough cooling air must be pleasant at any time for the PMGi. To mount the PMGi use the fixing holes diameter 6,5mm. See the safety instruction in your Generator and iControl Manual.
Inverter Panda PMGi 5000 PE-N Bridge Fig. 10.9-1: PE-N bridge Inside of the PMGi a PE-N bridge 1 10.9.1.2 Connection to a system with isolation control For the use of the PMGi with an isolation controlled grid, the internal PWE-N Bridge must be disconnected. A Manual for this modification can be downloaded under: http://www.fischerpanda.de/images/gensets/M_AC_50_INV_PMS_8000i/operatormanual/PMGi/ Modification_PMGi_isolation_control.eng.pdf 10.10Technical data 10.10.
Inverter Panda PMGi 5000 10.10.3 PMGi out Fig. 10.10.
Inverter Panda PMGi 5000 10.10.4 Overload - switch point Output type Max. current Comments 230VAC 30,0 A +/- 0.5 A When protection takes place the engine must be switched off and all appliances detached 10.10.5 Short circiut To operate the short circuit protection a fuse must be put in series with the live wire. The minimum requested feature for this fuse are the following. Rated current 1.2 1.5 2.75 4.0 10.
Inverter Panda PMGi 5000 Seite/Page 102 - Kaptitel/Chapter 10: Inverter Panda PMGi 5000 13.4.
Panda iControl2 Operating Manual Open-loop and closed-loop control system for Fischer Panda generators Panda iControl2_eng.R08 13.4.
Current revision status Document Current: Panda iControl2_eng.R08_13.4.17 Replaces: Panda iControl2_eng.R07 Revision Page Kontrolltätigkeiten vor dem Start eingefügt Emergency stop, Fehlerspeicher, Master Slave eingepflegt R08 Hardware Generator Revision Modification Strike Plate Date Upgrade Created by Fischer Panda GmbH - Head of Technical Documentation Otto-Hahn-Str. 32-34 33104 Paderborn - Germany Phone: +49 (0) 5254-9202-0 E-mail: info@fischerpanda.de web: www.fischerpanda.
Safety instructions for the Panda iControl2 11. Safety instructions for the Panda iControl2 11.1 Personnel The settings described here can be performed by the operator unless highlighted differently. The installation should be implemented by specially trained technical personnel or by authorised workshops (Fischer Panda Service Points), only. 11.2 Safety instructions Ensure compliance with the safety instructions in the Fischer Panda genset manual.
Safety instructions for the Panda iControl2 The flooding valve must be closed. (For PMS version only.) Also observe the safety instructions for the other components of your system. Seite/Page 106 - Kaptitel/Chapter 11: Safety instructions for the Panda iControl2 NOTE: 13.4.
General operation 12. General operation 12.1 The Panda iControl2 panel The "Panda iControl2 panel" control panel is the control and display unit for the Panda iControl2 control system and represents the interface between the user and the Panda iControl2 controller. The integrated display serves to present the most important data of the system as well as warnings and error messages. The control panel is equipped with four buttons for operating the Panda iControl2 controller: Fig. 12.
General operation 12.2 Starting preparation / Checks (daily) 12.2.1 Marine version 1. Oil level control (ideal level: 2/3 MAX). The level should be about 2/3 of the maximum level of a cold engine. Further, if installed, the oil level of the oil-cooled bearing must be controlled before each start - see sediment bowl at generator front cover!. 2. State of cooling water. The external expansion tank should be filled up to 1/3 of the maximum in a cold state.
General operation 12.3 Operation 12.3.1 Switching the controller on and off The Panda iControl2 controller is switched on and off with the On/Off button on the Panda iControl2 panel. Press and hold the On/Off button until the start screen with the panda bear appears on the display. The controller is switched off by actuating the On/Off button once more. On the start screen, the hardware version, the generator type, and the software version are shown at the bottom left. Fig. 12.3.1-1: .
General operation • Oil pressure status • Cylinder head temperature • Temperature of exhaust manifold • Winding temperature • Speed/RPM • Utilisation in percent Fig. 12.3.2-1: Default display screen The Display shows the iControl board input voltage. Note: At generator systems with 12 V starter system these is equal with the starter battery voltage. At generator system with 24 V starter system the starter battery voltage can not be displayed. 12.3.
General operation Fig. 12.3.3.1-1: Service information screen The total operating hours of the generator are given on the default display screen and on the service information screen. By actuating the cursor-up and cursor-down button in stand-by mode, the service screen can be accessed. This screen is marked with a screwdriver/spanner symbol. Here, the time until the next service is given. By actuating the cursor-up or cursor-down button, you can return to the default screen.
General operation The controller will only perform one starting attempt. If the generator could not be started, the text output "STARTING FAILS" informs you of the failure of the generator starting attempt. Note: Acknowledging the message with the cursor-up, cursor-down, or the Start/Stop button on the Panda iControl2 panel will return the system to stand-by mode.
General operation Display screen for single phase generators With the single phase i-series generators, there is an additional screen in operation mode for the inverter data. This screen provides the current inverter output voltage and the inverter temperature. You can access the inverter screen by actuating the cursor-up button while in operation mode. Fig. 12.3.3.
General operation This screen provides the latest inverter output voltage of the single phases with the matching conductor current and the circuit board temperature. The inverter will be switched off at a circuit board temperature of 75 °C. You can access the inverter screen by actuating the cursor-up button while in operation mode. Fig. 12.3.3.4-7: Phase voltage L3 12.3.3.
General operation 12.3.3.6 Stop mode By activating the Start/Stop button in operation mode, i.e., while the generator is running, you will stop the generator. After stopping the generator, the system will return to stand-by mode. The display status field reads "STOPPING". If the icontrol system detect a high cylinder head temperature (for example after a long time running with high load) the icontrol start a stopping delay timer. The Display shows „Cooldown“ and a countdown.
General operation The autostart function will remain active even after the controller is switched off and on again with the On/Off button. To deactivate the autostart function, the flag in the EEPROM must be reset with "Disable". Siehe “Activating/deactivating the autostart function ("Autostart")” auf Seite 119. .Warning!: Automatic start-up If the generator is manually started up and stopped while in automatic start-up mode, it will switch to stand-by mode for safety reasons.
General operation 12.4 Other operating functions 12.4.1 Set-up menu In the set-up menu, a series of parameters can be modified directly using the control panel. To access the set-up menu, you have to actuate the cursor-down button immediately after switching on the controller with the On/Off button and while the start screen with panda bear is still being displayed. This will open a menu with the following sub-items: Fig. 12.4.
General operation 12.4.2 Setting the brightness of the backlight ("backlight" and "dimtime") The brightness of the display backlight of the Panda iControl2 panel can be varied in ten increments (0-9). Also, the display can be dimmed with a timer if no button is actuated on the control panel for a parameter is able period. To adjust the default brightness and the dimmed brightness, the set-up menu offers the items "backlight 1" (default brightness) and "backlight 2" (dimmed brightness).
General operation 12.4.3 The configuration menu ("config") Settings in this area must only be entered by Fischer Panda associates and Fischer Panda service points. STOP! The "config" sub-menu is a password protected area in which the generator type can be selected, and generator parameters in the EEPROM can be modified. 12.4.4 The network ID Settings in this area must only be entered by Fischer Panda associates and Fischer Panda service points.
General operation To activate the autostart function, select the item "Autostart" in the set-up menu using the cursor buttons and confirm the selection with the Start/Stop button. Fig. 12.4.6-1: Set-up menu In the "Autostart" sub-menu, you can select between the options "Enable" and "Disable" using the cursor buttons: Fig. 12.4.6-2: "Autostart" sub-menu To activate the autostart function, select "Enable" and again confirm your selection with the Start/Stop button.
General operation Then, the controller is shut down. After switching the controller back on, the display status field reading "AUTOSTART" indicates that the autostart function is active, or, if it reads "STANDBY", this means that the autostart function was deactivated: The autostart function will remain active even after the controller is switched off and on again with the On/Off button. To deactivate the autostart function, the flag in the EEPROM must be reset with "Disable" as described above. Fig.
General operation Resetting the time until the next service Fig. 12.4.7-1: Resetting the time until the next service By actuating the Start/Stop button again, you can reset the service interval to the original interval. The service interval for each generator type is stored in the software. The controller is switched off after resetting the service interval. After restart, the new value will be displayed in the service screen. 12.4.
General operation 12.5 iControl2-Emergency-Stop The iControl2 is prepared for the connection of an emergency stop. The socket for the emergency stop is in the cable harness integrated and bridged (1X1, optional emergency off). The bridge must be removed and the emergency stop connected. After the emergency stop is initiated, the servo drives to zero position, all out of the iControl controller are switched off and the power supply to the inverter is switched off. The Panel shows „Emergency Stop“.
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Installation 13. Installation All connecting wires and instructions for installation are designed and adequate for „standard“ installation situations. WARNING: Properly dimension your system. As Fischer Panda does not know the specific installation and operating situation (e.g. special vehicle shapes, high travel speeds, and special application conditions, etc. ), this installation specification can only serve as a guideline and example.
Installation only an electrician may carry out the installation of the electrical connections of the generator. Generator and cooling water may be hot during and after operation. Burn/scalding hazard! WARNING: Hot surface/material During operation, overpressure may build up in the cooling system. For installation work, personal protective equipment is compulsory.
Installation 13.2.1 Panda iControl2 panel with installation housing Fig. 13.2.1-1: Panda iControl2 panel with panel connecting cable and closed housing 13.2.2 Terminal assignments on the Panda iControl2 panel The Panda iControl2 panel is connected via a 7-pin Phoenix jack. Fig. 13.2.
Installation 13.3 Dimensions Fig. 13.3-1: Housing of the Panda iControl2 panel Seite/Page 128 - Kaptitel/Chapter 13: Installation 13.4.
Installation Due to the terminals being exposed, the protection class IP 04 applies to the iControl2 panel. Please note! If properly installed with a seal (e.g. Sikaflex), up to IP66 can be achieved. 13.4 Wiring of the Panda iControl2 controller Fig. 13.4-1: Wiring of the Panda iControl2 controller The Panda iControl2 controller is connected to the wire harness with the 18-pin jack. The centre 6-pin jack is designed for the Fischer Panda standard bus.
Installation 13.4.1 Terminal assignments on the Panda iControl2 controller 13.4.1.1 Terminal assignment of 18-pin connector Fig. 13.4.1.
Installation 13.5 Master and Slave Panels With the iControl2 it is possible to have up to four remote control panels at one iGenerator. (One Master + three Slave) The standard iControl panel has the Art. No. 21.02.02.131P. This Panel has integrated termination resistors and is the Master Panel. The iControl2 Slave Panel has the Art. No. 21.02.02.132P. It is marked with a sticker „Slave Panel“ at the back side.
Installation 13.6 Start-up After completing the installation, the system must be started up. For this purpose, the start-up log for the generator is processed and filled in by the specialist installing the equipment. The completed log shall be handed over to the operating company. The operating company shall be instructed in the operation, maintenance, and hazards of the generator.
Maintenance 14. Maintenance 14.1 Maintenance of the iControl2 controller The iControl2 controller is maintenance-free. The fuses of the controller are self-healing. 14.1.1 Cleaning the iControl2 controller The housing shall be cleaned within the scope of the overall generator cleaning. The housing can be wiped off with a soft, lightly dampened cloth. In doing so, it must be ensured that no moisture enters the jacks and the housing. 14.
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Annex 15. Annex 15.1 Technical data 15.1.1 Technical data for iControl2 control unit Fig. 15.1.1-1: Technical data for iControl 2 control unit iControl 2 control unit Supply voltage 12 V-13.5 V (12 V automotive) Current consumption, nominal 175 mA Current consumption, stand-by 2.5 mA Operating temperature -20 °C to +85 °C Storage temperature -30 °C*to +85 °C Current sensor Hall element max. 20 A max. tightening torque for connecting bolts 1.2 Nm 15.1.
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Warnings and error messages 16. Warnings and error messages To enable the safe operation of the generator, the Panda iControl2 controller is programmed with a series of warnings and error messages that influence the generator operation. 16.1 Warnings Warnings are issued when the variable being monitored, e.g. temperature, reaches a defined warning threshold.
Warnings and error messages 16.1.2 Warning messages All warning messages defined for the Panda iControl 2 and the corresponding display output are compiled in the subsequent table. Fig. 16.1.
Warnings and error messages 16.2.1 Error messages All error messages defined for the Panda iControl 2 and the corresponding display texts are compiled in the subsequent table. Fig. 16.2.1-1: Error messages Error message on the display Meaning of error message „OUT“ is output instead of a temperature „Out of range“ - broken cable on corresponding temperature sensor Fig. 16.2.
Warnings and error messages Fig. 16.2.
Warnings and error messages 16.2.3 Bus errors If the communication connection is lost on the Fischer Panda bus, an error is output on the display after a period of 10 seconds: This error will occur if at least one of the two data lines of the Fischer Panda bus is disconnected. Once the connection is restored, the error message can be acknowledged with the Start/Stop button. Fig. 16.2.
Warnings and error messages 16.3.3 How do I exit the error memory after having read the entries? You can return to the standby page via the start-stop-key. 16.3.4 Can I delete the error memory? No, it is not possible to delete the error memory. 16.3.5 Where are the errors stored? In the EEPROM of the panel or in the storage of the control board? The errors are stored in the EEPROM of the control board. The control panel only displays the errors which are stored there.
Warnings and error messages Fig. 16.3.7-1: Image: Display of the stored errors on the control panel 13.4.
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