FPO1-0003759 - Fischer Panda

FPO1-0003759 - Fischer Panda
Manual
Marine Generator
Panda PMS-HD 22-4KU
Super silent technology
120/240V - 60Hz / 18,6kW
230V/400V - 50Hz / 18,6kW
Fischer Panda GmbH
Current revison status
Dokument
Actual:
Panda_22-4KU_HD_PMS.R02_16.6.08
Replace:
Panda 24 NE PMS Operation Manual
Revision
Page
Part 1 + Part 2 joined
Copyright
Duplication and change of the manual is permitted only in consultation with the manufacturer!
Fischer Panda GmbH, 33104 Paderborn, reserves all rights regarding text and graphics. Details are given
to the best of our knowledge. No liability is accepted for correctness. Technical modifications for improving the product without previous notice may be undertaken without notice. Before installation, it must
be ensured that the pictures, diagrams and related material are applicable to the genset supplied. Enquiries must be made in case o doubt.
2
Table of contents
Current revison status ........................................................................................................... 2
Safety first ............................................................................................................................... 8
Tools ........................................................................................................................................ 9
Safety Precautions ............................................................................................................... 11
5 Safety steps to follow if someone is the victim of electrical shock ............................. 13
WHEN AN ADULT STOPS BREATHING.............................................................................. 14
A
The Panda Generator................................................................................................... 15
A.1
Type plate at the Generator ........................................................................................... 15
A.2.1
A.2
A.2.2
A.2.3
A.2.4
A.2.5
A.3
Preliminary remark ............................................................................................................ 41
Daily routine checks before starting .................................................................................. 42
Starting Generator - see remote control panel datasheet ................................................. 43
Stopping the Generator - see remote control panel datasheet ......................................... 43
Starting the Generator by a „Failure bypass switch“ ......................................................... 43
Installation Instructions .............................................................................................. 45
B.1
Placement ....................................................................................................................... 45
B.1.1
Advice for optimal sound insulation ................................................................................... 45
B.2
Generator Connections ................................................................................................. 46
B.3
Cooling System Installation - Raw Water ..................................................................... 47
B.3.1
B.3.2
B.3.3
B.3.4
B.3.5
B.3.6
B.3.7
B.4
General Information ........................................................................................................... 47
Installation of the thru hull fitting in Yachts ........................................................................ 47
Quality of the Raw Water Sucking In Line ......................................................................... 48
Generator Installation above Waterline ............................................................................. 48
Generator Installation below Water-Line ........................................................................... 49
Generator Housing cooled by Raw Water ......................................................................... 51
Indirect Cooling of the Genset Housing (by the Heat Exchanger) ..................................... 51
The Freshwater Coolant Circuit .................................................................................... 52
B.4.1
B.4.2
B.4.3
16.6.08
Remote control panel - see remote control panel datasheet ............................................. 21
Components of Cooling System (Raw water) ................................................................... 21
Components of Cooling System (Freshwater) .................................................................. 23
Components of the fuel system ......................................................................................... 27
Components of combustion air .......................................................................................... 29
Components of the electrical system ................................................................................ 32
Sensors and switches for operating surveillance .............................................................. 35
Components of the oil circuit ............................................................................................. 38
External components ......................................................................................................... 39
Operation manual ........................................................................................................... 41
A.4.1
A.4.2
A.4.3
A.4.4
A.4.5
B
Left Side View ................................................................................................................... 17
Front View ......................................................................................................................... 18
Back View .......................................................................................................................... 19
View from above ................................................................................................................ 20
Details of functional units ............................................................................................. 21
A.3.1
A.3.2
A.3.3
A.3.4
A.3.5
A.3.6
A.3.7
A.3.8
A.3.9
A.4
Right Side View ................................................................................................................. 16
Description of the Generator ......................................................................................... 16
Position of the external cooling water expansion tank ...................................................... 52
Ventilating at the first filling of the Internal Cooling Water Circuit ...................................... 53
Pressure Test for Controlling the Cooling Water Circuit .................................................... 54
Panda_22-4KU_HD_PMS.R02 - Table of contents
Page 3
B.4.4
B.4.5
B.4.6
B.5
Water Cooled Exhaust System ...................................................................................... 57
B.5.1
B.5.2
B.5.3
B.6
C
Connection of the 12 V Starter Battery .............................................................................. 64
Connection of the remote control panel - see separate control panel manual .................. 65
Installation with looped in AC-Control box ......................................................................... 66
Installation AC-Box / distribution panel separate connected ............................................. 67
AC Control Box with VCS and ASB ................................................................................... 69
VCS Voltage Control ......................................................................................................... 70
Jump Start at High Starting Current (Booster) ................................................................... 71
Insulation Test ................................................................................................................ 71
Maintenance Instructions ............................................................................................73
C.1
General maintenance instructions ................................................................................ 73
C.1.1
C.1.2
Checks before starting ....................................................................................................... 73
Check of Hoses and Rubber Parts in the sound insulated capsule ................................... 73
C.2
Oil Change Intervals ....................................................................................................... 73
C.3
Execution of an oil change ............................................................................................ 74
C.3.1
C.4
C.5
Ventilating the Fuel System ............................................................................................... 77
Exchange of the Fuel Filter ................................................................................................ 78
Exchange the Air Filter Mat ............................................................................................... 79
Ventilation of the Coolant Circuit / Freshwater .................................................................. 80
Exchange of the V-Belt for the Internal Cooling Water Pump ........................................... 82
The Seawater Circuit ...................................................................................................... 84
C.5.1
C.6
Check Oil Level of the Oil-Cooled Bearing ........................................................................ 76
Checking the water separator in the fuel supply ......................................................... 76
C.4.1
C.4.2
C.4.3
C.4.4
C.4.5
Clean Seawater Filter ........................................................................................................ 84
Reason for Frequent Impeller Wear .............................................................................. 84
C.6.1
Exchanging the Impeller .................................................................................................... 85
C.7
Coolant Connection Block at the Generator Capsule ................................................. 87
C.8
Conservation of the Generator (long operation interruption) .................................... 88
C.8.1
C.8.2
D
General References .......................................................................................................... 60
The Electrical Fuel Pump .................................................................................................. 61
Connection of the Fuel Lines at the Tank .......................................................................... 62
Position of the Pre-Filter with Water Separator ................................................................. 62
Ventilating Air from the Fuel System ................................................................................. 63
Generator 12 V DC System Installation ........................................................................ 64
B.7.1
B.7.2
B.8.1
B.8.2
B.8.3
B.8.4
B.8.5
B.9
Installation of the Standard Exhaust System ..................................................................... 57
Exhaust / Water separator ................................................................................................. 58
Installation Exhaust-Water-Separator ................................................................................ 59
Installation of the Fuel System ...................................................................................... 60
B.6.1
B.6.2
B.6.3
B.6.4
B.6.5
B.7
Scheme for Freshwater Circuit at Two Circuit Cooling System ......................................... 55
Pressure Test for Controlling the Cooling Water Circuit .................................................... 55
Scheme for Freshwater Circuit at Two Circuit Cooling System ......................................... 56
Measures for preparation of winter storage ....................................................................... 88
Initiation during Spring ....................................................................................................... 89
Generator Failure..........................................................................................................91
D.1
Tools and Measuring Instruments ................................................................................ 91
D.2
Overloading the Generator ............................................................................................ 91
D.2.1
D.2.2
D.3
Monitoring the Generator Voltage ..................................................................................... 92
Automatic Voltage Monitoring and Auto-Shut Down ......................................................... 93
Setting the Speed Governor of the Actuator ................................................................ 93
D.3.1
D.3.3
D.3.4
Setting the maximum upper speed setting ........................................................................ 94
Greasing the trapezoidal thread spindle on the speed actuator ........................................ 96
Consequences of a continual overloading of the Actuator ................................................ 97
D.4
Generator-Output Voltage is too low ............................................................................ 99
D.4.1
D.4.2
D.4.3
D.4.4
D.4.5
D.4.6
D.5
Generator provides no voltage ................................................................................... 103
D.5.1
D.6
F
Rotor Magnetism Loss and "Re-magnetising" ................................................................. 103
Engine Starting Problems ........................................................................................... 103
D.6.1
D.6.2
D.6.3
E
Discharging the Capacitors ............................................................................................... 99
Checking the Capacitors ................................................................................................. 100
Check the Generator Voltage .......................................................................................... 101
Measuring the Ohm Resistance of the Generator Windings ........................................... 101
Check the Windings for Short Circuiting .......................................................................... 102
Measuring the Inductive Resistance ............................................................................... 102
Fuel Solenoid Valve ........................................................................................................ 103
Re-start with Failure Bypass Switch ................................................................................ 104
Troubleshooting Table ..................................................................................................... 105
Tables.......................................................................................................................... 107
E.1
Troubleshooting ........................................................................................................... 107
E.2
Types of coil ................................................................................................................. 117
E.3
Inspection checklist for services ................................................................................ 119
E.4
Engine oil ...................................................................................................................... 120
E.5
Coolant .......................................................................................................................... 121
Tables Panda PMS HD............................................................................................... 123
F.1
Capsule Mearuements ................................................................................................. 125
Generator Control Panel P6+ Manual ............................................................................... 127
Current revision status ...................................................................................................... 128
A
General operation ...................................................................................................... 129
A.1
Panel Generator Control .............................................................................................. 129
A.2
Rear view 12V-version ................................................................................................. 130
A.3
Rear view 24V-version ................................................................................................. 131
A.4
Terminal connections .................................................................................................. 132
A.5
Function of the jumpers .............................................................................................. 133
A.6
Starting preparation / Checks (daily) .......................................................................... 134
A.6.1
A.6.2
A.7
Starting and stopping the generators ........................................................................ 135
A.7.1
A.7.2
A.8
Terminal connections ...................................................................................................... 139
Master-Slave adapter - option ..................................................................................... 140
A.9.1
A.9.2
B
Starting the generator ...................................................................................................... 135
Stopping the generator .................................................................................................... 136
Automatic adapter - option .......................................................................................... 137
A.8.1
A.9
Marine version ................................................................................................................. 134
Vehicle version ................................................................................................................ 135
Terminal connections ...................................................................................................... 141
Configuration and adjustment ......................................................................................... 142
Measurements............................................................................................................ 145
B.1
Hole pattern .................................................................................................................. 145
Intentionally Blank
Page 6
Panda_22-4KU_HD_PMS.R02 - Table of contents
16.6.08
since
1977
since
1978
since
1988
since
1988
since
1988
Icemaster GmbH
Fischer Marine
Generators
Conclusion Fischer Icemaster GmbH
100 % water cooled
Panda generators
Panda Vehicle
Generators
Fischer Panda
FISCHER GENERATORS have been manufactured since 1978 and are a well-known brand for first class diesel
generators with especially effective sound-insulation.
Fischer has been one of the leading manufacturers in respect of quality and know-how during this period.
FISCHER, as the worldwide manufacturer of modern marine diesel generators, developed the Sailor-Silent series for
example and produced a GFK sound-insulated capsule as early as 1979 and the basis for new generator technology.
The companies Fischer and Icemaster amalgamated under the direction of Icemaster in 1988, in order to concentrate
on the development of new products. Production was moved to Paderborn.
The amalgamation of the two qualified companies led to the development of a complete new programme within a short
space of time. The generators developed at that time set new technological standards worldwide.
The generators became more efficient and powerful than other generators in the same nominal performance range,
because of the improved cooling. Panda generator demonstrated its superiority in several tests by renowned institutes
and magazines during the past years. The patented VCS (voltage Control System) means it can meet all demands
including motor speed. The start-booster (ASB) means Panda generators meet the highest demands in respect of
voltage stability and starting values. A Panda generator, with the same drive motor, produces 15 % more effective
output than the majority of conventional generators. This superiority in efficiency also ensures a fuel saving to the same
extent.
The 100% water-cooled Panda generators are currently manufactured in the performance range from 2 to 100 kW in
various versions. Fast running motors are preferred for performances up to approx. 30 kW (nominal speed 3000 rpm).
The heavier slow runners are preferred for the higher range. The fast running generators have proved themselves
many times for many uses, that they meet the demands in quality of yachts and vehicles, and offer space and weight
saving of 50 % compared to slow running generators.
In addition to the Panda series, Fischer Panda also supply the super compact high-tech sound-insulated battery
charging generators from the DC/AC Panda AGT series, which is a very interesting solution for the production of mobile
power.
The HTG-alternators ensure that a charging rate of 285 amps is achieved that was scarcely thought possible for this
compact construction. This alternator replaces a separate shipboard generators (constant 230 volts AC with up to 3500
kW from the main machine)
Fischer Panda GmbH, 33104 Paderborn, reserves all rights regarding text and graphics. Details are given to the best of our knowledge. No liability is accepted for correctness. Technical modifications for improving the product without previous notice may be undertaken without notice. Before installation, it must be ensured that the pictures,
diagrams and related material are applicable to the genset supplied. Enquiries must be made in case o doubt.
7
Safety first
These symbols are used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury. Read these instructions carefully. It is essential that you read the instructions and safety regulations
before you attempt to assemble or use unit.
This danger symbol refers to toxic danger and draws attention to special warnings,
instructions or procedures which, if not strictly observed, may result in severe personal injury or loss of life.
This danger symbol refers to electric danger and draws attention to special
warnings, instructions or procedures which, if not strictly observed, may result in
electrical shock which will result in severe personal injury or loss of life.
This warning symbol draws attention to special warnings, instructions or procedures
which, if not strictly observed, may result in damage or destruction of equipment,
severe personal injury or loss of life.
This warning symbol draws attention to special warnings, instructions or procedures
which, if not strictly observed, may result in damage or destruction of equipment
8
Tools
This symbols are used throughout this manual to show which tool must be used at maintenance or installation.
Spanners
X = required size
X
Hook wrench for oil filter
Screw driver, for slotted head screws and for recessed head screws
Multimeter, multimeter with capacitor measuring
Socket wrench set
Hexagon wrench keys
9
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
Attention, Important Directions regarding Operation!
1. The installation certificate must be completed when taken into use, and certified by a signature.
2. The installation certificate must be despatched within two weeks of use to Fischer Panda.
3. The official guaranty confirmation will be completed by Fischer Panda after receipt and sent to the customer.
4. A guaranty must be shown to make any claims.
Claims against the guaranty will not be accepted of the above said instructions are not, or only partially, carried out.
Manufacturer declaration in accordance with the machine guideline 98/37/EG
The generator has been developed in such a way, that all assembly groups correspond to the CE guidelines. If
machine guideline 98/37/EG is applied, then it is forbidden to start the generator, until it has been ascertained that
the system into which the generator is to be integrated, also corresponds to the machine guideline regulation 98/37/
EG. This includes the exhaust system, cooling system and electrical installation.
The evaluation of "protection against contact" must be carried out when installed, in conjunction with the respective
system. This includes correct electrical connections, a safe ground wire connection, foreign body and humidity protection, protection against humidity due to excessive condensation, as well as overheating through appropriate and
inappropriate use in its installed state. The responsibility lies with those who undertake installation of the generator in
the final system.
Use the advantages of the customer registration:
•
Thus you receive to extended product informations, which are sometimes safety-relevant
•
you receive, if necessarily free Upgrades
Far advantages:
By your full information Fischer Panda technicians can give you fast assistance, since 90% of the disturbances result
from errors in the periphery.
Problems due to errors in the installation can be recognized in the apron.
Technical Support per Internet:
info@fischerpanda.de
10
Safety Precautions
The electrical installations may only be carried out by trained and
qualified personnel!
Safety Instructions concerning operating the generator
•
The generator must not be taken into use with the cover removed.
•
If the generator is being installed without a sound insulation capsule, then make sure, that all rotating parts (beltpulley, belts etc) are covered and protected so that there is no danger to life and body!
•
If a sound insulation covering will be produced at the place of installation, then well-placed signs must show that
the generator can only be switched on with a closed capsule.
•
All servicing-, maintenance or repair work may only carried out, when the motor is not running.
•
There is full current in the AC control box when the generator is running. It must therefore be ensured that the control box is closed and cannot be touched when the generator is running.
•
Do not work in an ambient, where there are explosives. Working on an electrical system in an ambient where there
are flammable gases is dangerous.
•
Electrical voltages above 48 volts (battery chargers greater than 36 volts) are always dangerous to life). The rules
of the respective regional authority must be adhered to. Only an electrician may carry out installation of the electrical connections for safety reasons.
Ground Wire:
The generator, is "earthed" as series (centre and ground are connected together in the generator terminal box by a
bridge). This is an initial ground fuse, which offers protection, as long as no other measures are installed. Above all,
it is conceived for the delivery and possible test run.
This "neutralisation" (Protective Earthing Neutral - PEN) is only effective, if all parts of the electrical system are commonly "earthed" to a common potential. The bridges can be removed, if this is necessary for technical reasons and
another protective system has been setup.
Safety Instructions concerning working on the generator
The battery must always be disconnected, if work on the generator or electrical system is to be carried out, so that
the generator cannot be unintentionally started. It is not allowed to disconnect the battery during operation!
After the generator has been stopped, the battery can be disconnected!
Switch off all load when working on the generator
All load must be disconnected, in order to avoid damages to the devices. In addition the semi conductors in the AC
control box must be disconnected in order to avoid the boat capacitors being activated. The minus pole of the battery
ought to be removed.
11
Safety Instructions concerning the capacitors
Capacitors are required to run the generator. These have two varying functions:
A) The working capacitors
B) The (Booster) capacitors
Both Groups are located in a separate AC-Control box.
Capacitors are electrical stores. There could be a residual of high electrical current at the contacts for a period disconnection from the circuit. The contacts may not be touched for safety reasons, If the capacitors are to be
exchanged or checked, and then a short circuit between the contacts should be made so that the stored energy is
discharged.
If the generator is switched off in the normal manner, the working capacitors are automatically discharged by means
of the windings. The booster capacitors are discharged by means of internal discharge resistors.
All capacitors must be short-circuited before work is carried out on the AC-Control box for safety reasons.
Safety Instructions concerning the cables
Cable Type
It is recommended is that the cable used be UL 1426 (BC-5W2) compliant, with Type 3 stranding (ABYC Section E11)
Cable Size
The cable size must be selected taking into account the amperage, voltage and conductor length (from the positive
power source connection to the electrical device and back to the negative power source connection.
Cable Installation
It is recommended that a self draining wire loom classified as V-2 or better in accordance with UL 94 be installed in
the section of the cable routed in the interior of the sound capsule. Care should be taken to avoid hot surfaces such
as the exhaust manifold or engine oil drain bolt and routed clear of any possible sources of chafing.
Battery
Warning:
Do not use Gel-Cel batteries, because the regulation voltage is high for this type of batteries.
Do not use large batterybanks as a starting battery. The generator must have a dedicated starter battery (maximum
size group 24).
Recommend starter battery size (if model not shown - please see engine manual)
Panda 6000 -8000
12V, 28AH equivalent
Panda 18
12V, 65AH equivalent
Panda 9000-14000
12V, 36AH equivalent
Panda 24-30
12V, 70AH equivalent
Panda 16
12V, 52AH equivalent
Panda 33-42
12V, 100 to 120AH equivalent
12
5 Safety steps to follow if someone is the
victim of electrical shock
1
Do not try to pull or grab the individual.
12
Send for help as soon as possible.
13
If possible, turn off the electrical power.
14
If you cannot turn off the electrical power, pull, push, or lift the person to safety using a
wooden pole, rope, or some nonconductive material.
15
After the injured person is free of contact with the source of electrical shock, move them a
short distance away and immediately start necessary first aid procedures.
13
WHEN AN ADULT STOPS BREATHING
WARNING
DO NOT attempt to perform the rescue breathing techniques provided on this page, unless
certified. Performance of these techniques by uncertified personnel could result in further
injury or death to the victim.
1 Does the Person Respond?
2 Shout, "Help!"
Tap or gently shake victim.
Call people who can phone for help.
Shout, "Are you OK?"
3 Roll Person onto Back.
Roll victim toward you by pulling slowly.
4 Open Airway.
5 Check for Breathing.
Tilt head back, and lift chin.
Look, listen, and feel for breathing
for 3 to 5 seconds.
Shout, "Are you OK?"
6 Give 2 Full Breaths.
Keep head tilted back.
Pinch nose shut.
Seal your lips tight around victim's
mouth.
Give 2 full breaths for 1 to 1½ seconds
each.
7 Check for Pulse at side of Neck.
8 Phone EMS for Help.
Feel for pulse for 5 to 10 seconds.
Send someone to call an ambulance.
9 Begin Rescue Breathing.
10 Recheck Pulse Every Minute.
Keep head tilted back.
Keep head tilted back.
Lift chin.
Feel for pulse for 5 to 10 seconds.
Pinch nose shut.
If victim has pulse, not breathing,
continue rescue breathing. If no
pulse, begin CPR.
Give 1 full breath every 5 seconds.
Look, listen, and feel for breathing between breaths.
14
The Panda Generator
A. The Panda Generator
A.1 Type plate at the Generator
Fig. A.1-1: Type plate
Fig. A.1-2: Discription type plate
Panda_22-4KU_HD_PMS - Chapter A: The Panda Generator
Page 15
The Panda Generator
A.2 Description of the Generator
A.2.1 Right Side View
10
11
01
20
12
02
19
13
03
04
05
06
07
08
01.
02.
03.
04.
05.
06.
07.
08.
09.
10.
Page 16
Thermostat housing
12V-DC-alternator
V-belt for DC-alternator and cooling water pump
V-belt for
V-Belt for raw water pump
Raw water pump
Sound cover - base part
Hose for raw water flow to heat exchanger
Oil pressure switch
Thermo-switch exhaust elbow
Panda_22-4KU_HD_PMS - Chapter A: The Panda Generator
09
11.
12.
13.
14.
16.
16.
17.
18.
19.
20.
14
15
16
Cooling water filler neck with cap
Water-cooled exhaust elbow
Starter motor
Cooling water backflow pipe
Injector for raw water
Generator housing with coil
Exhaust hose
Exhaust outlet
Thermo-switch exhaust
AIr suction housing with air filter
17
18
The Panda Generator
A.2.2 Left Side View
02
01
03
04
05
06
07
08
22
21
09
10
11
01.
02.
03.
04.
05.
06.
07.
08.
09.
10.
11.
12
13
Power terminal box
Air suction housing with air filter
Suction hose, air suction housing - induction elbow
Fuel filter
Fuel filterStop solenoid for engine stop
Actuator
Ventilation screw thermostat housing
Thermostat housing
Cooling water connection block
Sound cover base part
Cooling water pipe, connection block - water pump
Panda_22-4KU_HD_PMS - Chapter A: The Panda Generator
Page 17
14 15
16 17
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
18
19
Generator housing with coil
Failure bypass switch
Electrical fuses (blue=15A, white=25A)
Relay Ks for starter motor
Relay K3 for fuel pump
Relay K4 for stop solenoid
Relay K2 for glow plugs
Oil filter
Passage for oil drain hose
Stop solenoid for engine stop
Fuel solenoid valve
20
The Panda Generator
A.2.3 Front View
21
20
19
01
18
17
02
03
16
15
04
14
05 06
01.
02.
03.
04.
05.
06.
07.
08.
09.
10.
11.
Page 18
Fuel solenoid valve
Stop solenoid for engine stop
Fuel filter
Cooling water pipe, connection block - water pump
Fuel intake connection
Fuel backflow connection
Electrical cable for load
Electrical cable fuel pump (2x1,5mm²)
Electrical cable remote control panel
Electrical cable VCS
Starter battery minus (-)
Panda_22-4KU_HD_PMS - Chapter A: The Panda Generator
07
08
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
09 10
11 12
13
Starter battery plus (+)
Raw water inlet
Pulley for raw water pump
V-belt for raw water pump
V-belt for DC-alternator and internal cooling water pump
12V DC-alternator
Pulley for internal cooling water pump
Thermo-switch at thermostat housing
Thermostat housing
Ventilation screw internal cooling water pump
The Panda Generator
A.2.4 Back View
12
01
11
10
02
09
08
07
03
01.
02.
03.
04.
05.
06.
04
05
06
Water-cooled exhaust elbow
Exhaust hose
Exhaust outlet
Intake from the external cooling water expansion tank
Backflow to the external cooling water expansion tank
Connection external ventilation vlave
Panda_22-4KU_HD_PMS - Chapter A: The Panda Generator
Page 19
07.
08.
09.
10.
11.
12.
Thermo-switch at oil cooled bearing
Cooling water connection block
Oil flow glas
Generator front plate
Power terminal box
Air suction housing with air filter
The Panda Generator
A.2.5 View from above
02
01
15
01.
02.
04.
04.
05.
06.
07.
08.
Page 20
03
14
Air suction housing with air filter
Exhaust port
Cylinder head
Cooling water filler neck with cap
Oil filler neck
Water-cooled exhaust elbow
Hose for backflow to external cooling water expansion tank
Ventilation screw thermostat housing
Panda_22-4KU_HD_PMS - Chapter A: The Panda Generator
04
13
05
06
12
11
07
10
08
09
09. Stop solenoid for engine stop
10. Fuel solenoid valve
11. Actuator
12. Fuel filter
13. Terminal block
14. Suction hose, air suction housing - induction elbow
15. Power terminal box
The Panda Generator
A.3 Details of functional units
A.3.1 Remote control panel - see remote control panel datasheet
The remote control panel is necessary to control the generator and to evaluate the motor/generator properties. The generators will automatically cutout if it does not run as required. The generator may not be run without the remote control panel.
A.3.2 Components of Cooling System (Raw water)
Raw water intake
The diagram shows the supply pipes for
the generator. The connection neck for
the raw water connection is shown on the
left hand side. The cross-section of the
intake pipe should be nominally larger
than the generator connection.
Fig. A.3.2-1: Raw water intake
Raw water impeller pump
The raw water pump is fitted with a rubber
impeller. This pump is self-inductive. If, for
example, you forget to open the sea
valve, then you must expect the impeller
to be destroyed after a short period of
time. It is recommended to store several
impellers on board as spare parts.
Fig. A.3.2-2: Raw water inpeller pump
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The Panda Generator
Heat exchanger
Separates the raw water system from the
freshwater system.
Fig. A.3.2-3: Heat exchanger
Ventilation valve
A siphon must be installed if the generator
sinks below the water line because of the
rocking of the boat, even if it is only for a
short period of time. A hosepipe on the
generator casing has been produced for
this. Both connecting pieces are bridged
by a formed piece of hose.
Fig. A.3.2-4: Connection external ventilation valve
Cooling water injector nozzle
The injection point for the marine generator water-cooled exhaust system is situated at the exhaust connection pieces The
exhaust connections must be regularly
checked for signs of corrosion.
Fig. A.3.2-5: Cooling water injector nozzle
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The Panda Generator
A.3.3 Components of Cooling System (Freshwater)
Cooling water filler neck
The cooling water filler nck situated at the
water-cooled manifold are only used,
when the generator is initially started.
Since the generator is normally already filled with cooling water, these components
are only by the user, if repairs are to be
carried out. Topping up with cooling water
may only carried out at the external cooling water compensation tank. Note that
the water level in the cooling water compensation tank is only 20% of the volume
in a cold state.
Fig. A.3.3-1: Cooling water filler neck
Ventilation pipe
The ventilation pipe at the water-cooled
exhaust manifold leads to the external
expansion tank. This pipe only serves as a
ventilation pipe, if both pipes are to be
connected to the external expansion tank
(ventilation pipe and intake pipe).
Fig. A.3.3-2: Ventilation pipe
Hose connection pieces for the external
expansion tank
The external expansion tank is connected
by two hose connections. The connecting
pieces shown here serves as constant
ventilation for the water-cooling system.
In case the external expansion tank is
connected with two hoses, the system will
ventilate itself. In this case, additional ventilation is only necessary when the generator is initially filled, or if the cooling water
is not circulating.
Fig. A.3.3-3: External expansion tank
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Page 23
The Panda Generator
Freshwater backflow
The cooling water is fed to the heat
exchanger from the water-cooled manifold
by means of the pipe shown in the diagram.
Fig. A.3.3-4: Freshwater backflow
Heat exchanger
Separates the raw water system from the
freshwater system.
Fig. A.3.3-5: Heat exchanger
Cooling water connection block
The cooling water is fed to the generator
and drained via the cooling water connection block. The cooling water connection
block consists of an aluminium alloy,
which can behave like a sacrificial anode.
Fig. A.3.3-6: Cooling water connection block
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The Panda Generator
Internal cooling water pump
The diesel motor cooling water pump (see
arrow) aids the circulation of the internal
freshwater system.
Fig. A.3.3-7: Internal cooling water pump
Cooling water intake
The intake pipe from the external cooling
water expansion tank is connected here.
Fig. A.3.3-8: Internal cooling water pump
Thermostat housing
The cooling water flows through the
engine and gets then to the thermostat
housing.
Fig. A.3.3-9: Thermostat housing
Panda_22-4KU_HD_PMS - Chapter A: The Panda Generator
Page 25
The Panda Generator
Ventilation screw thermostat housing
The ventilation screw on the thermostat
housing should occasionally be opened
for control purposes. Standing machinery
should principally carry out ventilating.
Fig. A.3.3-10: Ventilation screw thermostat housing
Water-cooled exhaust manifold
The manifold is cooled by means of the
internal cooling system (freshwater). The
cooling water filler necks on the casing of
the manifold may not be opened. These
cooling water necks are only required to
fill the motor with cooling water in cases of
repair. The normal cooling water controls
may only be carried out at the external
expansion tank.
Fig. A.3.3-11: Water-cooled exhaust manifold
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The Panda Generator
A.3.4 Components of the fuel system
External fuel pump
The Panda generator is always supplied
with an external, electrical (12 V of DC) fuel
pump. The fuel pump must be always
installed in the proximity of the tank. The
electrical connections with the lead planned for it are before-installed at the generator. Since the suction height and the
supply pressure are limited, it can be
sometimes possible that for reinforcement
a second pump must be installed.
Fig. A.3.4-1: External fuel pump
Connecting pieces for the fuel pipe
1. Fuel intake
2. Fuel backflow
1
Fig. A.3.4-2: Fuel connections
Fuel filter with water separator
A consequential filtering of fuel is especially important for all marine systems. A fine
filter, which is firmly attached to the inside
of the sound insulation capsule for the
marine version, is supplied on delivery, and
loose for other makes. In all cases a further
pre-filter with water separator must be
installed. See directions for fuel filter installation.
Fig. A.3.4-3: Fuel filter with water separator
Panda_22-4KU_HD_PMS - Chapter A: The Panda Generator
Page 27
2
The Panda Generator
Fuel solenoid valve
The fuel solenoid valve opens automatically if „START“ is pressed on the remote
control panel“. The solenoid closes, if the
generator is switched to „OFF“ position. It
takes a few seconds before the generator
stops. If the generator does not start or
does not run smoothly (i.e. stutters), or
does not attain full speed, then the cause
is fore-mostly the solenoid.
1) Fuel solenoid valve
2) Ventilation screw solenoid valve
3) Magnetic coil
Fig. A.3.4-4: Fuel solenoid valve
Injection nozzles
If the engine does not start after the ventilation, the fuel injection lines must be deaerated individually.
Fig. A.3.4-5: Injection nozzles
Glow plugs
The glow plugs serve the pre-chamber for
the heating with cold start. The heat-treat
fixture must be operated, if the temperature of the generator is under 16°C. This
is practically with each start the case. The
heat-treat fixture may be held down also
during start and favoured the starting procedure.
Fig. A.3.4-6: Glow plugs
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Panda_22-4KU_HD_PMS - Chapter A: The Panda Generator
3
1
2
The Panda Generator
Stop solenoid for engine stop
Some model are additional equipped with
an stop solenoid. The generator is stopped by the co-operation of the stop solenoid immediately after switching off. The
adjustment of the stop solenoid must
always be checked, in order to be sure
that the stop lever can move also during
the operation freely and is not under prestressing.
Fig. A.3.4-7: Stop solenoid
A.3.5 Components of combustion air
Air suction openings at the sound cover
The sound cover is provided at the back
side with drillings, through which the combustion air can influx.
It must be consistently paid attention that
the generator is installed in such a way
that from down no water can arrive into
the proximity of these air openings.
Fig. A.3.5-1: Combustion air intake
Air suction housing
If the cover is removed, the inside of the
air suction housing becomes visible. In
these air suction housings is a filter element. At the marine version the filter is
normally not changed. It should be chekked once in a while.
Fig. A.3.5-2: Air suction housing
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Page 29
The Panda Generator
Air suction housing with air filter set
The figure shows the air filter element in
the air suction housing. However the
return pipe of the crank case exhaust
flows also into the air suction housing, it
can be faced with older generators and/or
with engines on high running time that oel
vapors affect the air filter. Therefore an
check is advisable once in a while.
Filter type: MANN FILTER C 34109
Fig. A.3.5-3: Air filter set
Combustion chamber intake elbow
The figure shows the induction elbow at
the combustion engine. At the front of this
induction elbow you can see the hose
connection between air suction housings
and induction elbow. The air filter must be
checked, if this hose pulls together at operation.
Fig. A.3.5-4: Combustion chamber intake elbow
Exhaust elbow
On the back of the engine is the watercooled exhaust elbow. On the top side the
pipe union for the internal raw water circuit
is to be seen and the filler neck for the
cooling water. This cooling water filler
neck is used only at first filling. Control of
the cooling water and if necessary refill
takes place at the external cooling water
expansion tank.
Fig. A.3.5-5: Exhaust elbow
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Panda_22-4KU_HD_PMS - Chapter A: The Panda Generator
The Panda Generator
Exhaust connection at the exhaust elbow
Raw water from the external cooling circle
is fed here.
Fig. A.3.5-6: Exhaust connection
Exhaust outlet
Connect the exhaust pipe with the water
lock.
Fig. A.3.5-7: Exhaust outlet
Panda_22-4KU_HD_PMS - Chapter A: The Panda Generator
Page 31
The Panda Generator
A.3.6 Components of the electrical system
Connection starter battery
1. Cable for starter battery (minus)
1
2. Cable for starter battery (plus)
During the connection to the starter battery it must be always ensured that the
contact is perfectly guaranteed.
Fig. A.3.6-1: Cable for starter battery
Electrical connection for control
At the front of the generator also all remaining cables for the electrical connections
are depending upon type. The allocation
of the connections result from the plan for
the AC-Control box. See here:
1
3
1. Fuel pump
2. Remote control panel
2
3. VCS
Fig. A.3.6-2: Electrical connection fuel pump
Load
At the front of the sound cover is also the
withdrawal for the cable for the main
power. Depending upon type of the generator are here also the cables for the connection of the external condensers (see
for this the connection diagram for the ACControl box!)
1
Fig. A.3.6-3: Load
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Panda_22-4KU_HD_PMS - Chapter A: The Panda Generator
2
The Panda Generator
Starter motor
1. Starter motor and
2. Solenoid switch
The Diesel engine is electrically started.
On the back of the engine is accordingly
the electrical starter with the solenoid
switch.
1
2
Fig. A.3.6-4: Starter motor
Actuator for speed regulation
The generator voltage is determined by
progressive speed control through "VCS"
in conjunction with the speed actuator.
Speed increases with increasing load.
Fig. A.3.6-5: Actuator
Blind plug for speed sensor
All Panda generators can be equipped
with an external automatic start. For the
operation of this automatic starting system
a separate speed sensor is necessary. At
some models the speed sensor is standard installed. At other models the opening for the speed sensor is locked by a
plug.
Fig. A.3.6-6: Blind plug
Panda_22-4KU_HD_PMS - Chapter A: The Panda Generator
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The Panda Generator
DC-alternator
All Panda generators from Panda 6.000
are provided with its own charge system
for the 12V DC mains. This DC-alternator
is powered over a v-belt together with the
internal cooling water pump.
The 12V charge system may be used only
for the generator-own starter battery.
Fig. A.3.6-7: DC-alternator
Generator Power Terminal Box 230V/50Hz
N
L
L
Z
To locate the Terminalbox see Chapter A2.
In these terminal boxe there are the electrical connection points for the AC generator. Here is also the bridge for the
protective grounding of the generator. The
cover may only be removed, if it is guaranteed that the generator cannot be inadvertently started.
Sample Picture
Fig. A.3.6-8: Generator Power Terminal Box 230V/50Hz
Generator Power Terminal Box 400V/50Hz
L1
L2
L3
To locate the Terminalbox see Chapter A2.
In these terminal boxe there are the electrical connection points for the AC generator. Here is also the bridge for the
protective grounding of the generator. The
cover may only be removed, if it is guaranteed that the generator cannot be inadvertently started.
Sample Picture
Fig. A.3.6-9: Generator Power Terminal Box 400V/50Hz
Page 34
Panda_22-4KU_HD_PMS - Chapter A: The Panda Generator
N
PE
The Panda Generator
Generator Power Terminal Box 120V/60Hz
PE
HOT
Z1.2
To locate the Terminalbox see Chapter A2.
In these terminal boxe there are the electrical connection points for the AC generator. Here is also the bridge for the
protective grounding of the generator. The
cover may only be removed, if it is guaranteed that the generator cannot be inadvertently started.
Z2.2
N
Fig. A.3.6-10: Generator power terminal box
Terminal block for fuses and power
relay
F1 fuse 15A for DC-wiring
Ks
F2 fuse 25A for starter motor
K3
Ks power relay for starter motor
K2 power relay for glow plugs
K3 power relay for fuel pump
K4 power relay for stop solenoid
F1 F2
Fig. A.3.6-11: Terminal block
A.3.7 Sensors and switches for operating surveillance
Thermo-switch at cylinder head
The thermo-switch at the cylinder head
serves the monitoring of the generator
temperature. All thermo-switches for the
generators from Panda 6.000 upward are
two-pole and laidout as "openers".
110°C and 130°C
Fig. A.3.7-1: Thermo-switch at cylinder head
Panda_22-4KU_HD_PMS - Chapter A: The Panda Generator
Page 35
K4
K2
The Panda Generator
Fig. A.3.7-2:
Thermo-switch at thermostat housing
98/83°C
Fig. A.3.7-3: Thermo-switch at thermostat housing
Thermo-switch at exhaust elbow
At some models a thermo-switch is also at
the water-cooled exhaust elbow. This
thermo-switch serves only for the additional monitoring. He is partly no more installed with the recent models.
105/90°C
Fig. A.3.7-4: Thermo-switch at exhaust elbow
Thermo-switch at exhaust connection
If the impeller pump drop out and deliveres no more raw water, the exhaust connection becomes extremely hot.
98/83°C
Fig. A.3.7-5: Thermo-switch at exhaust connection
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The Panda Generator
Thermo-switch at the endshield
The generator bearing is equipped with an
oil thermoswitch, which switches the
engine off if the oil temperature becomes
to high.
120°C
Fig. A.3.7-6: Thermo-switch at endshield
Oil pressure switch
In order to be able to monitore the lubricating oil system, an oil pressure switch is
built into the system. The oil pressure
switch is on the back of the engine (next to
the DC-alternator).
Fig. A.3.7-7: Oil pressure switch
Thermo-switch in the generator coil
1. Generator coil
2. Thermo-switch 4x165°C
1
3. Housing
For the protection of the generator cil
there are two thermo-switches inside the
coil, which are for inserted parallel and
safety's sake independently from each
other.
Fig. A.3.7-8: Thermo-switch coil
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Page 37
2
3
The Panda Generator
Failure bypass switch
The failure bypass switch offers the possibility of starting the generator if the electrical control switched off due to an error in
the cooling system by overheating.
Fig. A.3.7-9: Failure bypass switch
A.3.8 Components of the oil circuit
Oil filler neck with cap
Normally the filler neck for the engine oil
is on the top side of the valve cover. At
numerous generator types a second filler
neck is attached additionally at the operating side. Please pay attention that the filler necks are always well locked after
filling in engine oil.
Consider also the references to the
engine oil specification.
Fig. A.3.8-1: Oil filler neck with cap
Oil dipstick
At the dipstick the permissible level is indicated by the markings "maximum" and
"minimum". The engine oil should be
never filled up beyond the maximum conditions.
Fig. A.3.8-2: Oil dipstick
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The Panda Generator
Oil filter
The oil filter should be exchanged with an
oil change.
Fig. A.3.8-3: Oil filter
Oil drain hose
The Panda generator is equipped that the
engine oil can be drained over an drain
hose. The generator should be always
installed therefore that a collecting basin
can be set up deeply enough. If this is not
possible, an electrical oil drain pump must
be installed.
Note: Lubricating oil should be drained in
the warm condition!
Fig. A.3.8-4: Oil drain hose
A.3.9 External components
External fuel pump
The Panda generator is always supplied
with an external, electrical (12V of DC)
fuel pump. The fuel pump must be always
installed in the proximity of the tank. The
electrical connections with the lead planned for it are before-installed at the generator. Since the suction height and the
supply pressure are limited, it can be
sometimes possible that for reinforcement
a second pump must be installed.
Fig. A.3.9-1: External fuel pump
Panda_22-4KU_HD_PMS - Chapter A: The Panda Generator
Page 39
The Panda Generator
AC-Control box
At operating the generator the operating
voltage of 120/230 and/or 230/400V lies at
the AC-Control box. It must be guaranteed
that the generator cannot be inadvertently
started, if the Control box is opened. For
this reason the negative pole of the starter
battery is to be disclamped with all work
on the electrical system.
Fig. A.3.9-2: AC-Control box
Voltage control VCS
The figure shows the control printed board
for the VCS voltage regulation. Over this
control printed board the control signals
are given for the actuator for speed regulation. On the VCS board are also adjustment possibilities for the control
parameters.
Fig. A.3.9-3: VCS
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Panda_22-4KU_HD_PMS - Chapter A: The Panda Generator
The Panda Generator
A.4 Operation manual
A.4.1 Preliminary remark
Pre-heating the diesel motor
The motor must be pre-heated, if the diesel motor is designed as a "pre-combustion chamber
motor" for indirect fuel injection. A quick glow fitting is used for all Kubota-diesel motors. If you
press the "run/stop“ button an automatic pre-glow phase will be activated. After this phase the
engine starts.
Tips regarding Starter Battery
Fischer Panda recommends normal starter battery use. If an genset is required for extreme winter conditions, then the starter battery capacity should be doubled. It is recommended that the
starter battery be regularly charged by a suitable battery-charging device (i.e., at least every 2
Months). A correctly charged starter battery is necessary for low temperatures.
Panda_22-4KU_HD_PMS - Chapter A: The Panda Generator
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The Panda Generator
A.4.2 Daily routine checks before starting
1. Oil Level Control (ideal level: MAX).
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 maximum level, if the level drops below
the mark between maximum und minimum levels.
The oil level of the oil cooled bearing must be checked before every start - see flow glas at the generator
front cover!
2. State of Cooling Water.
The external compensation tank should be filled up to a maximum of in a cold state. It is very important that large
expansion area remains above the cooling water level.
3. Open Sea Cock for Cooling Water Intake.
For safety reasons, the seacock must be closed after the generator has been switched off. It should be re-opened
before starting the generator.
4. Check Raw Water Filter.
The raw water filter must be regularly checked and cleaned. The impeller fatigue increases, if residual affects the
raw water intake.
5. Check all Hose Connections and Hose Clamps are Leakage.
Leaks at hose connections must be immediately repaired, especially the raw water impeller pump. It is certainly
possible that the raw water impeller pump will produce leaks, depending upon the situation. (This can be caused by
sand particles in the raw water etc.) In this case, immediately exchange the pump, because the dripping water will
be sprayed by the belt pulley into the sound insulated casing and can quickly cause corrosion.
6. Check all electrical Lead Terminal Contacts are Firm.
This is especially the case with the temperature switch contacts, which automatically switch off the generator in
case of faults. There is only safety if these systems are regularly checked, and these systems will protect the generator, when there is a fault.
7. Check the Motor and Generator Mounting Screws are Tight.
The mounting screws must be checked regularly to ensure the generator is safe. A visual check of these screws
must be made, when the oil level is checked.
8. Switch the Land Electricity/Generator Switch to Zero before Starting or Switch Off all the load.
The generator should only be started when all the load have been switched off. The excitation of the generator will
be suppressed, if the generator is switched off with load connected, left for a while, or switched on with extra load,
thus reducing the residual magnetism necessary for excitation of the generator to a minimum. In certain circumstances, this can lead to the generator being re-excitated by means of a DC source. If the generator does not excitate itself when starting, then excitation by means of DC must be carried out again.
9. Check the Automatic Controls Functions and Oil Pressure.
Removing a cable end from the monitoring switch carries out this control test. The generator should then automatically switch off. Please adhere to the inspection timetable (see Checklist in the appendix).
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The Panda Generator
A.4.3 Starting Generator - see remote control panel datasheet
A.4.4 Stopping the Generator - see remote control panel datasheet
A.4.5 Starting the Generator by a „Failure bypass switch“
There is a "pressure switch" on the operation side above the power relays. Faults (e.g. caused by
overheating) can be manually overcome by means of this switch. The generator can be started by
using the remote control panel. The operating temperature can be reduced for a short period of
time (without stress of course), so that the fault switch returns to the original position should overheating cause the generator to shut down because of overheating.
ATTENTION: - Before using the failure bypass switch, it is important to check the oil
level, since the oil gauge is deactivated by the switch. For a further reason it is important
to switch off the generator electrical load before the generator is shut down:
Before stopping the generator it is highly recommended that electrical devices (e.g. refrigerating
compressors, air conditioning compressors etc) are switched off, because the voltage drops as
the rotational speed (rpm) decreases as the engine comes to a halt.
(Also see information regarding voltage control with automatic shut-off for protection of load when
over or undervoltage occurs).
This is also the case when the generator is started when load is switched on.
Normally the generator will no longer excitate if a certain amount of base load is stepped up. The
electrical load should also be shut-off before starting the generator.
If started under electrical load, the engine will still run but the generator will not generate the proper voltage (or even no voltage) since the stator windings do not have the chance to reach full
excitation. Electrical units which are switched on in this condition could possibly be damaged
(special caution should be practised with electric motors to avoid burnout).
Panda_22-4KU_HD_PMS - Chapter A: The Panda Generator
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The Panda Generator
Blank
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Panda_22-4KU_HD_PMS - Chapter A: The Panda Generator
Installation Instructions
B. Installation Instructions
B.1 Placement
Since Panda generators have extremely compact dimensions, they can be installed in tight locations. Attempts are sometimes made to install them in almost inaccessible places. Please consider
that even almost maintenance-free machinery must still remain accessible at least at the front
(drive belt, water pump) and the service-side (actuator, dipstick). Please also note that in spite of
the automatic oil-pressure sensor it is still essential that the oil level has to be checked regularly.
The generator should not be placed in the proximity of light walls or floors, which can have resonance vibrations because of airborne sounds. If this should be unavoidable, then it is recommended that this surface is lined with 1 mm lead foil, which will change the mass and the vibration
behaviour.
You should avoid fixing the generator on a slippery surface with little mass (i.e.). This acts as an
amplifier of airborne sounds in the most unreasonable case. An improvement can be achieved by
reinforcing these surfaces with ribs. In addition, the breakthroughs, which interrupt these surfaces, should be sawed off. The lining of the surrounding walls with a heavy layer (i.e lead) and
foam additionally improve the conditions.
The generator sucks its air from the surrounding engine room. Therefore it must be ensured that
sufficient ventilation openings are present, so that the generator cannot overheat.
High temperature of the intake air decline the power of the generator and increases the coolant
temperature. Air temperatures of more than 40 °C red uce the power by 2 % per temperature rise
of 5 °C. In order to keep these effects as small as possible, the temperature in the engine room
should not be higher than 15 °C in relation to the o utside temperature.
B.1.1 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" downward, the combustion air can be sucked in unhindered.
In addition are void the vibrations, which would arise
with a closed soil.
Fig. B.1.1-1: Generator Base
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Seite 45
Installation Instructions
B.2 Generator Connections
Connect all electrical wires within the capsule tightly to the motor and the generator. This is also
the case for fuel lines and cooling water lines.
The electrical connections MUST be carried out according to the respective valid regulations. This also concerns used cable materials. The cable supplied is meant for laying "protected" (i.e. in pipe) at a temperature up to a max of. 70 °C (160 °F). The on-board circuit
must also be fitted with all essential fuses.
ATTENTION! Before working (installation) on the System read the section
„Safety Instructions“ in this Manual.
1
10
2
1.
2.
3.
4.
5.
6.
3
4
5
raw water inlet
Fuel supply (in)
Fuel return line (out)
Electrical cable for external fuel pump
Motor oil drain hose
Electrical cable to remote control panel
6
7.
8.
9.
10.
11.
7
8
11
9
VCS cable to AC-Control box
Generator output cable to AC-Control box
Generator AC-output cable
Generator Starter-battery negative (-)
Generator Starter-battery positive (+)
Fig. B.2-1: Generator Connections
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Panda PMS 8.000 NE - 42 NE Manual.R04 - Capture B: Installation Instructions
16.6.08
Installation Instructions
1
2
01) external expansion tank
02) external vent valve
Fig. B.2-2: Generator Connections
B.3 Cooling System Installation - Raw Water
B.3.1 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:
For the avoidance of galvanic corrosion, refer to the chapter "Service instruction for
marine generators (corrosion protection)".
B.3.2 Installation of the thru hull fitting in Yachts
It is good practice for yachts to use a thru
hull fitting with an integrated strainer. The
thru hull fitting (raw water intake) is often
mounted against the sailing direction to
induce more water intake for cooling.
For Panda generators, the thru hull inlet
should NOT point in the sailing direction!
When sailing at higher speeds more water
will be forced into the inlet than the pump
can handle and your generator will flood!
Fig. B.3.2-1: Position of the Thru Hull Fitting
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Installation Instructions
B.3.3 Quality of the Raw Water Sucking In Line
In order to keep the suction resistance in the line at a minimum, the raw water intake system (i.e.
sea cock, thru-hull fitting, inlet filter, etc.) must have an inner diameter of at least 1" (25 mm).
This applies also to installation components such as thru-hull fitting, sea cock, raw water filter etc.
The intake suction line should be kept as short as possible. Install the raw water inlet in close proximity to the genset.
After start-up the cooling water quantity must be measured (e.g. by catching at the
exhaust). The flow rate, as well as the necessary cross section of the cooling water pipe
see section E.3, “Technical Data Generator,” on page 83
B.3.4 Generator Installation above Waterline
The Panda is equipped with a direct drive water intake pump mounted directly on the motor.
Since the intake pump is an impeller pump there are wearing parts which 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. If this is not possible, an external intake pump could be installed in an easily
accessible location.
If the generator is installed above the waterline, it is possible that the impeller will wear out faster,
because after starting, the pump runs dry for some seconds.
The raw water hose should form a loop as near as possible to the raw water inlet of the generator
(see picture below). This ensures the pump only sucks in air for a short time. The impeller pump
will be lubricated by raw water and the impeller life span will be increased.
By the installation of a check valve in the raw water inlet line, which is under the waterline, this
problem can be restricted.
The impeller pump will remain intact longer, if an electrical booster pump is installed, and is strongly recommended in order to preserve the impeller pump.
NOTE:
Never change the impeller for many years, without exchanging the old pump. If the
sealing ring is defective within the pump, raw water runs into the sound cover of the
genset. A repair is then very expensive.
Replacement impeller and also a spare pump should always be on board. The old
pump can be sent back to Fischer Panda.
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1. Raw water filter
2. Water cock
3. Thru hull
Make certain that the raw water filter lies
above the water level, otherwise with cleaning water can penetrate by the thru hull.
An external pre-pump can relieve the
impeller.
1
An external pre-pump can relieve the
impeller.
2
3
Fig. B.3.4-1: Einbau des Generators über der Wasserlinie
B.3.5 Generator Installation below Water-Line
If the generator cannot be attached at
least 600 mm above the waterline, a vent
valve must be installed at the raw water
line.
Possible heeling must be taken into consideration if installed at the "mid-ship line"!
The water hose for the external vent valve
is located at the back of the sound insulated cover. This hose is split in the middle
and extended respectively at each end by
an additional hose and a connecting
nipple. Both hose ends must be led outside of the sound cover to one point, if
possible 600 mm over the waterline in the
mid-ship line. The valve is connected at
the highest place to the two hose ends.
Note: The vent valve must be installed directly behind the water pump.
If the water pump ceases, the valve spring ensures that air can enter and therefore, a syphon effect is avoided.
The de-aeration valve must be regularly controlled. If the water pump stops, the
valve spring ensures that air enters. It must be opened, cleaned and greased.
Fig. B.3.5-1: Vent Valve
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Installation Instructions
Cut the hose for the external vent valve....
Fig. B.1: Connection Vent Valve
...and bend it upwards.
Both hose ends must be led out outside of
the sound cover to one point, if possible
600 mm over the waterline at the midships line. The valve is connected at the
highest place with the two hose ends.
Fig. B.3.5-2: Connection Vent Valve
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B.3.6 Generator Housing cooled by Raw Water
1. Vent valve
2. Coolant connection block
3. Raw water pump
4. Exhaust manifold
5. Raw water filter ø 1"
6. Water cock ø1"
7. Thru hull
Fig. B.3.6-1: Installaton Scheme for Direct Cooling
B.3.7 Indirect Cooling of the Genset Housing (by the Heat Exchanger)
1. Vent valve
2. Exhaust manifold
3. raw water pump (Raw water impeller pump)
4. Heat exchanger
5. raw water filter
6. Water cock
7. Hull inlet
Fig. B.3.7-1: Installation Scheme Indirect Cooling of teh Genset Housing
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B.4 The Freshwater Coolant Circuit
B.4.1 Position of the external cooling water expansion tank
Position of the external cooling water
expansion tank
The Panda generator is normally supplied
with an additional, external cooling water
expansion tank. This tank must be installed in such a way that its lower edge is at
least 500 mm more highly arranged than
the upper edge of the sound cover.
If this 500 mm should be fallen below, i.e.
the cooling water expansion tank is lower
installed, very large problems can occur
with filling and ventilating. Extend and displace the hose lines to the outside or possibly even up to the deck.
Fig. B.4.1-1: Position of the External Cooling Water Expansion Tank
ATTENTION! The external cooling water expansion tank may be filled
only up to the lower edge of the lower tension tape (see note "max") in
the maximum filling level in cold condition.
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B.4.2 Ventilating at the first filling of the Internal Cooling Water Circuit
1. Fill up the external cooling water expansion tank with coolant.
ATTENTION: maximum fill level = „max.“- mark.
The cover of the external expansion tank temporarily must be
opend (all other closures are now closed!).
Fig. B.4.2-1: Expansion ttank
2. Open vent screw on the pipe socket of
the internal cooling water pump. Close the
vent screw when air free water comes out
Check the water level in the expansion
tank during the vanting. Fill up if necessary.
Never open the vent screw while the
generator is running
10
Fig. B.4.2-2: Venting screw
3.Open vent screw on the thermostat housing. Close the vent screw when air free
water comes out
Check the water level in the expansion
tank during the vanting. Fill up if necessary.
Never open the vent screw while the
generator is running
10
Fig. B.4.2-3: venting screw
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4. Start the Generator
After filling the generator it must be started. During this first phase of start-up, the generator may
not be loaded. Switch the generator off after about 10 sek. of operation!
6. Repeat the steps 1-4 till no air comes out of the vent screw at tthermostat housing.
Close the vent screws.
Fill up the expansion tank.
Close the expansion tank.
7. Re-ventilating process 10 Operating hours after the first start-up (and if necessary)
Also after the first implementing a small amount of air can be reside in the cooling circuit. To
ensure an imaculate und actual operating of the cooling system the ventilating process must be
repeated casual in the next few days (weeks, if necessary). Small amount of air will still exit out of
the ventilating openings, especially if the generator stood still for a long time.
ATTENTION! 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 could be that the cooling
water is not circulating. The generator will heat up very quickly and
switch off, because of overheating.
Anti-freeze
In the interest of safety, the freezing point of the closed circuit coolant should be checked on a
regular basis. Be sure that the coolant/antifreeze mixture is good for at least -15°C (5 ° F) and if i t
is possible that your genset experiences lower temperatures, for example during storage or transportation, then the entire cooling system should be drained and purged
B.4.3 Pressure Test for Controlling the Cooling Water Circuit
Check if a temperature difference exists between cooling water in-flow and cooling water return
flow by use of the hand.
Feel the cooling water in-flow line at the internal cooling water pump.
Feel the cooling water return pipe either at the outlet of the water-cooled exhaust elbow union or
at the side, where this pipe exits at the heat exchanger.
The temperature difference between in-flow and return should be approx 10 degrees.
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B.4.4 Scheme for Freshwater Circuit at Two Circuit Cooling System
1. Expansion Tank
2. Exhaust Manifold
3. Thermostat Housing
4. Freshwater pump
5. Heat Exchanger
6. Cooling Water Connection Block
Fig. B-1: Scheme for Freshwater Circuit at Two Circuit Cooling System
B.4.5 Pressure Test for Controlling the Cooling Water Circuit
Check if a temperature difference exists between cooling water in-flow and cooling water return
flow by use of the hand.
Feel the cooling water in-flow line at the internal cooling water pump.
Feel the cooling water return pipe either at the outlet of the water-cooled exhaust elbow union or
at the side, where this pipe exits at the heat exchanger.
The temperature difference between in-flow and return should be approx 10 degrees.
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B.4.6 Scheme for Freshwater Circuit at Two Circuit Cooling System
1. Expansion Tank
2. Exhaust Manifold
3. Thermostat Housing
4. Freshwater pump
5. Heat Exchanger
6. Cooling Water Connection Block
Fig. B-2: Scheme for Freshwater Circuit at Two Circuit Cooling System
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B.5 Water Cooled Exhaust System
By injecting the outlet raw water into the exhaust manifold, the exhaust gases are cooled and the
noise emissions from the exhaust system are reduced.
B.5.1 Installation of the Standard Exhaust System
The generator exhaust system must remain completely independent and separate from the
exhaust system of any other unit(s) on board. The exhaust hose has an inner diameter of 30 mm.
The water lock must be installed at the lowest point of the exhaust system. An optional noise
insulated water lock can also be installed. The exhaust hose descends from the capsule to the
water lock. Then the hose rises via the "goose neck" to the silencer (see drawing). The goose
neck must be vertical and sit preferably along the ship's keel centre line. The exhaust system
must be installed so that the back pressure inside the exhaust does not exceed 0.4 bar (6 psi)
and total length does not exceed 6 m (20 ft.).
Exhaust diameter see section E.3, “Technical Data Generator,” on page 83.
1. Generator
2. Water lock
3. Goose neck
4. Silencer
5. Hull outlet
Fig. B.2: Installation Scheme Standard Exhaust System
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B.5.2 Exhaust / Water separator
In order to reduce the noise level of the generator unit to a minimum, an optional exhaust outlet
muffler can be mounted next to the thru-hull fitting. Additionally there is a component at Fischer
Panda, which acts as both an "exhaust goose neck", and water separator. With this "exhaust/
water separator" the cooling water is derived over a separate pipe. The exhaust noises emanating from the exterior of the yacht are strongly decreased. Particularly the "water splash".
The water flow on the exhaust/water
separator unit has an inner diameter (ID)
of 30 mm. If the path from the water separator to the raw water outlet is very short,
the hose can be further reduced to 1"
(25mm) ID.
Fig. B.5.2-1: Water Flow Exhaust Water Separator
1. Raw water outlet ø 30mm
2. Hose connector ø 30mm
3. Reducer 30/20mm (if required)
4. Hose
5. Hose connector
6. Sea cock
7. Hull outlet
8. Hose Clips
Fig. B.5.2-2: Exhaust Water Separator
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B.5.3 Installation Exhaust-Water-Separator
If the exhaust/water separator was sufficiently highly installed, a goose neck is no longer necessary. The exhaust/water separator 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. The best result is reached, if the hose line, which derive the cooling
water, is relocate on a short way "falling" directly to the outlet and this outlet is under the waterline.
1
2
4
3
5
6
1. Generator
2. Silencer / Water lock
3. Exhaust-Water-Separator
4. Silencer
5. Sea cock
6. Hull outlet
If the thru-hull exhaust outlet has to be mounted far from the generator, an exhaust-water separator must definitely be installed. The raw water from the separator must then run along the shortest
possible path is the thru-hull outlet. For such long exhaust routes, the exhaust hose diameter
should also be increased from NW40mm to NW50mm in order to reduce the back-pressure. The
exhaust may have a length of over 10m (32 ft.) if the exhaust hose diameter is increased to
50mm. An additional outlet exhaust muffler close to the hull outlet will help further to reduce noise
emissions.
The generator will not disturb your boat neighbours, if the "Super silent Exhaust System has been
correctly installed. The exhaust noise should be almost inaudible.
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Example of an unfavourable installation:
- Water lock not far enough below the highest level of the generator
- Distance water lock to exhaust/water separator too large
Fig. B.5.3-1: Expample for an Unfavourable Installation
B.6 Installation of the Fuel System
B.6.1 General References
Inside the generator capsule itself, there is the fuel filter installed (exception: Panda 4200 and
4500). Additional fuel filters (with water separator) must be mounted outside the capsule in easily
accessible places in the fuel lines between the tank intake fuel pump and the diesel motor's fuel
pump.
Generally forward and return fuel flow pipes must be mounted to the diesel tanks. Do not connect
the generator fuel supply lines with any other fuel lines of other diesel systems.
•
The following items need to be installed:
•
Fuel supply pump (12 V - DC)
•
Pre-filter with water separator (not part of the delivery)
•
Fine particle fuel filter
•
Return fuel line to fuel tank (unpressurized)
The fuel supply pump should be mounted as close to the fuel tank as possible. The electric cable
for the fuel pump is already installed on the generator (length 5 m).
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1
4
3
2
5
6
8
7
1. Generator
2. Fuel stopcock
3. Fuel filter
4. Fuel return
5. Condensation water suction pump
6. Fuel tank
7. Fuel supply
8. Electrical fuel pump (12V-DC)
Fig. B.6.1-1: Installation Scheme Fuel System
B.6.2 The Electrical Fuel Pump
Electrical Fuel Pump
With the Panda generator is usually supplied an external, electrical fuel pump (12 V
DC). The fuel pump must be installed
close at the fuel tank. The electrical connections are pre-loaded at the generator
with the lead planned.
Fig. B.6.2-1: Electrical Fuel Pump
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•
Suction hight of the pump: max. 1,2 m at 02, bar
•
Diameter of fuel lines: section E.3, “Technical Data Generator,” on page 83.
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Installation Instructions
B.6.3 Connection of the Fuel Lines at the Tank
Lead the return fuel pipe connected to the day tank to the floor
The return pipe connected to the tank must be dropped to the same depth as the suction pipe, if
the generator is mounted higher than the tank, in order to prevent fuel running back into the tank
after the motor has been switched off, which can lead to enormous problems, if the generator is
switched off for a long period.
Non-return Valve in the Suction Pipe
A non-return valve must be fitted to the suction pipe, which prevents the fuel flowing back after
the generator has been switched off, if it is not possible to use the return flow pipe as a submerge
pipe placed in the tank. The instructions "Bleeding Air from the Fuel System" must be read after
initial operation or after it has stood still for a long period, in order to preserve the starter battery.
ATTENTION! Non-return valve for the Fuel Return Pipe
If the fuel tank should be installed over the level of the generator (e.g. daily
tank), then a non-return valve must be installed into the fuel return pipe to
guarantee that through the return pipe no fuel is led into the injection pump.
B.6.4 Position of the Pre-Filter with Water Separator
Additionally to the standard fine filter a
pre-filter with water separator must be
installed outside of the sound insulation
capsule in the fuel system line (not included in the delivery).
Fig. B.6.4-1: Pre-Filter with Water Separator
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B.6.5 Ventilating Air from the Fuel System
Normally, the fuel system is designed to vent air itself i.e. as soon as the electric starter motor
starts; the fuel pump starts working and the fuel system will be air-vent automatically after some
time. It is, nevertheless essential, to vent the system as follows prior to the first operation (as all
hoses are empty):
1. Switch main power switch on control panel "ON".
2. Push failure bypass switch and hold tight.
The electric fuel pump has to be run audibly. By moving the failure bypass switch you can hear
the solenoid valve of the generator starting and stopping (when the sound insulation cover is
taken off).
3. After the fuel pump has been running 3 to 4 minutes, because the failure bypass switch has
been pressed down, the bleeding screw of the solenoid valve has to be unscrewed. The switch
has to be continuously depressed, when opening the screw. A piece of cloth or absorbent paper
should be put under the connection to avoid fuel entering the sound insulation cover.
4. The air vent screw can be screwed in again, as soon as fuel runs out without bubbles. Then
release the depressing the failure bypass switch.
5. Starting the generator
Now the generator can be started by pushing the "START"-button. The generator should start
after a short while. One of the pipe union nuts of an injection hose has to be unscrewed, should
the unit not start; then try to restart the generator. After the generator has started, the pipe union
nut has to be tightened again.
Main power switch "OFF"
Vent Screw at the fuel stop solenoid valve
Fig. B.6.5-1: Vent Screw at the Fuel Stop Solenoid Valve
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B.7 Generator 12 V DC System Installation
The Panda generators from 8.000 NE upwards have their own dynamo to charge a 12 V starter
battery.
It is recommended to install an additional starter battery for the generator.
The generator is then independent from the remaining battery set. This enables you to start the
genset at any time with its own starter battery even if the other batteries are discharged. A further
advantage of a separate starter battery is that it isolates the generator's electric system from the
rest of the boat's DC system, i.e. minus pole (-) is not connected electrically to Earth/Ground.
The generator is then Earth/Ground free.
B.7.1 Connection of the 12 V Starter Battery
The positive (+) battery cable is connected directly to the solenoid switch of the
starter.
Fig. B.7.1-1: Positive 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 or with
the protective grounding of the 120 V
installation!
Fig. B.7.1-2: Negative Battery Cable
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The Panda generators 8000 to 30 are
equipped with various DC-relays, which
can be found under the terminal strip. The
various relays have the following tasks
(also see the DC circuit diagram)
1. Starter motor relay
2. Pre-glow relay (glow plugs)
3. Fuel pump relay
1
2
3
Fig. B.7.1-3: DC-Relay
All Panda generators are equipped with
an independent 12 V DC starter motor.
The connecting lines cross-section from
the battery to the DC system should measure 25 mm².
1
1. Solenoid switch for starter motor
2. Starter motor
2
Fig. B.7.1-4: 12 V DC Starter Motor
B.7.2 Connection of the remote control panel - see separate control panel
manual
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B.8 Generator AC System Installation
ATTENTION! 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.
B.8.1 Installation with looped in AC-Control box
1. Generator
2. Battery
3. AC-Control Box
4. Distribution panel
5. Remote control panel
6. Fuel pump
Fig. B.8.1-1: Installation with looped in AC-Control box
All electrical safety installations have to be made on board.
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B.8.2 Installation AC-Box / distribution panel separate connected
1. Generator
2. Battery
3. AC-Control Box
4. Distribution panel
5. Remote control panel
6. Fuel pump
Fig. B.8.2-1: Installation AC-Box / distribution panel separate connected
A power source selector switch must be installed between the generator (or if applicable,
AC-Control box) and the ship's electrical supply system. This switch must used to ensure
that all AC consumers can be switched off at once. This switch should also be installed to
keep the generator and shore (grid) power systems separate.
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
Fig. B.8.2-2: 3-Way Cam Switch
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The cam-type switch must have 2 poles, so that "MP" and "phase" can be switched off.
If a 3-phase current system is also installed with the option of supplying from either the generator
or shore power, an additional switch must be installed to keep these systems separate.
An alternative to a manual rotating switch is an automatic power relay. When the generator is not
running, the relay remains in the shore power position. As soon as the generator is running, the
power relay switches automatically to the generator position.
Note: If the system has both single and 3-phase AC, it is CRITICAL that the two systems
remain SEPARATE!
Protection conductor
The generator is provided with a PEN safety system, as standard, which connects the 3-phase
delta centre point "N" to the safety ground strap.
If a separate ground protection cable is necessary (i.e. due to national safety regulations), the
bridge between the generator housing and ground (in the AC-Control box) must be disconnected.
Once such a ground protection cable is installed, it must be connected to the ground straps of all
on board electrical devices.
In order to monitor the electrical system, it is recommended to install a voltmeter (and, if possible,
a current meter) down line from the power source selector switch so that all respective power
sources can be monitored. A separate voltmeter for the generator, itself, is therefore not required.
Electrical fuses
It is absolutely essential that the electrical system installation is inspected by a qualified electrical
technician. The generator should have its own AC input electrical fuses. The fuses should be
sized such that the rated current of the generator on each of the individual phases is not exceeded by more than 25%.
Data for gensets with power output greater than 30 kW on request!
The fuses must be of the slow type. A 3-way motor protection switch must be installed to protect
the electrical motor.
Required fuses see Tabelle 8, “Rated current,” auf Seite 114
Required cable cross-sections
The following recommended electrical cable dimensions (cross sections) are the minimum required sizes for a safe installation. (siehe Tabelle 9, “Cable cross-section,” auf Seite 114)
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B.8.3 AC Control Box with VCS and ASB
The required capacitors for the excitation of the generator are located in the AC-Control box, as
well as the electronic control for voltage/speed regulation (VCS) and the starting current reinforcement (ASB). The AC-Control box must be connected by electrical wires (high voltage and
low-voltage) to the generator.
The front panel must always be closed, since the AC-Control box produces 400 V during operation.
The AC-Control box must be electrically connected to the generator (high and low
voltage).
Danger - High voltage
ATTENTION! Before working on the System read the "Section Safety Instructions in this Manual".
1. Inlet VCS-connection (X1)
2. Inlet measuring voltage (X3)
1
2
3. Excitation cable to generator
(X4)
3
Fig. B.8.3-1: Opened AC Control Box
From Panda 30 upwards
Fig. B.8.3-2: Opened AC Control Box from Panda 30 upwards
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B.8.4 VCS Voltage Control
All Panda generators from Panda 8000 upwards are fitted with the electronic voltage control
"VCS" as standard.
The VCS controls the generator voltage and motor speed. A actuator on the injection pump can
increase the engine speed by up to 8%.
If the generator is run without load, the voltage should be 231V with a frequency of approx 48.5 to
49Hz. The frequency (equates to the speed) can be increased by up to 8%. This ensures that the
engine speed is increased when there is an extra load. The maximum speed is achieved when
80% load is reached.
The speed gauge is governed by an adjusting screw, above and below. Adjustment of this screw
may not occur without the expressive approval of the manufacturer.
All signals pass through the circuit board in the AC-Control box. The signal impulse for the actuator is passed to the electric motor by means of the 5 core wire.
The generator maintains its full capability if the VCS has a defect.
In this case the base current must be raised to at least 240 V by adjusting the minimum setting on
the speed gauge, in order to ensure that the generator output voltage at 70% nominal load does
not drop below 215 V.
1
2
3
6
4
7
5
1. Connection measuring voltage
2. Adjusting booster voltage (do not adjust!)
3. Adjustment VCS-voltage
4. Connection VCS inlet
5. Electrical fuse (1.6 A, slow to blow)
6. Potentiometer for booster time
7. Connection for PC
Fig. B.8.4-1: VCS Control
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B.8.5 Jump Start at High Starting Current (Booster)
Additionally, the automatic start booster is located on the circuit control board. The starting current is increased by connecting a second group of capacitors (C2), if the voltage drops below a
pre-set voltage. The starting current can be increased by 300% for a short period by combining
both components voltage/speed control and ASB Start booster.
B.9 Insulation Test
ATTENTION: Once the electrical system installation is complete, a
ground insulation test must be performed as follows:
1.) Switch off all on-board electrical devices.
2.) Start the generator.
3.) Measure the AC-voltage with a voltmeter (adjust to Volt/AC) between
a) generator housing and AC-Control box
b) generator housing and ground.
The measured voltage must not exceed 50mV (millivolts).
4. Once the safety systems have been installed, they must be checked. If a Leakage Current
Relay has been installed, it also has to be tested, in order to ensure that it functions properly.
The individual phrases must be checked against each other, and between phase and ground,
(the single phase or 4th phase also needs to be checked in this fashion).
5. If the generator is protected by a ground connection, then ALL electrical devices must also be
connected to this "common" ground (usually ground contacts are attached to the devices'
metallic housings).
The electrical system installation must also comply with the hook-up requirements of the shore
current grid. Generally a leakage current relay is sufficient for safe electrical operation; however,
this must be confirmed by the electrical safety standard in the region where the system is attached to a main land power grid. The relay has to meet the required safety standard regulations.
Checking the Electrical Connections
There is always the possibility that circuits have been rerouted/changed or individual components
have not been not been correctly laid out on the circuit diagrams.
The installation electrician should therefore check and label all electrical connections to ensure
that they correspond to the main circuit diagram. The inspection and correct labelling is especially
critical for terminals L1/ L2/L3/L1'/N (for the 230 V - 50 Hz model) and for terminals L1/L2/L3/N
&1/ 2/ 4 for the 60 Hz (120 V) models. The electrician is therefore obliged, before installation to
check whether the generator is earth-free. As long as this test has not been carried out all other
components for electrical installation must be removed. Once the system has been installed and
inspected, this test should also be performed with all electrical devices (i.e. voltage check between common and metallic housings) while the generator is running.
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.
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Maintenance Instructions
C. Maintenance Instructions
C.1 General maintenance instructions
C.1.1 Checks before starting
•
Oil level
•
Cooling system leaks
•
Visual check for any changes, leaks oil drain system, v-belt, cable connections, hose clips, air
filter, fuel lines
Once a month
•
Grease/oil the servo motor - Trapezoid thread-Spindle
Maintenance invervals siehe “Inspection checklist for services” auf Seite 119.
C.1.2 Check of Hoses and Rubber Parts in the sound insulated capsule
Check all hoses and hose connections for good condition. The rubber hoses are very sensitive to
environmental influences. They wear quickly in an environment of dry air, oil and fuel vapours,
and high temperatures. The hoses must be checked regularly for elasticity. There are operating
situations, when hoses must be renewed once a year.
Additionally to usual tasks of maintenance (oil level check, oil filter control etc.) further maintenance activities are to be accomplished for marine generators, such as control of the sacrificial
anode (cooling water connection block) and the front seal cover at the generator.
C.2 Oil Change Intervals
The first oil change is to be accomplished after a period of operation from 35 to 50 hours. Afterwards the oil is to be changed after 100 hours. For this the oil SAE30 for temperatures over 20°C
and SAE20 for temperatures between 5°C and 20°C is to be used. At temperatures under 5°C oil
of the viscosity SAE10W or 10W-30 is prescribed.
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C.3 Execution of an oil change
Oil drain hose
For the oil change an oil drain hose is fed
through the sound insulation capsule.
Fig. C.3-1: Oil Drain Hose
Oil Drain Screw
The oil can be discharged by opening the
oil drain screw. For countering use a
second wrench.
17
Fig. C.3-2: Oiil Drain Screw
Oil Drain Pump
If drainage of the oil is not possible, we
recommend the employment of a hand
pump, which can be attached to the oil
drain hose.
Close the oil drain screw.
Fig. C.3-3: Oil Drain Pump
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Oil Filter Change
The oil filter can be loosened by means of
an oil filter strap.
Fig. C.3-4: Oil Filter Change
Oil filter gasket
The gasket should be coated with oil
before inserting the new oil filter.
Tighten the oil filter by hand only.
Fig. C.3-5: Oil Filter Gasket
Refill Oil
New oil is poured in, after opening the cap
of the oil filler neck. Please wait a
moment, before measuring the oil level;
the oil must first settle in the sump.
Fig. C.3-6: Oil Filler Neck
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Oil Dipstick
The oil level is checked by use of the
engine oil dipstick. The prescribed filling
level may not exceed the "Max"marking.
Fig. C.3-7: Oil Dipstick
C.3.1 Check Oil Level of the Oil-Cooled Bearing
The oil level of the oil-cooled bearing must be checked regularly.
C.4 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.
This water sinks to the bottom, due to its
density. It is heavier than the diesel
Fig. C.4-1: Pre-filter with water separator
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Maintenance Instructions
C.4.1 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):
1. Main power switch "OFF"
2. Press failure bypass switch and keep
firmly pressed. The electrical fuel
pump must be audible. Switching on
and off the solenoid valve at the generator will be audible by pressing the
failure bypass switch (if capsule removed).
Fig. C.4.1-1: Failure Bypass Switch
3. Pressing the failure bypass switch for
approx 3 - 4 minutes will loosen the
ventilation screw located at the fuel
solenoid valve. The button must continue to be pressed, whilst opening the
screw. A large cloth or Kleenex tissue
must be laid beneath the connection to
prevent escaping fuel running into the
capsule. If the fuel runs out without air
bubbles, then the ventilation screw can
be closed. Only then may the button
be released.
10
Fig. C.4.1-2: Ventilation Screw at the fuel solenoid valve
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4. Pressing the starter button can now
start the machine. The machine should
start after a short period.
5. If this does not occur, then a connecting nut fitted to the injection line must
be loosened and starting procedure
repeated. Retighten the washers after
successfully starting. The injection line
must be raised by several millimetres.
6. Switch main switch "OFF"
17
Fig. C.4.1-3: Injection nozzles
C.4.2 Exchange of the Fuel Filter
Exchanging the filter, depending upon fuel
contamination, should take place after 300
operational hours at the very least. The
inlet must be clamped, before exchanging
the filter.
Remove the hoses from the used filter
and fasten them to the new filter. The
arrow on the filter housing indicates the
direction of the fuel flow. A clogged filter
causes a decreased power output of the
generator.
Fig. C.4.2-1: Fuel Filter
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C.4.3 Exchange the Air Filter Mat
1. Open the air suction housing by loosen
the six screws on the housing cover.
8
Fig. C.4.3-1: Air Suction Housing
2. Change the air filter mat
3. Close the suction air housing
Fig. C.4.3-2: Opened Air Suction Housing
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C.4.4 Ventilation of the Coolant Circuit / Freshwater
Special notes for the ventilation of the cooling system
If the cooling water is drained, or if other air has entered the cooling system, it is necessary to
ventilate the cooling system. This ventilating procedure must be repeated several times:
ATTENTION! The
generator must be
switched off before
opening the ventilating points!
Pay attention that the external coolant
expansion tank is connected with the
generator by the intended connection
point.
Further it should be guaranteed that the
expansion tank is attached in sufficient
height (600 m) over the level of the generator exhaust elbow union.
Fig. C.4-1: Expansion Tank
1. Open the ventilating screw above the
cooling water pump casing.
10
Fig. C.4-2: Ventilating Screw
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2. Open the ventilating screw on the thermostat casing.
10
Fig. C.4-3: Ventilating Screw on the Thermostat Housing
3. Pour cooling water into the cooling
water filling necks.
4. If the cooling water level no longer
drops (the cooling water level in cold
waters must cover the tin in the
exhaust elbow), close the filler cover
and the cooling water screws and then
start the generator.
5. Run the generator for approx. 60
Seconds, then switch off
6. Refill cooling water via the compensation tank.
Fig. C.4-4: Colling Water Filler Cap
7. The compensation tank is connected to the generator by two hoses.
The external compensation tank should be filled to a max 20% in a cold state. It is very
important that a larger expansion area is maintained above the cooling water level.
8. Repeat this procedure 1 - 5 times.
If there is no change to the state of the cooling water level, the generator is re-started for 5 minutes. Thereafter the de-aeration must be repeated two to three times.
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The ventilation screw
above the cooling water
pump casing may not
be opened under any
circumstances, whilst
the generator is running. Air will be sucked
through the opening, if this should happen
by mistake. Venting the whole system
afterwards is necessary and very difficult.
Fig. C.4-5: Ventilation Screw above the Cooling Water Pump Casing
C.4.5 Exchange of the V-Belt for the Internal Cooling Water Pump
The relative high ambient temperature in the closed sound insulated capsule (about 85°C) can be
a reason for a reduced lifespan of the v-belts. It is possible that the "softener" in the rubber compound lose their effect after a short operating time because the air in the sound insulated capsule
can be relative warm and dry. The v-belt must be controlled at very short time intervals. It may be
required to change the v-belt after several weeks because of unfavourable conditions. Therefore,
control should be carried out after an interval of 100 operating hours. The v-belt is a wearing part.
There should be enough spare v-belts on board. We recommend that you have the respective
manual within reach.
1. Loosen the screw on the deflection
pulley bracket
13
Fig. C.4.5-1: Screw on the deflection pulley bracket
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2. Loosen the screw beneath the alternator
13
Fig. C.4.5-2: Screw beneath the Alternator
3. Press the alternator in the direction of
the thermostat casing
4. Exchange Belt Pulleys
Fig. C.4.5-3: DC Alternator
5. Re-tighten Belt Pulleys
The belt pulleys should only be tightened to the extent that it can be pushed
to the length of a thumb (approx. 10
mm).
6. Re-tighten the screws above and
below the alternator
Fig. C.4.5-4: Drawing belt pulley
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C.5 The Seawater Circuit
C.5.1 Clean Seawater Filter
Residue should be regularly removed
from the seawater filter. The seacock
must, in each case, be closed first. It often
suffices to merely hit the filter punnet.
If water should seep through the cover of
the seawater filter, this may never be sealed with adhesive or sealant. The cause
for the leakage must be sought. The
sealing ring between caps and filter holders must be exchanged in the simplest
cases.
Fig. C.5.1-1: Seawater Filter
C.6 Reason for Frequent Impeller Wear
1. Unreasonable operating conditions
The Cooling water pump Impeller must be regarded as a wearing part. The life expectancy of an
impeller can vary greatly and depends exclusively upon the operating conditions. The PANDA
Generator cooling pumps are so designed that the speed of the pump in comparison to other
generators is relatively low. This has a positive effect on the life expectancy of the pump.
2. Longer Suction Distance of Cooling Water
If the cooling water suction distance is long, or is blocked, this has a negative effect on the impeller, so that an under-pressure occurs in the cooling water suction area. This can reduce the
efficiency of the impeller and place strain on the blades. This can greatly reduce the life expectancy.
3. Operating in contaminated waters
The impeller is placed under great strain in waters with high contamination. The use of the impeller in coral waters is also critical. There are known cases, whereby the impeller was so fatigued
after 100 hours use, that the lip seals were grinded away by the shaft. In these cases sharp crystal parts from the coral press into the rubber seals and act as a grinding material on the stainless
steel shaft of the impeller pump.
4. Generator mounted above the water level
It is especially disadvantageous for the impeller pump, if the generator is mounted above the
water level. This means that a few seconds will pass before the impeller can suck in cooling
water. This short dry running period damages the impeller. The increased wear can also lead to a
breakdown. (See special instruction: "Effect on the impeller pump, if the generator is mounted
above the water line").
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C.6.1 Exchanging the Impeller
1. Close the seawater valve.
Fig. C.6.1-1: Seawater valve
The seawater pump is located on the front
side of the genset.
Fig. C.6.1-2: Seawater pump
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Remove the cover of the seawater pump
by loosen the 4 wing screws from the housing.
Fig. C.6.1-3: Cover Seawater Pump
2. Remove the impeller from the shaft by
means of multi grip pliers..
3. Mark the impeller, to make sure that it
is in the correct position when re-installation is carried out.
Fig. C.6.1-4: Impeller
4. Check the impeller for damage and
replace it if necessary.
5. The impeller should have been lubricated with glycerine or with a non-mineral
oil based lubricated e.g. silicone spray,
before re-insertion into the housing.
Attention: This is very important,
because the impeller can quickly be
damaged.
Fig. C.6.1-5: Impeller
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6. Attach the impeller to the pump shaft (if
the old impeller is re-used, initially
check the marking).
7. Fastening the cover and use a new
seal.
Fig. C.6.1-6: Cover Pump Shaft
C.7 Coolant Connection Block at the Generator Capsule
Control of the coolant connection
block
The coolant terminal block at the side of
the generator housing must be thoroughly
checked in the case of all seawater-cooled generators. This coolant terminal
block is manufactured from a special aluminium alloy and also serves as a sacrificial anode. If the aluminium alloy of the
generator is damaged by the Direct Current, it initially affects the coolant inlet
block. If visible corrosion is identifiable
from the outside of the coolant terminal
block, then the block must be replaced at
regular intervals (at least once per year).
In this case the coolant terminal block is a wearing part. It should always be available in all cases
as a spare part on board.
Fig. C.7-1: Coolant Connection Block
Replacement of the Coolant Connection Block
A "special" sealant is used for the coolant connection block. The fixing bolts are not intended to fix
the coolant terminal block firmly to the surface area. These screws serve only to keep coolant terminal block firmly secured until the sealant has hardened. The fixing bolts should only be tightened by hand.
ATTENTION! On the side, the fixing bolts must be applied with an electrically neutral fat
(e.g. anti seize). If the fixing bolts (high-grade steel) are screwed into the aluminium
threads without the grease being used, then there is a danger of corrosion, and it is possible that the thread wears out when loosening the screws.
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C.8 Conservation of the Generator (long operation interruption)
C.8.1 Measures for preparation of winter storage
1. Rinse seawater circuit with an anti-freeze solution, if this contains a corrosion protection solution. The seawater intake must be stopped at the seacock. The anti-freeze protection mixture
is to be sucked up from a container by means of a hose connection. The cooling water mixed
with the exhaust gases should be fed back to the suction container. The circuit must be kept
upright some minutes to ensure the anti-freeze protection mixture reaches all parts of the cooling system.
2. The anti-freeze mixture concentration in the internal cooling circuit must be checked with a
suitable measuring instrument. The concentration must be adequate for the lowest expected
temperatures.
3. Clean seawater filter and check seal.
4. Check seacock for practicability. And spray with a corrosion protection oil from the inside or
lubricate with acid-resistant grease.
5. Check all hoses and hose connectors for good condition. The rubber hoses are very sensitive
to environmental influences. They can deteriorate quickly in environments with dry air, light oil,
fuel fumes and increased temperatures. The hoses must be checked regularly for elasticity.
The hoses must be renewed once in the year in particular operating situations.
6. Doubly check the hose connections at all seawater valves, and if possible protect them with
double hose clamps.
7. Dismount the cooling water pump impeller and check for wear. The impeller may not remain in
the pump. It must be greased with Vaseline and be kept in a dark place. It can be re-integrated
again into the pump, during the spring, if it is in good condition. The impeller is a wearing part,
and it is recommended that it is always renewed in the spring, depending upon the number of
hours the generator has been running.
8. Control of the vent valve at the seawater inlet. A vent valve is always necessary, if the generator is installed below the waterline. The vent valve must also be regularly checked during the
season. The vent valve should always be disassembled, checked and greased during winter
storage. Hardened or dirty parts are to be replaced.
9. Check water lock: If the generator were rinsed with an anti-freeze mixture, the anti-freeze mixture can escape from the water lock. If the generator were rinsed with fresh water, the water in
the water lock must be drained. Otherwise there is a danger of the collector being destroyed
by ice through expansion.
10.Check the exhaust/water separator for leakage and whether the hose connections at the lower
surface of the separation unit are in normal condition. (in the case of extremely sulphurous
fuels, it is possible that high-grade steel tube ends are attacked.)
11. Check all construction units of the generator inside the sound cover for leakages. If there are
traces of humidity in the sound cover, the cover must be dried. Furthermore, the cause for
damp must be searched and eliminated.
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C.8.1 Measures for preparation of winter storage
12.During the winter storage the upper section of the sound inulated capsule must be taken off, in
order to avoid condensed moisture formation, if traces of humidity remain in the sound insulation capsule inside casing by leakages in the seawater circuit.
13.The generator housing and the housing of the engine should be sprayed with a corrosion protection oil before the winter storage. This procedure is recommended also in the season. This
procedure can avoid that arising and humidity marks on the surface of the aluminum construction units be noticed too late.
14.Disconnect the starter battery (positive and negative pole).
15.Lubricate the spindle for the number of revolutions adjustment device with a special lubricant
(Antiseize grease).
16.Check cooling water connection block at the generator housing on traces of corrosion and if
necessary renew. (Only such traces are to be considered, which refer to clear "blossoming" of
the material. If the surface is only grey coated, this is only an indication for the fact that aluminum came into contact with condensed moisture.)
17.Use of a air dehumidifier. The best way to protect a yacht in the winter storage against
damage by humidity is, to places a air dehumidifier inside the ship and locks all hatches. The
devices have a hygrometer, which switches the device off, if the humidity is under the adjusted
value. There is no better method, in order to protect pads, cable, electronics, wood, engines
etc. optimally against any rotting by humidity.
C.8.2 Initiation during Spring
•
Before starting, turn the engine once with the hand, in order to eliminate the beginnings of existing corrosion to the bushes. If necessarily carry out normal engine inspection.
•
Change engine oil and engine oil filters.
•
Reintegrate the impeller of the cooling water pump and check pump for leakage.
•
Charge starter battery of the generator, connect cables and check battery voltage.
•
Start generator and check the basic adjustments of the generator such as voltage, speed regulation etc...
•
Check all switching off devices for function by operational procedures.
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D. Generator Failure
D.1 Tools and Measuring Instruments
In order to be able to manage disturbances while driving, the following tools and measuring instruments should belong to the equipment kept on board:
•
Multi-meter for voltage (AC), frequency and resistance
•
Measuring instrument for inductance
•
Measuring instrument for capacity
•
Current absorbing clamps
•
Thermometer (ideal is a infra-red thermometer)
•
Pressure device (pincer) for coolant circuit
D.2 Overloading the Generator
Please ensure that the generator is not overloaded. This must be considered, especially with
regards to multi power generators. In this case the extra load including the electrical performance
can be considerably greater than the drive performance of the motor, which can eventually lead
to a damaged motor.
The full nominal performance of the generator is fore-mostly for short term use. It is, however,
required to start electric motors with high starting current or achieve special starting procedures at
peak loads. 70% nominal load is ideal for a long motor life. (Continual use means uninterrupted
use of the generator for many hours). This should be taken into consideration when connecting
devices. This ensures extended motor life.
It is no problem for the motor to be run occasionally for 2 - 3 hours at full load. The complete conception of Panda Generator ensures that even during extreme conditions, an overheating of the
motor will not occur. Accumulation of soot will occur if run for long periods at full load.
Effects of Short Circuiting and Overloading on the Generator
The generator cannot be damaged by short-circuiting or overloading. Short-circuiting and overloading suppress the magnetic excitation of the generator, thus, no current is generated and the
voltage will collapse. This condition is immediately offset, once the short circuit has been eliminated and/or the electrical overload removed.
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Overloading the Generator with Electric Motors
With the operation of electric motors it must be considered that these take up a multiple of their
rated output as starting current (six to tenfold).
If the power of the generator for the engine is not sufficient, the voltage in the generator breaks
down after switching on the engine. For special approach problems the manufacturer can give
recommendations regarding the accomplishment of the situation (e.g. amplified condensers, gradual start switch or extra developed starting unit for electric motors).
The system efficiency can be improved up to 50 % and the starting current can be improved up to
100 % by a professional adjustment of the engines. If the inductive load (electrical motors etc.)
lies over 20 % of the generator rated output compensation is appropriate (see in addition also the
writing: "Operation Instructions for Generators with Inductive Loads").
D.2.1 Monitoring the Generator Voltage
ATTENTION!
see “Safety Precautions” on Page 11.
The voltage range of the power stations normally lies between 200 and 240 V (100 - 130 V in the
60 Hz version). In some countries even substantially larger tension deviations are being called
"normally". The Fischer Panda generators are aligned that they keep these default values during
normal load.
With high load or overload it can occur that the voltage drops on 190 V (95 V in the 60 Hz version) and partly still more deeply. That can become critical for certain devices (e.g. for electric
motors, cooling compressors and possibly for electronic devices). It must be paid attention that
the voltage for such consumers are sufficient. This can be supervised by a voltmeter.
The voltmeter should be always installed behind the change over switch generator/land power, so
that each voltage source is shown. No further voltmeter is provided for the generator itself.
If additional consumers are switched on, the voltage must be controlled in each case at the voltmeter. Sensitive devices must be switched off so long, until the voltage exceed the critical parameter.
Under certain circumstances the generator provides overvoltage. This arises if the number of
revolutions of the generator is increased. Changing the number of revolutions may be made only
with a tachometer and/or a voltmeter.
If sensitive and/or valuable devices are used, which are to be protected against this risk, an automatic overvoltage protection must be mounted (voltage control with disconnection).
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D.2.2 Automatic Voltage Monitoring and Auto-Shut Down
If air conditioning units (compressors) or other such valuable equipment is installed on-board, it is
recommend that an automatic voltage monitoring unit be installed to protect this equipment from
possible sharp voltage drops. The voltage monitoring system shuts down the entire system (and
therefore all users) by means of a circuit breaker relay as soon as the voltage falls below a set
value (the monitor will also shut down the on-board grid automatically when the generator is stopped). Such a relay with contactor can be obtained from the installator or as a complete unit from
your Fischer Panda dealer.
D.3 Setting the Speed Governor of the Actuator
The speed of the generator is determined by two independent settings; an upper and lower speed
governor:
•
By means of the adjusting nuts on the spindle of the servomotor right and left from the spindle
nut (Setting of the normal speed limit).
•
By means of an adjusting screw that is located on the base of the speed control lever. (Setting
of the maximum upper speed).
After working on the components of the actuator, the speed must be checked.
1. Servo motor
2. Trapezoidal Thread Spindle
3. Adjusting nuts for max. speed
4. Spindle nut with speed adjusting lever
5. Adjusting nuts for the lower setting
1
2
3
4
5
Fig. D.3-1: Actuator
During any operation at the generator all consumers have to be switched off to avoid damages at
the equipments. Also the solid state relay, which is installed in the AC control box must be disconnected to avoid an accidentally activation of the booster capacitors.
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D.3.1 Setting the maximum upper speed setting
1. Remove the plug from the electrical input for the actuator.
2. Loosen the counter nuts of the speed governor screws with a combination wrench SW 10.
3. Connect a voltmeter with a range up to 300 Volts AC to the AC Output of the AC Control Box.
4. Ensure that no electrical load has been set.
5. Start generator.
6. Raise the speed of the generator by turning the spindle of the servomotor until the voltmeter
reaches 260 Volts (130 Volts).
7. Turn the governor screw firmly against the stop setting of the speed adjustment lever.
8. Secure the governing screw by means of the counter nut.
9. Once again check whether the generator voltage is governed to 260 Volts (130 Volts).
The upper speed settings serve as an additional safety factor. The value for the maximum voltage
is therefore approx 5 volts above the normal running limit.
1. Counter nut
2. Adjustment screw for upper setting
3. Speed Adjustment Lever
10
This setting should not be changed
otherwise the guaranty will expire.
1
2
3
Fig. D.3.1-1: Counter nut, Adjustment screw and speed adjustment lever
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D.3.2 Setting the normal speed settings
Setting the lower speed limit
1. Remove the plug from the electrical input.
2. Loosen the counter nuts against each other by means of two combination spanners SW 10.
3. Connect an electrical voltmeter in the range up to 300 Volt AC to the AC Control Box output.
4. Ensure there is no electrical load.
5. Start generator.
6. By turning the servo meter spindle downwards by hand until the voltmeter shows a value of
225 volts (110V).
7. Tighten both nuts tightly against each other.
8. Once again check whether the lower generator voltage of the generator without load is limited
to 225 volts (110 volts).
Setting the upper speed limit:
1. Continue as above and tighten the counter nuts at a voltage of max. 260 volts (130 volts).
2. Once again check whether the upper generator voltage without load is limited to 260 V (130 V)
1. Adjustment screw for the upper
speed limit
2. Adjustment screw for the lower
speed limit
10
1
2
Fig. D.3.2-1: Adjustment Screw Speed Governor
The electrical plug must be reconnected to drive the actuator servo motor, once the adjustment
has been completed.
The connection must be remade should the electrical input wires have been removed from the
AC control box.
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D.3.3 Greasing the trapezoidal thread spindle on the speed actuator
(The speed setting of the trapezoidal thread spindle must be regularly greased. Only high temperature-resistant grease (up to 100 °C) may be used. The end of the nuts must also be smeared
with grease.
If the spindle has not been sufficiently greased, then it can jam. The generator then cuts out when
over or under-heated.
All screws on the rotary servomotor and the spindle should be secured with a screw securing
solution, so that they can be easily loosened.
The trapezoidal thread spindle must be checked, if the generator has cut out, because of under or
over voltage.
Servicing intervals also includes the checking of cut out functions in cases of defect. Only by
making regular checks can it be ensured that the generator switches off, if there is a fault The
generator will not switch off, if the cut out control of the solenoid valve does not function.
1. Speed actuator
2. Trapezoidal Thread Spindle
1
2
Fig. D.3.3-1: Trapezoidal Thread Spindle
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D.3.4 Consequences of a continual overloading of the Actuator
If the generator is overloaded the voltage falls on account of a not adequate motor power under
the nominal value. The actuator stays at the upper keystroke and tries to rev up the diesel engine.
An internal regulation limits the current to the actuator, nevertheless a longer overload can
damage the winding of the actuator. (short of the winding). The motor gets not strictly inoperative
but it can happen that the cranking torque of the actuator is getting weak. This has the consecuence that the rev spindle can not be turned to all positions faultless. Therefore the voltage of the
generator is regulated not good or sometimes not at all.
If the generator is overloaded, the voltage falls under the nominal value due to insufficient engine
power. The actuator is already at the upperst speed limit and still tries to rise the rev. speed of the
engine. There is an internal control which limits the actuator current, but an overloading over a
longer period of time can still damage the winding of the actuator.
This will not effect the operation ability of the engine, but it can happen that the cranking torque of
the actuator is getting weak. This has the consequence that the rev. spindle can not be turned to
all positions correctly. Therefore the voltage regulatiron of the generator is very bad or the generator is temporarily not beeing regulated at all.
If you should notice that the actuator for the spindle sometimes does not run smoothly, then a
check must be made to determine whether the generator has been effectively overloaded for
periods, therefore causing damage to the internal winding of the actuator. The actuator must then
be exchanged.
The electrical fuses on the circuit board must be checked, if the actuator for controlling the speed
does not turn.
Change this fuse
(1,6 A slow to blow)
Fig. D.3.4-1: Fuse for the actuator at the remote control panel
True, overloading cannot damage the actual generator, since the windings are safe from overloading and short circuiting, but damage is always possible to peripheral consumers. This is especially the case for connected consumers, which can easily be damaged because of current that is
too low.
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Generator Failure
Check the voltage control if there is a fault
Problem
The spindle of the actuator jams
Fuse on the printed circuit board of the
VCS control is melted.
Possible Cause
•
Not regularly lubricated.
•
Surface has mechanical damage.
•
Actuator is defective (evtl. winding short cut).
•
Defect of the VCS control.
•
Signal 230 V (115 V) AC missing.
•
Limiting nut jams the spindle.
•
Constant overload of the generator.
Steps to check the voltage control in case of a failure:
1. Switch off all electrical consumers.
2. Remove plug from the actuator.
3. Turn the actuator by hand to determine whether the adjusting nut has jammed against the
speed governor.
4. Turn the actuator by hand to check whether the adjusting nut runs smoothly on the spindle.
If the above test produces no result, it can be assumed that the actuator operates smoothly. The
electrical groups of components must then be checked:
1. Re-connect plug.
2. Start generator.
3. Turn the actuator by hand to check whether the Spindle is reversed by the motor.
4. It can be assumed that the actuator is faultless, if the turning of the actuator is too much for the
hand (It is not normally possible to stop the motor with the fingers). It must be assumed that
there is a fault with the voltage control (VCS).
The following measures are necessary if the actuator is jammed:
1. If the actuator only turns weakly:
•
Actuator has a destroyed winding and must be exchanged. (In future it should be ensured that
the generator is not overloaded).
2. If the actuator does not move, but the spindle can be turned by hand:
•
Remove plug from the actuator and temporarily connect it to an external 12 volt direct current
source. The motor is defective if the actuator still does not turn when connected to the external
electrical source. Exchange the motor.
The VCS circuit board should be exchanged if these measures do not produce clarity.
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Checking the generator voltage limitation
The mechanical voltage limitation must be checked regularly.
1. Switch off all consumers.
2. Disconnect the plug of the actuator.
3. Connect an electrical voltmeter.
4. Start the generator.
5. Turn the actuator to the lowest limit point by hand. The max. voltage is 260 V (130 V).
6. The voltage must be 225 V (110 V).
7. Turn the actuator to the upper limit by hand. The max. voltage is 260 V (130 V).
8. A new adjustment is necessary in case of deviants.
D.4 Generator-Output Voltage is too low
If the AC generated is too low, then the consumers should be disconnected, one after the other, in
order to reduce the load on the generator. Generally the problem is then solved. The frequency
should be checked, if the output voltage is correct after the consumers have been disconnected.
Should this be above the prescribed generator idling speed, it can be assumed that one or
several condensers are defective.
D.4.1 Discharging the Capacitors
ATTENTION! Never work on the control box, if the generator is running!
Do not touch the capacitors contacts, see “Safety first” on Page 8.
1.Switch off the generator.
2.Remove the starter battery.
3.Open the AC-Control Box.
The capacitors are discharged by short
fusing both contacts. The contacts (Flat
plug) can be bridged by means of a
screwdriver with an insulated handle
(short-circuiting).
Fig. D.4.1-1: Capacitors
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D.4.2 Checking the Capacitors
ATTENTION: If the capacitors are to be checked, make sure that the capacitors has been discharged.
A visual check can give information on
whether the capacitors are defective:
- Dielectric leak?
- did the capacitor become longer?
The capacitors can be tested with a multimeter. Switch the measuring instrument to
"pass" and connect both connections of
the capacitors to the connections at the
measuring instrument.
Touch the two contacts of the capacitors
by means of the test prods. A charge
should be fed to the capacitor by the internal battery.
The capacitors can be tested by means of
a multi-meter, which is fitted with a buzzer. The multi-meter should be switched to open and both
capacitor connections connected to the multi-meter.
Fig. D.4.2-1: Multimeter
Should a steady sound or no sound be heard, the capacitors are defective and must be replaced.
A capacity measuring instrument must be used in order to check whether the capacitors
have full capacity.
The capacitors, which do meet the prescribed capacity value at this measurement, should be
exchanged as fast as possible. If all capacitors prove to be still functional, then a check must be
made, as to whether the connections to the strip are correct.
Checking the electrical connections to the capacitors
It must be ensured that the electrical connections to the capacitors are always tight fitting. Loose
connections with transitional resistance can mean that the contact surfaces will become heated
externally. This can lead to an increased deterioration of the capacitors.
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D.4.3 Check the Generator Voltage
The following steps must be taken, in order to test whether the stator winding generates
sufficient voltage:
1. The following steps must be taken, in order to test whether the stator winding generates sufficient voltage:
2. Ensure that the connection to the shipboard circuit is interrupted.
3. Remove all electrical wires in the generator junction box.
4. Starter battery must be connected to the generator.
5. Start generator.
6. Measure the current between the phases and neutral. It can be assumed that damage has
been caused to the windings, if the measured values are below the values given in Table 5 on
Page 112
Both partial windings must be connected for the 60Hz Version, i.e. there must be a connection
made between wire 1 and 3 (see circuit plan).
(Note: The current arises from the rest magnetism of the rotor, which induces a voltage in the winding).
D.4.4 Measuring the Ohm Resistance of the Generator Windings
If a short circuit could not be found by using a multi-meter, then the windings parts of the
generator must be checked by means of an Ohmmeter that is suitable for low resistance
values.
•
Set the measuring device to measure resistance. If you hold the poles of the measuring device
against each other, then 0.00 Ohms should be shown. If the pole has been isolated then the
display should show an overflow. Please carry out this test to check the device.
•
Measure the resistance within the individual windings.
If there are large deviations, it must be assumed that there is a windings short circuit. This also
leads to non-excitation of the generator.
The actual values between the windings parts and the earth cannot, however, be exactly determined. Fore-mostly, the values of all three measurements must be the same, if possible. Deviations
from each other show there is windings short-circuit. In this case, the generator windings must be
renewed by an electrician.
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D.4.5 Check the Windings for Short Circuiting
Ensure that the generator has been switched off and cannot be inadvertently switched on. Disconnect the wires to the battery for this.
1. All wires in the junction box or - if necessary - in the circuit distribution box must be disconnected. Ensure that the wires are no longer carrying an electrical current, before being disconnected (see “Discharging the Capacitors” on Page 99.)
2. Remove the Bridges between "N"and "PE", so that the windings and casing do not come into
electrical contact.
3. Make a check, by means of a Multimeter, as to whether there is a current between the individual winding terminals and the casing (PE).
The contacts to measured are not relevant to
the type of generator (see type plate):
HP1 - 50 Hz: L, Z
HP1 - 60 Hz: L, Z
HP3 - 50 Hz: L1, L2, L3
HP3 - 60 Hz: L1, L2, L3, 1, 2, 3, 4
DVS - 50 Hz: L1, L2, L3, L1’
DVS - 60 Hz: L1, L2, L3, L1’, 1, 2, 3, 4
The generator must be sent for a check to the factory or be re-winded locally, when a pass (beep)
should be detemined. Windings data can be requested for this, if it is necessary.
Fig. D.4.5-1: Generator type plate
D.4.6 Measuring the Inductive Resistance
An Ohm measurement of a winding does not always give reliable information concerning the
state of the winding. If there are resistance irregularities between the windings parts, this is a sure
sign that the winding is defective. This means the opposite cannot be concluded. This means a
winding can also be defective, if the resistance values between the windings parts do not show
great deviation.
Measurement of the inductive resistance gives a better reading. A Special measuring device is
necessary for this.
The inductivity is measured in the same manner as the resistance, i.e. the windings parts are
compared. The value of the inductive resistance is given in mH (milli Henry).
The correct values for the inductive resistance can be obtained from Table 4 on Page 112.
Note: The values are greatly dependent upon the measuring method (type of ohmmeter).
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D.5 Generator provides no voltage
D.5.1 Rotor Magnetism Loss and "Re-magnetising"
ATTENTION! “Safety Instructions” on Page iv
In the case of asynchronous generators, the generator cannot independently increase voltage
after standing still, or, if it is switched off under full load. This is because the rotor has lost its
remaining magnetism.
This remaining magnetism can be restored simply by use of a DC battery. In
addition the "shore power"must be switched off and any connection to an ACsource must be interrupted.
Likewise the generator must be switched off, i.e. also the starter may not be
operated. The power source selector is switched to "generator". Only the plug
socket must be connected with the generator.
Now the two poles of a 9 Volt battery are connected to the plug socket or held
against the appropriate contacts of the on-board current distributor. Do not use a battery bank or
the generator starter battery, this could damage the winding. The DC voltage only may be applied
for a short time (1-2 seconds). In the winding the remaining magnetism is restored by a short current pulse, and the generator can normally be started.
D.6 Engine Starting Problems
D.6.1 Fuel Solenoid Valve
The fuel solenoid valve is located in front of the injection pump. It opens automatically, if the
"START"-button is pressed on remote control panel. If the generator is switched to "OFF", the
solenoid valve closes. It takes some seconds, before the generator stops.
If the generator fails to start, runs rough, does not reach the proper RPM, or does not stop properly, the first item to suspect in most cases it is the fuel solenoid valve and should be inspected
first.
A check of the fuel solenoid valve by removing the plug from the fuel solenoid valve for a short
period whilst in operation (first remove the small retention screw) and replace it immediately. The
motor should "react immediately" by revving high. If the motor does not react sharply to the
reconnection of the solenoid wire, it is a sign that the solenoid valve could be faulty.
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Generator Failure
1. Fuel solenoid valve
2. Fuel injector
2
3. Ventilation screw
1
3
Fig. D.6.1-1: Fuel Solenoid Valve
D.6.2 Re-start with Failure Bypass Switch
The start-failure bypass switch enables an immediate restart facility of the generator, should it cut
out, even if this was caused by over-heating. There is normally a requirement to wait until the
motor has cooled down to the correct temperature. This can last for several hours in certain circumstances, since the generator is enclosed in a sound-insulated casing, which prevents heat
loss.
Failure Bypass Swtich
Fig. D.6.2-1: Failure Bypass Switch
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This period can be reduced by pushing the button on the front of the generator. The generator
can be started by means of the remote control as long as the button is depressed. The switch/
button bypasses any faults allowing the generator to run.
Before depressing the button, a manual check of the oil dip stick must be carried out to determine
whether the generator has sufficient oil, as it is possible that the oil pressure switch causes the
generator to cut out. If it has been ascertained that the reason for the motor cutting out is overheating and not lack of oil, the generator can be run for several minutes without load, so that the
motor is cooled by the circulating coolant.
BEWARE:
If the temperature is the reason for the generator cutting out when it is running under load, then
an immediate check must be made to determine the cause. It could be a fault with the cooling
system, one of the fans, the air-intake or a fault with the external cooling system.
Continual use of the starter-failure bypass switch should be avoided, while the generator cuts out
during operation.
The generator must always run without load for several minutes before being switched off, so that
temperature compensation occurs. Heat accumulation can cause the generator to overheat, even
after it has been switched off.
Should the overheating alarm be set off, caused by heat accumulation, after the generator has
been switched off, then this can also be bypassed using the switch.
Damage to starter motor
The starter is fitted with a free wheel or axial rotating spring cog, which prevents the starter being
driven externally by means of the motor. The free wheel will be heavily worn, if the starter still
operates, thereby causing damage to the springs, roller bearings or cog teeth. This could lead to
complete destruction of the starter.
It is important that every person who operates the generator is informed of this situation.
This is practically the only handling error that can be made on board that can lead to fatal
consequences for both generator and operator.
D.6.3 Troubleshooting Table
For Troubleshooting see Table “Troubleshooting” on Page I.
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Tables
E. Tables
E.1 Troubleshooting
GENERATOR OUTPUT VOLTAGE TOO LOW
For 50 Hz versions: less than 200 V
Cause
Solution
Generator is overloaded.
Reduce the electrical load (switch off load)
Motor is not reaching the rated rpm.
Refer to "motor faults" section.
Defective capacitor(s).
Check capacitors and replace if necessary.
GENERATOR VOLTAGE TOO HIGH (MORE THAN 240 V - 50 Hz)
If the generator is providing excessively high voltage, the following potential causes should be investigated:
Cause
Solution
Over-energizing due to wrong capacitors.
Check capacitors type and replace if necessary.
Measurering voltage on the VCS circuit board is missing.
Check VCS System, check cable connections.
GENERATOR VOLTAGE FLUCTUATES
Cause
Solution
1. Disturbances on the electrical system/user side.
1. Check if electrical load is fluctuating.
2. Motor disturbances.
2. Refer to section: "Motor runs irregular".
GENERATOR NOT ABLE TO START ELECTRIC MOTOR
Cause
Solution
If the generator is unable to supply enough power to
start an electric motor (230 V - 50 Hz), it is usually
because the motor draws too much current during starting process.
Check the motor's current draw required for starting
(switch to 380 V, if possible). This could be remedied
by providing stronger capacitors or installing an optional "Easy Start Booster Set" (see Appendix).
Enquire at your nearest Panda dealer or directly at the
manufacturer.
Panda PMS 8.000 NE - 42 NE Manual - Chapter E: Tables
Page 107
Tables
DIESEL MOTOR FAILS TO START
Cause
Solution
Starter battery switched "OFF".
Check position of battery switch and switch "ON" (if
installed).
Starter battery voltage insufficient (battery too weak).
Inspect battery terminals and cables for a good electrical connection (Inspect against corrosion, tattered
wires, etc.).
Starting current disrupted.
During the normal starting process, the battery voltage
drops to 11V with a fully charged battery. If the voltage
does not drop during starting, the electrical connection
is faulty. If the battery voltage drops lower than 11V,
then the battery has been discharged.
STARTER IS TURNING MOTOR, BUT FAILS TO START
Cause
Solution
Fuel inlet solenoid valve not opening.
Check wire connections and circuitry to solenoid valve.
(ref. DC wiring diagram: Relay K2, Fuse)
Fuel pump not working.
Check fuel-filter and pump: clean if necessary.
Lack of fuel.
Check fuel supply.
Glow-plugs not working correctly.
Check glow plugs and heating time.
Too much air in fuel lines.
Test fuel system for leakage. Bleed air from fuel system
(refer to section "Bleeding Air from Fuel System").
Fuel-filter blocked.
Replace fuel filter.
MOTOR DOES ACHIEVE ENOUGH SPEED DURING STARTING PROCESS
Cause
Solution
Starter battery voltage insufficient.
Check battery.
Damaged bearing(s) piston (seized).
Repairs need to be carried out by Kubota-Service.
(refer to Kubota motor-manual)
Cooling water in combustion chamber.
1. Turn generator "OFF" at control panel.
2. Remove the glow plug (see Kubota-manual).
3. Rotate the motor by hand carefully.
4. Check if there is water in the oil and change both oil
and filter if necessary.
5. Determine cause for excess water in the combustion
chamber. The excess water can be caused by a
defective air vent in the cooling water system, which
should be checked and cleaned, or replaced if
faulty.
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Panda PMS 8.000 NE - 42 NE Manual - Chapter E: Tables
Tables
MOTOR DOES ACHIEVE ENOUGH SPEED DURING STARTING PROCESS
Cause
Solution
Starter battery voltage insufficient.
Check battery.
Damaged bearing(s) piston (seized).
Repairs need to be carried out by Kubota-Service.
(refer to Kubota motor-manual)
Cooling water in combustion chamber.
1. Turn generator "OFF" at control panel.
2. Remove the glow plug (see Kubota-manual).
3. Rotate the motor by hand carefully.
4. Check if there is water in the oil and change both oil
and filter if necessary.
5. Determine cause for excess water in the combustion chamber. The excess water can be caused by
a defective air vent in the cooling water system,
which should be checked and cleaned, or replaced
if faulty.
MOTOR SPEED DROPS
Cause
Lack of fuel
Solution
Check fuel supply system:
- fuel filter, renew if necessary
- check fuel pump
- check fuel lines (bleed if necessary)
Lack of intake air.
Check air intake paths.
Check and clean air filter (and intake muffler if installed).
Generator overloaded by too many load.
Reduce the electrical load (switch off load).
Generator overloaded by over-energizing.
Check that the proper capacitor type is installed and
that they are connected correctly.
Defective generator (windings, bearings, or other).
Generator must be sent to manufacturer for repair of
damaged bearings or winding.
Damaged engine.
Repair of bearing damage, etc., by Kubota-Service.
MOTOR RUNS IN OFF POSITION
Cause
Solution
Fuel inlet solenoid valve or throttle shut solenoid is not
switching off.
Check wire connections to solenoid. Check valve
functions as in the "Fuel Solenoid Valve" or in the trottle
shut off solenoid sections. Replace if necessary.
Panda PMS 8.000 NE - 42 NE Manual - Chapter E: Tables
Page 109
Tables
MOTOR STOPS BY ITSELF
Cause
Solution
Lack of fuel.
Check fuel supply system.
Excess heat in cooling system (thermo switch tripped)lack of cooling water. Is indicated on the remote control
panel.
Check cooling water system flow: water pump, inlet
water filter, extra heat exchanger coolant flow.
Lack of oil (oil pressure sensor tripped). Is indicated on
the remote control panel.
Check oil-level and if necessary top up.
Check motor's oil-pressure and have repaired by
Kubota-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 faulty.
Replace injector.
Valve clearance incorrect.
Readjust valve clearance to correct value (refer to
Farymann-manual).
Poor fuel quality.
Use better quality diesel (recommended: 2-D Diesel).
Poor combustion.
Incorrect AFR (air/fuel ratio) due to motor timing adjustment. Have motor serviced by Kubota.
GENERATOR MUST BE SHUT OFF IMMEDIATELY IF:
Cause
- motor rpm suddenly rises or drops
- unusual noise comes from genset
- exhaust colour suddenly becomes dark
- leakage in the cooling water system.
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Panda PMS 8.000 NE - 42 NE Manual - Chapter E: Tables
Solution
Refer to respective section of manual and if necessary,
have repaired by Kubota-Service, or Panda representative.
Tables
Table 1: Resistor generator coil HP1
Table 2: Inductance generator coil HP1
L-N[Ohm]
L-N[Ohm]
Mains
Panda 8000
Panda 9000
Panda 12000
Panda 18
Panda 24
Maint
120V / 60Hz
ca. 0,7
ca. 0,65
ca. 0,45
ca. 0,2
ca. 0,06
Mains:
Panda 8000
Panda 9000
Panda 12000
Panda 14000
Panda 18
Panda 24
Panda 30
L-Z[Ohm]
ca. 2,8
ca. 2,8
ca. 3,5
ca. 3,2
ca. 0,3
Mains
230V / 50Hz
ca. 0,9
ca. 0,8
ca. 0,3
ca. 0,25
ca. 0,25
ca. 0,17
ca. 0,1
120V / 60Hz
Panda 8000
Panda 9000
Panda 12000
Panda 18
Panda 24
ca. 0,7
ca. 0,65
ca. 0,45
ca. 0,2
ca. 0,06
ca. 2,8
ca. 2,8
ca. 3,5
ca. 3,2
ca. 0,3
230V / 50Hz
Panda 8000
Panda 9000
Panda 12000
Panda 14000
Panda 18
Panda 24
Panda 30
ca. 0,9
ca. 0,8
ca. 0,3
ca. 0,25
ca. 0,25
ca. 0,17
ca. 0,1
L-Z[Ohm]
ca. 3,7
ca. 3,7
ca. 3,5
ca. 2,3
ca. 1,8
ca. 1,3
ca. 0,9
ca. 3,7
ca. 3,7
ca. 3,5
ca. 2,3
ca. 1,8
ca. 1,3
ca. 0,9
Table 3: Resistore generator coil DVS
L1-N[Ohm]
L2-N[Ohm]
L3-N[Ohm]
Mains
Panda 8000
Panda 9000
Panda 12000
Panda 18
Panda 24
1-2[Ohm]
3-4[Ohm]
120V / 60Hz
ca. 0,7
ca. 0,65
ca. 0,45
ca. 0,2
ca. 0,06
ca. 0,7
ca. 0,65
ca. 0,45
ca. 0,2
ca. 0,06
ca. 0,7
ca. 0,65
ca. 0,45
ca. 0,2
ca. 0,06
Mains:
Panda 8000
Panda 9000
Panda 12000
Panda 14000
Panda 18
Panda 24
Panda 30
L1'-N[Ohm]
ca. 0,15
ca. 0,17
ca. 0,15
ca. 0,05
ca. 0,15
ca. 0,17
ca. 0,15
ca. 0,05
230V / 50Hz
ca. 0,9
ca. 0,8
ca. 0,3
ca. 0,25
ca. 0,25
ca. 0,17
ca. 0,1
ca. 0,25
ca. 0,25
ca. 0,17
ca. 0,1
ca. 0,9
ca. 0,8
ca. 0,3
ca. 0,25
ca. 0,25
ca. 0,17
ca. 0,1
ca. 0,9
ca. 0,8
ca. 0,3
ca. 0,4
ca. 0,4
ca. 0,2
ca. 0,12
ca. 0,1
ca. 0,1
ca. 0,08
Panda PMS 8.000 NE - 42 NE Manual - Chapter E: Tables
Page 111
Tables
Table 4: Inductance generator coil DVS
L1-N[mH]
L2-N[mH]
L3-N[mH]
Mains
L1'-N[mH]
1-2[mH]
3-4[mH]
120V / 60Hz
Panda 8000
Panda 9000
Panda 12000
Panda 18
Panda 24
ca. 2,8
ca. 2,8
ca. 3,5
ca. 3,2
ca. 0,3
ca. 2,8
ca. 2,8
ca. 3,5
ca. 3,2
ca. 0,3
ca. 2,8
ca. 2,8
ca. 3,5
ca. 3,2
ca. 0,3
Mains:
ca. 0,8
ca 1,0
ca. 0,8
ca. 0,9
ca. 1,0
ca. 0,4
ca. 0,9
ca. 0,4
230V / 50Hz
Panda 8000
Panda 9000
Panda 12000
Panda 14000
Panda 18
Panda 24
Panda 30
ca. 3,7
ca. 3,7
ca. 3,5
ca. 2,3
ca. 1,8
ca. 1,3
ca. 0,9
ca. 3,7
ca. 3,7
ca. 3,5
ca. 2,3
ca. 1,8
ca. 1,3
ca. 0,9
ca. 3,7
ca. 3,7
ca. 3,5
ca. 2,3
ca. 1,8
ca. 1,3
ca. 0,9
ca. 2,3
ca. 2,3
ca. 2,3
ca. 1,5
ca. 1,1
ca. 0,8
ca. 0,6
Table 5: Voltage values stator coil
Terminal
Panda 8000
Panda 9000
Panda 12000
Panda 14000
Panda 18
Panda 24
Panda 30
L1 - L2
3-5 Volt
4-6 Volt
5-7 Volt
6-9 Volt
6-10 Volt
6-11 Volt
7-12 Volt
L2 - L3
3-5 Volt
4-6 Volt
5-7 Volt
6-9 Volt
6-10 Volt
6-11 Volt
7-12 Volt
L3 - L1
3-5 Volt
4-6 Volt
5-7 Volt
6-9 Volt
6-10 Volt
6-11 Volt
7-12 Volt
L1’ - N (50Hz)
~ 2-3 Volt
~ 2-3 Volt
~ 3-4 Volt
~ 3-5 Volt
~ 3-5 Volt
~ 3-5 Volt
~ 3-6 Volt
4 - 2 (60Hz)
~ 2-3 Volt
~ 2-3 Volt
~ 3-4 Volt
~ 3-5 Volt
~ 3-5 Volt
Table 6: Voltage values stator coil
Terminal
Panda 8000
Panda 9000
Panda 12000
Panda 14000
Panda 18
Panda 24
Panda 30
L-N
~ 2-3 Volt
~ 2-3 Volt
~ 3-4 Volt
~ 3-5 Volt
~ 3-5 Volt
~ 3-5 Volt
~ 3-6 Volt
4 - 2 (60Hz)
~ 2-3 Volt
~ 2-3 Volt
~ 3-4 Volt
~ 3-5 Volt
~ 3-5 Volt
Page 112
Panda PMS 8.000 NE - 42 NE Manual - Chapter E: Tables
Tables
Table 7: Diameter of conduits
Ø Cooling water conduit
Ø Fuel conduit
Frehwater
Seawater
Ø Exhaust conduit
[mm]
[mm]
[mm]
[mm]
[mm]
Panda PMS 3,8 ND
12
12
30
8
8
Panda PMS 4,5 ND
12
12
30
8
8
Panda PMS 4500 SCB
12
12
30
8
8
Panda PMS 5000 SCE
12
12
30
8
8
Panda PMS 4500 FCB
12
12
30
8
8
Panda PMS 5000 LPE
16
16
30
8
8
Panda PMS 6000 ND
20
20
40
8
8
Panda PMS 8000 NE
20
20
40
8
8
Panda PMS 9000 ND
20
20
40
8
8
Panda PMS 12000 NE
20
20
40
8
8
Panda PMS 14000 NE
20
20
40
8
8
Panda PMS 18 NE
25
20
50
8
8
Panda PMS 24 NE
25
20
50
8
8
Panda PMS 30 NE
25
20
50
8
8
Panda PMS 33 KU
30
25
50
8
8
Panda PMS 42 KU
30
30
50
8
8
Panda PMS 32 YA
30
30
50
8
8
Panda PMS 50 YA
30
30
60
8
8
Panda PMS 60 YA
-
-
60
8
8
Panda PMS 50 MB
40
30
60
8
8
Panda PMS 60 MB
40
40
60
8
8
Panda PMS 75 MB
40
30
60
8
8
Panda PMS-HD 7,5-4 KU
25
20
40
8
8
Panda PMS-HD 09-4 KU
25
20
50
8
8
Panda PMS-HD 12-4 KU
25
20
50
8
8
Panda PMS-HD 17-4 KU
25
25
60
8
8
Panda PMS-HD 22-4 KU
30
30
60
8
8
Panda PMS-HD 30-4 KU
30
30
60
8
8
Panda PMS-HD 40-4 KU
30
30
60
8
8
Panda PMS-HD 60-4 DZ
-
-
-
-
-
Panda PMS-HD 70-4 DZ
-
-
-
-
-
Panda PMS-HD 85-4 DZ
-
-
-
-
-
Panda PMS-HD 110-4 DZ
-
-
-
-
-
Panda PMS-HD 130-4 DZ
-
-
-
-
-
Generator type
Supply
Return
Panda PMS 8.000 NE - 42 NE Manual - Chapter E: Tables
Page 113
Tables
Table 8: Rated current
Panda 8000 - 230 V / 50 Hz
Panda 8000 - 400 V / 50 Hz
Panda 8000 - 120 V / 60 Hz
27,0 A
8,3 A
61,8 A
Panda 18 - 230 V / 50 Hz
Panda 18 - 400 V / 50 Hz
Panda 18 - 120 V / 60 Hz
60,3 A
20,0 A
128,0 A
Panda 9000 - 230 V / 50 Hz
Panda 9000 - 400 V / 50 Hz
Panda 9000 - 120 V / 60 Hz
34,9 A
11,1 A
74,5 A
Panda 24 - 230 V / 50 Hz
Panda 24 - 400 V / 50 Hz
Panda 24 - 120 V / 60 Hz
89,1 A
30,1 A
161,1 A
Panda 12000 - 230 V / 50 Hz
Panda 12000 - 400 V / 50 Hz
Panda 12000 - 120 V / 60 Hz
41,7 A
13,7 A
89,0 A
Panda 30 - 230 V / 50 Hz
Panda 30 - 400 V / 50 Hz
Panda 30 - 120 V / 60 Hz
Anfrage
35 A
219 A
Panda 14000 - 230 V / 50 Hz
Panda 14000 - 400 V / 50 Hz
Panda 14000 - 120 V / 60 Hz
48,0 A
15,2 A
112,7 A
Table 9: Cable cross-section
Voltage
Required cable cross-section
< 6 kW
6-10 kW
10-15 kW
15-20 kW
20-35 kW
35-45 kW
45-65 kW
120V 1-ph.
4x6mm²
4x10mm²
4x16mm²
4x25mm²
4x35mm²
4x50mm²
4x70mm²
230V 1-ph.
2x4mm²
2x6mm²
2x10mm²
2x16mm²
2x25mm²
2x35mm²
2x35mm²
400V 3-ph.
4x2,5mm²
4x4mm²
4x6mm²
4x10mm²
4x16mm²
4x16mm²
4x25mm²
Page 114
Panda PMS 8.000 NE - 42 NE Manual - Chapter E: Tables
Tables
Panda PMS 8.000 NE - 42 NE Manual - Chapter E: Tables
Table 10: Technical Data
Page 115
Panda
Panda
Panda
Panda
Panda
Panda
Panda
Panda
6000 ND
8000 NE
9000 ND
12000 NE
14000 NE
18 NE
24 NE
30 NE
Type
Z482
Z482
D722
D722
D782
D1105
V1505
V1505 TD
Govenor
mechanical
VCS
mechanical
VCS
VCS
VCS
VCS
VCS
Automatic startbooster
yes
yes
yes
yes
yes
yes
yes
yes
Cylinder
2
2
3
3
3
3
4
4TD
Bore
67mm
67mm
67mm
67mm
67mm
78mm
78mm
78mm
Stroke
68mm
68mm
68mm
68mm
73,6mm
78,4mm
78,4mm
78,4mm
Stroke volume
479cm3
479cm3
719cm3
719cm3
782cm3
1123cm3
1498cm3
1498cm3
Max. power (DIN 6271-NB) at 3000rpm
9,32kW
9,32kW
14,0kW
14,0kW
13,5kW
18,7kW
23,3kW
31,3kW
Rated speed 50 Hz
3000rpm
3000rpm
3000rpm
3000rpm
3000rpm
3000rpm
3000rpm
3000rpm
Idle running speed a
3120rpm
2900rpm
3120rpm
2900rpm
2900rpm
2900rpm
2900rpm
2900rpm
Valve clearance (engine cold)
0,2mm
0,2mm
0,2mm
0,2mm
0,2mm
0,2mm
0,2mm
0,2mm
Cylinder head nut torque
42Nm
42Nm
42Nm
42Nm
68Nm
68Nm
68Nm
68Nm
Compression ratio
23:1
23:1
23:1
23:1
23:1
22:1
22:1
23:1
Lubrication oil capacity
2,5l
2,5l
3,8l
3,8l
3,8l
5,1l
6,0l
6,7l
Fuel consumption b
ca. 0,53-1,4l
ca. 0,68-1,8l
ca. 0,79-2,1l
ca. 1,05-2,8l
ca. 1,25-3,3l
ca. 1,68-4,5l
ca. 2,20-5,85
ca. 2,7-7,2l
28-40l/min
28-40l/min
40-50l/min
Oil consumption
Cooling water requirement for seawater circuit
Permissible max. permanent tilt of engine
max. 1% of fuel consumption
16-28l/min
16-28l/min
16-28l/min
16-28l/min
16-28l/min
a) 25° across the longitudinal axis
b) 20° in the longitudinal direction
a. progressive speed by VCS
b. 0,35l/kW electrical power, the randomized values between 30% and 80% of the rated speed
Tables
Panda PMS 8.000 NE - 42 NE Manual - Chapter E: Tables
Table 11: Technical Data
Page 116
Panda
Panda
Panda
Panda
Panda
Panda
Panda
Panda
33 KU
42 KU
32 YA
50 YA
60 YA
50 MB
60 MB
75 MB
Type
V2203
F2803
4JH3E
4JH3TE
4JH3HTE
OM 601
OM 602
OM 603
Govenor
VCS
VCS
VCS
VCS
VCS
VCS
VCS
VCS
Automatic startbooster
yes
yes
yes
yes
yes
yes
yes
yes
Cylinder
4
5
4
4
4
5
6
Bore
87mm
87mm
84mm
mm
84mm
89mm
89mm
89mm
Stroke
92,4mm
92,4mm
90mm
mm
90mm
92,4mm
92,4mm
92,4mm
Stroke volume
2197cm3
2746cm3
cm3
cm3
cm3
2298cm3
2874cm3
3000cm3
Max. power (DIN 6271-NB) at 3000rpm
32,7kW
40,8kW
kW
kW
kW
58kW
70kW
75kW
Rated speed 50 Hz
3000UpM
3000UpM
3000UpM
3000UpM
3000UpM
3000UpM
3000UpM
3000UpM
Idle running speed a
2900UpM
2900UpM
2900UpM
2900UpM
2900UpM
2900UpM
2900UpM
2900UpM
Valve clearance (engine cold)
0,2mm
0,2mm
0,2mm
0,2mm
0,2mm
0,2mm
0,2mm
0,2mm
Cylinder head nut torque
98Nm
98Nm
Nm
Nm
Nm
25Nm
25Nm
25Nm
Compression ratio
23:1
23:1
22:1
22:1
22:1
Lubrication oil capacity
9,5l
12,0l
7,0l
7,5l
7,5l
Fuel consumption b
ca. 2,94-7,5l
ca. 3,8-10,1l
ca. 4,4-11,8l
ca. 5,4-14,3l
ca. 6,8-18,2l
50-60l/min
60-75l/min
75-85l/min
ca. 2,9-7,8l
ca. 4,3-11,5
Oil consumption
Cooling water requirement for seawater circuit
Permissible max. permanent tilt of engine
ca. 5,5-14,6l
max. 1% of fuel consumption
50-60l/min
50-60l/min
50-60l/min
50-60l/min
60-75l/min
a) 25° across the longitudinal axis
b) 20° in the longitudinal direction
a. progressive speed by VCS
b. 0,35l/kW electrical power, the randomized values between 30% and 80% of the rated speed
Tables
E.2 Types of coil
HP1 - 230V / 50 Hz
HP1 - 120V / 60 Hz
HP3 - 400V / 50 Hz
Panda PMS 8.000 NE - 42 NE Manual - Chapter E: Tables
Page 117
Tables
HP3 - 120V / 60 Hz
DVS - 400V / 50 Hz
DVS - 120V 240V / 60 Hz
Page 118
Panda PMS 8.000 NE - 42 NE Manual - Chapter E: Tables
Tables
E.3 Inspection checklist for services
Inspection-Category
Inspection work
D
E
F
G
A Installation check /
B daily
C 35 - 50 h
100 h
1) check r
2) measure
3) clean
500 h
1000 h
5000 h
Inspection-Category
A
B
C
D
E
4) changer
5) sealing
6) check isolation
F
G
Inspection work
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
3)
3)
3)
3)
oil strainer / oil filter
05.
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)
09.
1)
10.
1)
1)
1)
4)
5)
4)
4)
4)
fine particle fuel filter
1)
1)
1)
valve clearance
4)
4)
4)
valve cover gasket
11.
1)
1)
1)
1)
coolant therm (sensor)
12.
1)
1)
1)
1)
exhaust temp sensor
13.
1)
1)
1)
1)
oil pressure sensor
14.
15.
1)
1)
1)
1)
1)
1)
1)
belt tension
1)
1)
1)
4)
4)
4)
toothed-belt
1)
1)
thermostat
16.
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)
starter motor mounting screws
22.
1)
1)
1)
1)
1)
1)
1)
screws generator-engine
23.
2)
2)
2)
2)
2)
2)
input temp of coolant under load
24.
2)
2)
2)
2)
2)
2)
outlet temp of coolant under load
4)
4)
generator rotor bearing
25.
26.
1)
1)
1)
1)
1)
signs of corrosion to generator
27.
1)
1)
1)
1)
1)
check generator coolant block
28.
1)
1)
1)
1)
1)
capacitors in AC-Control box
29.
1)
1)
1)
1)
1)
1)
ASB function test
30.
1)
1)
1)
1)
1)
1)
VCS function test
31.
2)
2)
2)
2)
2)
2)
voltage without load
32.
2)
2)
2)
2)
2)
2)
voltage under load
33.
2)
2)
2)
2)
2)
2)
generator output under load
34.
2)
2)
2)
2)
2)
2)
engine speed (rpm)
35.
1)
4)
injector test
36.
1)
1)
compression
1)
1)
hose clips
37.
1)
1)
1)
1)
1)
Panda PMS 8.000 NE - 42 NE Manual - Chapter E: Tables
Page 119
Tables
E.4 Engine oil
Engine oil classification
Operating range:
The operating range of an engine oil is determined by SAE class. "SAE" is for the union of American engineers
(Society of Automotives Engineers). The SAE class of an engine oil only informs over the viscosity of the oil (larger number = more viscous, lower number = more highly liquidly) e.g. to 0W, 10W, 15W, 20, 30, 40. The first number shows the liquid of cold weather, the second number refers to the fluidity with heat. Complete yearly oils have
usually SAE 10W-40, SAE 15W-40 etc.
Quality of oil:
The quality of an engine oil is specified by the API standard ("American Petroleum Institutes"). The API designation is to be found on each engine oil bundle. The first letter is always a C.
API C for diesel engines
The second letter is for the quality of the oil. The more highly the letter in the alphabet, the better the quality.
Examples for diesel engine oil:
API CG Engine oil for highest demands, turbo-tested
Engine oil types
above 25°C
SAE30
or SAE10W-30
SAE10W-40
0°C to 25°C
SAE20
or SAE10W-30
SAE10W-40
below 0°C
SAE10W or SAE10W-30
SAE10W-40
Page 120
Panda PMS 8.000 NE - 42 NE Manual - Chapter E: Tables
Tables
E.5 Coolant
Use a mixture of water and antifreeze. The antifreeze needs to be suitable for aluminium. The antifreeze concentration must be regularly checked in the interests of safety.
Fischer Panda recommend to use the product: GLYSANTIN PROTECT PLUS/G 48.
Engine coolant automotive industry Product description
Product name
GLYSANTIN ® PROTECT PLUS / G48
Chemical nature
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
Panda PMS 8.000 NE - 42 NE Manual - Chapter E: Tables
Page 121
Tables
Page 122
Panda PMS 8.000 NE - 42 NE Manual - Chapter E: Tables
Tables Panda PMS HD
F. Tables Panda PMS HD
Tabelle 1: Diameter of conduits Panda PMS HD
Ø Cooling water conduit
Ø Fuel conduit
Frehwater
Raw water
Ø Exhaust conduit
[mm]
[mm]
[mm]
[mm]
[mm]
Panda PMS-HD 7,5-4 KU
25
20
40
8
8
Panda PMS-HD 09-4 KU
25
20
50
8
8
Panda PMS-HD 12-4 KU
25
20
50
8
8
Panda PMS-HD 17-4 KU
25
25
60
8
8
Panda PMS-HD 22-4 KU
30
30
60
8
8
Panda PMS-HD 30-4 KU
30
30
60
8
8
Panda PMS-HD 40-4 KU
30
30
60
8
8
Panda PMS-HD 60-4 DZ
-
-
-
-
-
Panda PMS-HD 70-4 DZ
-
-
-
-
-
Panda PMS-HD 85-4 DZ
-
-
-
-
-
Panda PMS-HD 110-4 DZ
-
-
-
-
-
Panda PMS-HD 130-4 DZ
-
-
-
-
-
Generator type
Panda_22-4KU_HD_PMS - Chapter F: Tables Panda PMS HD
Page 123
Supply
Return
Tables Panda PMS HD
Tabelle 2: Technical data
Type
Kubota F2803
Govenor
mechanical + VCS
Cylinder
5
Bore
87 mm
Stroke
92,4 mm
Stroke volume
2746 ccm
Cont. power (SAE J1349) at 2800rpm
37,3 kW
Maximum bare speed
3000 rpm
Idle running speed a
1800 rpm
Valve clearance (engine cold)
0,18 -0,22 mm
Cylinder head nut torque
93,1 - 98,0 Nm
Compression ratio
23
Lubrication oil capacity
12,0 l
Fuel consumption b
1,9 - 5,2 l
Output voltage
220V
Output current
102A
Frequency
60Hz
Coil
Da= 300mm
1 phase
Di= 190 mm
Rotor
Lfe= 250 mm
Coil resistance
H1/H2: approx. 0,11 Ohm
Z1/Z2: approx. 0,16 Ohm
Coil inductance
H1/H2: approx. 0,16 mH
Z1/Z2: approx. 1,1 mH
a. progressive speed by VCS
b. 0,35l/kW electrical power, the randomized values between 30% and 80% of the rated speed
Page 124
Panda_22-4KU_HD_PMS - Chapter F: Tables Panda PMS HD
Tables Panda PMS HD
F.1
Capsule Mearuements
Panda_22-4KU_HD_PMS - Chapter F: Tables Panda PMS HD
Page 125
Tables Panda PMS HD
Panda_22-4KU_HD_PMS - Chapter F: Tables Panda PMS HD
Page 126
16.6.08
Panel Generator Control P6+ RE0703_Kunde_eng.R01
Generator Control Panel P6+ Manual
12V version - 21.02.02.009H
24V special version - 21.02.02.012H
Option automatic adapter - 21.02.02.016H
Option master-slave adapter - 21.02.02.015H
Fischer Panda GmbH
Current revision status
Document
Actual:
Panel Generator Control P6+ RE0703_Kunde_eng.R01_16.6.08
Replace:
Revision
Page
ATTENTION!: Please read the safety instructions
in your generator manual!
128
General operation
A. General operation
A.1 Panel Generator Control
Fischer Panda Art. No. 21.02.02.009H
01
02
08
09
11
12
03
01. LED for coolant temperature red1
02. LED for waterleak red/yellow1 (sensor optional)
03. LED for AC-voltage fault red/yellow1
04. LED for AC-voltage ok green1
05. LED for winding temperature red1
06. LED for oil pressure red1
07. LED for battery charge voltage fault green/red1
1
04
05
06
07
10
14
13
15
08. LED for pre-glow „heat“ orange1
09. LED for Generator „start“ green1
10. LED for Generator „stand-by“ green1
11. Push button for pre-glow „heat“
12. Push botton for Generator „start“
13. Operating hours counter
14. Push button panel „off“
15. Push button panel „on“
LED green: normal operation mode, LED red: fault, LED yellow: warning, LED orange: active
Fig. A.1-1: Panel front
16.6.08
Panel Generator Control P6+ RE0703_Kunde_eng.R01 - Chapter A: General operation
Page 129
General operation
A.2 Rear view 12V-version
Fischer Panda Art. No. 21.02.02.009H
01
02
03
04
01. Control board
02. Terminal block (master-slave adapter: left row; automatic adapter: right row)
03. Terminals 1-12 (see section A.4, “Terminal connections,” on page 132)
04. Fuse 630mA slow-blow
Fig. A.2-1: Panel rear view 12V-version
Page 130
Panel Generator Control P6+ RE0703_Kunde_eng.R01 - Chapter A: General operation
16.6.08
General operation
A.3 Rear view 24V-version
Fischer Panda Art. No. 21.02.02.012H
01
02
03
04
05
06
01. Control board
02. Terminal block (master-slave adapter: left row; automatic adapter: right row)
03. Fuse 630mA slow-blow
04. Terminals 1-12 (see section A.4, “Terminal connections,” on page 132)
05. Linear controller 24V
06. Linear controller 24V
Fig. A.3-1: Panel rear view 24V-version
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General operation
A.4 Terminal connections
Standard for NC temperature switch configured i.e. in case of failure „open“.
Clamp
no.
Clamp
name
IN /
OUT
Description
1
Vbat
IN
Current supply + 12V (or optional 24V, must be adjusted by jumper)
2
GND
IN
Current supply -
3
T-Engine
IN
Error “coolant temperature”. Input for thermo-switch to GND. The input is adjustable for NC/NO
(N = no error) (must be adjusted by solder Jumper). The input loads the switch with ≥22mA to
+12V (with 24V-operated internally generated). The occurrence of an error is delayed, for analysis and displayed, around 100ms. Omission not. The in/out status is indicated with red LED.
4
5
Water
leak
(Replace air filter)
IN
Oil-Press
IN
Error “water leak”. Input for sensor switch to GND. The input is adjustable for NC/NO (N = no
error) (must be adjusted by solder Jumper). The input loads the switch with ≥10mA to +12V
(with 24V-operated internally generated). The occurrence of an error is delayed, for analysis
and displayed, around 100ms. Omission not. The input status is indicated with red LED.
The input can be used alternatively for the signal “Replace air filter” (must be adjusted by solder Jumper). Then the signal does not lead to switching off and is indicated with yellow LED.
Error “oil pressure“. Input for oil pressure switches to GND. The input is adjustable for NC/NO
(N = no error) (must be adjusted by solder Jumper). The input loads the switch with ≥22mA to
+12V (with 24V-operated internally generated). The occurrence of an error is delayed, for analysis and displayed, around 1s. Omission not. The input status is indicated with red LED.
6
DC-Control
IN
OUT
7
AC-Control
IN
AC control display. Input for NC-open-collector-sensor-switch to GND (N = OK). The input
loads the switch with ≥2,5mA to +12V (with 24V-operated internally generated). The input status is indicated with red and green LED´s.
8
Heat
OUT
Output for pre-glow relays. The output is so long active, as the button “Heat” is pressed. The
output supplies, if active, the voltage of clamp 1. Additionally the output can be operated via the
button “start” (must be adjusted by solder Jumper). Consider (notes 1-4).
9
Fuel-Pump
OUT
Output for fuel pump relay. The output is active, if no error is present (inputs 3, 4, 5, 11 and 12,
if configured accordingly). The button “start” suppresses the error analysis and the output is
then also active in the case of error, if the button “start” is pressed. The output supplies, if
active, the voltage of clamp 1. Consider (notes 1-4).
10
Start
OUT
Output for starting relay. The output is active, as long as the button “start” is pressed. The output supplies, if active, the voltage of clamp 1. Consider (notes 1-4).
11
AC-Fault (Fuel
Level) [former TOil]
/
Load control display. Input for signal of the dynamo. The input is adjustable for GND = OK or
12V/24V = OK (must be adjusted by solder Jumper). The input loads the signal with 5mA at
12V and 10mA at 24V. The input status is indicated with red and green LED.
The connection can supply an energizing current for the dynamo over a fixed resistor with 68R.
Either with the control panel switched on or with “Fuel pump” switched on (must be adjusted by
solder Jumper). This function is available only in 12V-operation.
Error generator AC input for NC-open-collector-sensor-switch to GND (N = no error). The input
loads the switch with ≥2,5mA to +12V. (with 24V-operated internally generated). The occurrence of an error is delayed, for analysis and displayed, around 100ms. Omission not. The
input status is indicated with red LED.
IN
The input can be used alternatively for the signal “Fuel level” (must be adjusted by solder Jumper). The signal does not lead to switching off and is indicated with yellow LED.
The input can be used alternatively for the signal “error oil-temperature”. The input is adjustable
for NC/NO (N = no error) (must be adjusted by solder Jumper). The load of the sensor switch is
adjustable to ≥10mA by +12V (must be adjusted by solder Jumper).
12
T-Winding
IN
Error “winding temperature”. Input for thermo-switch to GND. The input is adjustable for NC/NO
(N = no error) (must be adjusted by solder Jumper). The input loads the switch with ≥22mA to
+12V (with 24V-operated internally generated). The occurrence of an error is delayed, for analysis and displayed, around 100ms. Omission not. The input status is indicated with red LED.
Fig. A.4-1: Terminal connections
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General operation
Notes:
1. Power rating of the output: max. 0,5A in continuous operation and briefly 1,0A.
2. The supply of all output currents may not exceed (less 0,2A power consumption) the rated current of the safety
device of the control panel.
3. The output has a free wheeling diode, which short circuits negative voltages (related to GND).
4. The output has a Z-diode, which prevents a supply of positive voltage (related to GND) into the output.
A.5 Function of the jumpers
Jumper
Status
Description
closed
during operation of the start button heat is along-operated
open
Function deactivated
1-2
Dynamo excitation resistor 68R is switched on with Fuel-Pump
2-3
Dynamo excitation resistor 68R is switched on with Panel-ON
open
Dynamo excitation resistor is deactivated
closed
12V - operation
open
24V - operation (optional)
1-2
T-Engine-input is configured for NC
2-3
T-Engine-input is configured for NO
1-2
Water leak-input / Replace air filter is configured for NC
2-3
Water leak-input / Replace air filter is configured for NO
1-2
Oil-Press-input is configured for NC
2-3
Oil-Press-input is configured for NO
1-2
AC-Fault-input / Fuel level is configured for NC
2-3
AC-Fault-input / Fuel level is configured for NO
1-2
T-Winding-input is configured for NC
2-3
T-Winding-input is configured for NO
1-2
Input Water leak has red LED and switches off
2-3
Input Water leak has yellow LED and does not switch off
1-2
Input AC-Fault has red LED and switches off
2-3
Input AC-Fault has yellow LED and does not switch off
1-2
DC-Control-Signal (-) = OK alternator
2-3
DC-Control-Signal (+) = OK three-phase alternator
1-2
DC-Control-Signal (-) = OK alternator
2-3
DC-Control-Signal (+) = OK three-phase alternator
closed
Input AC-Fault has Pull-Up-current ≥10mA
open
Input AC-Fault has Pull-Up-current ≥2,5mA
J1
J3
J101
J201
J202
J203
J204
J205
J206
J207
J208
J209
J210
Fig. A.5-1: Function of the solder jumpers
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General operation
NC = normal closed
NO = normal open
The solder jumper are marked on the printed circuit board (with jumper no. and at three-part solder jumper with
solder area no.).
A.6 Starting preparation / Checks (daily)
A.6.1 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. It is very important that a large expansion area
remains above the cooling water level.
3. Check if sea cock for cooling water intake is open.
For safety reasons, the sea cock must be closed after the generator has been switched off. It should be re-opened before starting the
generator.
4. Check raw water filter.
The raw water filter must be regularly checked and cleaned. The impeller fatigue increases, if residual affects the raw water intake.
5. Visual inspection.
Control fixing bolts, check hose connectors for leakages, control electrical connections.
6. Switch off the load.
The generator should only be started without load.
7. Open fuel valve, if installed.
8. Close battery main switch (switch on).
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General operation
A.6.2 Vehicle 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. It is very important that a large expansion area
remains above the cooling water level.
3. Visual inspection.
Control fixing bolts, check hose connectors for leakages, control electrical connections.
4. Switch off the load.
The generator should only be started without load.
5. Open fuel valve, if installed.
6. Close battery main switch (switch on).
A.7 Starting and stopping the generators
A.7.1 Starting the generator
1. Press button „on“ (switch on).
LED for "on“ = green.
2. Press button „heat“ (preglow engine).
LED for "heat“ = orange.
Depending upon engine type and execution pre-heating can be necessary. Pre-heat is necessary at an operating temperature <20°C.
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General operation
A.7.1 Starting the generator
3. Press button „start“ (start engine).
LED for "start“ = green.
The electric starter may only be used for a maximum of 20 seconds.
Thereafter, a pause of at least, 60 seconds is required. If the genset
does not immediately start, then the fuel intake should be checked to
ensure it is flowing freely. (For temperatures below - 8°C check whether there is winter fuel)
4. Switch on load.
The load should only be switched on if the generator voltage is within the permissible range. Parallel connection of several loads
should be avoided, especially if there are loads with electric motors, such as air-conditioning units in the system. In this case, the load
must be connected Step by Step.
A.7.2 Stopping the generator
1. Switch off load.
2. Recommendation: With turbo engines and during load more than highly 70% of the rated output, stabilize
generator temperature at least 5 minutes with load switched off.
At higher ambient temperatures (more than 25°C) the generator should always run for at least 5 minutes without load, before it is switched off, regardless of the load.
3. Press button „off“ (switch off).
LED for "on“ = off.
NOTE: Never switch off the battery until the generator has stopped, if necessary close fuel valve!
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General operation
A.8 Automatic adapter - option
Fischer Panda Art. No. 21.02.02.016H
03
02
01
01. Main terminals
02. Automatic adapter 21.02.02.016H
03. 8-pole DIP-switch
Fig. A.8-1: Panel 21.02.02.009H with Automatic adapter 21.02.02.016H
Function:
The automatic adapter RE0704 extends the generator control panel P6+ with an automatic input. A potential-free
contact can be attached to this input. If this contact is closed, then the generator, which is attached to the generator control panel P6+, is started automatically. If the contact is opened, then the generator is stopped automatically.
The automatic starting procedure consists of pre-heating (heat) and operating the starter (start). It can be again
aborted at any time by opening the contact at the automatic input.
For automatic stopping (stop) the output “Fuel pump” (clamp 9 generator control panel) is switched off. The time
for the automatic stop procedure can be terminated only by switching off generator control panel prematurely.
The times for “heat”, “start” and “stop” are separately adjustable (see below).
The additional automatic adapter switched on and off using the generator control panel with its push buttons “on”
and “off”.
If the contact at the automatic input is connected, while the generator control panel is switched on, then the automatic starting procedure is carried out.
If the current supply is attached or switched on using the generator control panel, while the contact of the automatic input is closed, then the automatic starting procedure won´t be carried out, because the generator control
panel is always switched off after attaching the current supply (generator the control panel must have been separate from the current supply for at least 60s).
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General operation
The mechanism entrance:
With (-) characterized connection is connected to GND.
With (+) characterized connection is the input.
The input is connected through a resistance to 12V (with 24V-operated internally generated). If the two connections are short circuited over a potential-free contact, then the input current flows.
To be considered for an electronic contact the low input current and the polarity is to be selected.
The high input current is to be selected for an electromechanical contact.
The input is debounced (delay time approx.1s).
On the input an external voltages must not be set.
Data:
Parameter
Information
Operation voltage
The automatic adapter power is supplied via the generator control panel P6+. The
same absolute maximum ratings obtain as with the generator control panel P6+.
Operation temperature
The same absolute maximum ratings obtain as with the generator control panel
P6+.
Proper power consumption
10mA - 20mA
Tolerance of times
± 10%
8-pole DIP-switch S1 settings (S1.1 to S1.8):
standard
S1.1
S1.2
2,5s
OFF
OFF
5s
ON
OFF
OFF
ON
ON
ON
S1.3
S1.4
S1.5
OFF
OFF
ON
OFF
64s
OFF
ON
128s
ON
ON
S1.6
S1.7
S1.8
Heat-time
10s
X
20s
8s
X
OFF
Start-time
16s
ON
16s
32s
X
Stop-time
Normal
X
OFF
Operation-mode
Test (all times over 16)
Input current
ON
1,25mA
7mA
OFF
X
ON
Fig. A.8-2: Settings
Attention:
The automatic adapter must only be used together with a device. The starter should only be switched on when the generator stationary (shutdown)!
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General operation
A.8.1 Terminal connections
Connection for the automatic adapter X2 (row with odd pin numbers // I/O viwe from operating panel)
Pin-no.
Pin-name
I/O
Description
1
VBF
O
Current supply + (operation voltage behind fuse)
3
GND
O
Current supply - (ground)
5
VBFS
O
Current supply + switched (voltage Pin 1, with panel switched on)
7
12V
O
Current supply + switched, at 12V-operation over closed soldered jumper J101 connected with
VBFS (at optional 24V-operation: VBFS over internal voltage regulator at 12,9V regulated)
9
GND
O
Current supply - (ground)
11
GND
O
Current supply - (ground)
13
/Heat-signal
I
Heat is active, if the input is switched to GND
15
/Start-signal
I
Start is active, if the input is switched to GND
17
GND
O
Current supply - (ground)
19
GND
O
Current supply - (ground)
21
GND
O
Current supply - (ground)
23
GND
O
Current supply - (ground)
25
GND
O
Current supply - (ground)
27
/Stop-signal
I
The Fuel pump signal is switched off, as long as the input is switched to GND, (also when starting)
29
FP-Int
O
Fuel pump signal internally, decoupled over diode from external signal
31
/Fault-signal
O
Output is switched to GND, if an error is present (inputs 3, 4, 5, 11 and 12, if configured and
generally for 2s, after switching on the panel)
33
GND
O
Current supply - (ground)
Fig. A.8.1-1: Terminal connections automatic adapter
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General operation
A.9 Master-Slave adapter - option
Fischer Panda Art. No. 21.02.02.015H
configured as master
02
01
01. Main terminals
02. Master-slave adapter 21.02.02.015H
Fig. A.9-1: Panel 21.02.02.009H with master-slave adapter 21.02.02.015H (master)
Fischer Panda Art. No. 21.02.02.01H
configured as slave
02
01
01. Main terminals open
02. Master-slave adapter 21.02.02.015H
Fig. A.9-2: Panel 21.02.02.009H with master-slave adapter 21.02.02.015H (slave)
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General operation
The Master-Slave-Adapter RE0706 offers the possibility to combine two Generator Control Panels P6+ RE0703
into a Master-Slave-Combination. This constellation is achieved by connecting a Master-Slave-Adapter RE0706
to each Generator Control Panels P6+ RE0703. The generator Control Panels P6, are connected using the 13
pole connectors found in each Master-Slave-Adapter in a 1:1 method. The Master-Panel is hereby defined when
the generator is connected to the main connector. Thus, the main connector of the Slave-Panel should not be
occupied (unconnected).
The solder jumpers on the Master-Panel have to be coded in the same manner as for a Master-Panel without a
Slave-Panel as in normal operation. The solder jumpers on the Slave-Panel are coded as for slave operation
(please see the appropriate adjustment pages for the Generator Control Panel P6+ RE0703). The Master-Panel
and Slave-Panel are identical, and only differs as a result of the coding. Both Master-Slave-Panels are also identical.
Terminal Connections:
X2: (13 poles) Master-Slave-Connection (1:1 wired)
X3: (2 poles) Panel-ON-Signal from Generator Control Panel P6+ RE0703
The Panel-ON-Signal is active when the panel is switched on. The voltage level is 0,7V less than the supply
voltage for the generator Control Panel P6+ RE0703. This output has a free wheeling diode which short circuits
externals voltage supplies under 0V and a decoupling diode which decouples the circuitry from external power
feeding. Both X3 connectors are have the same Panel-On-Signal.
Fuse:
A 0,8AT fuse must be installed on the Master-Panel.
A.9.1 Terminal connections
Pin-No.
Pin-name
I/O
Description
1
VBF
O
Current supply + (operation voltage behind fuse 12Vdc or 24Vdc depending on system)
2
GND
O
Current supply - (ground)
3
ON-Signal
I/O
Panels are switched on, if the connection is switched using a push button (on master or slave)
to VBF
4
OFF-Signal
I/O
Panels are switched off, if the connection is switched using a push button (on master or slave)
to VBF
5
/Heat-Signal
I/O
Heat is active, if the connection is switched over a push button (on master or Slave) to GND
6
/Start-Signal
I/O
Start is active, if the connection is switched over a push button (on master or Slave) to GND
7
LED-T-Engine
O
Output for LED T-Engine on the Slave panel, is switched to GND, if the LED is illuminated
8
LED-Water
leak (Replace
air filter)
O
Output for LED Waterleak on the Slave panel, is switched to GND, if the LED is illuminated
9
LED-OilPress
O
Output for LED Oil-Press on the Slave panel, is switched to GND, if the LED is illuminated
10
LED-AC-Fault
(Fuel Level)
O
Output for LED AC-Fault on the Slave panel, is switched to GND, if the LED is illuminated
11
LED-T-Winding
O
Output for LED T-Winding on the Slave panel, is switched to GND, if the LED is illuminated
12
DC-Control
O
Output for LED DC-Control-display on the Slave panel, is switched to GND, if the LED is illuminated
13
AC-Control
O
Output for LED AC-Control-display on the Slave panel, is switched to GND, if the LED is illuminated
Fig. A.9.1-1: Terminal connections terminal X2 (IN/OUT from the view of the master-control-panel)
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General operation
The use of these connections for other purposes, other than the master-slave connection of two generator control
panels, is generally forbidden. In individual cases, after consultation and clarifying the technical details, a release
for another use can, if technically possible, be allowed.
Pin-No.
Pin-name
IN /
OUT
1
Panel ON
OUT
2
Panel ON
OUT
Description
With panel (ON/OFF) switched voltage of clamp X2.1 (VBF). (Consider notes 1-4)
Fig. A.9.1-2: Terminal connections terminal X3
Notes:
1. Power rating of the output: max. 0,5A in continuous operation and briefly 1,0A.
2. The supply of all output currents may not exceed (less 0,2A power consumption) the rated current of the safety
device of the control panel.
3. The output has a free wheeling diode, which short circuit negative voltages (related to GND).
4. The output has a Z-diode, which prevents an overvoltage (related to GND) into the output.
A.9.2 Configuration and adjustment
Standard jumpering for use as Slave panel in connection with an master-slave adapter RE0706 and a generator
control panel P6+ RE0703 as master panel. Both 12V operation, and 24V operation is possible (see J101).
A 0,63AT fuse must be installed.
The circuitry is designed for a rating of 24V.
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General operation
Jumper
Status
Conf.
closed
Description
during operation of the start button heat is along-operated
J1
open
J3
XM
Function deactivated
1-2
Dynamo excitation resistor 68R is switched on with Fuel-Pump
2-3
Dynamo excitation resistor 68R is switched on with Panel-ON
open
XM
Dynamo excitation resistor is deactivated
closed
M
12V - operation
open
M
24V - operation (optional)
J101
1-2
T-Engine-input is configured for NC
J201
2-3
XM
1-2
T-Engine-input is configured for NO
Water leak-input / Replace Air filter is configured for NC
J202
2-3
XM
1-2
Water leak-input / Replace Air filter is configured for NO
Oil-Press-input is configured for NC
J203
2-3
XM
1-2
Oil-Press-input is configured for NO
AC-Fault-input / Fuel level is configured for NC
J204
2-3
XM
1-2
AC-Fault-input / Fuel level is configured for NO
T-Winding-input is configured for NC
J205
2-3
XM
T-Winding-input is configured for NO
1-2
M
Input Water leak has red LED and switches off
2-3
M
Input Water leak has yellow LED and does not switch off
1-2
M
Input AC-Fault has red LED and switches off
2-3
M
Input AC-Fault has yellow LED and does not switch off
1-2
M
DC-Control-Signal (-) = OK alternator
2-3
M
DC-Control-Signal (+) = OK three-phase alternator
1-2
M
DC-Control-Signal (-) = OK alternator
2-3
M
DC-Control-Signal (+) = OK three-phase alternator
J206
J207
J208
J209
Input AC-Fault has Pull-Up-current ≥10mA
closed
J210
open
XM
Input AC-Fault has Pull-Up-current ≥2,5mA
Fig. A.9-1: Settings of soldered jumper for this configuration (column Conf.)
NC = normal closed
NO = normal open
The jumpers are marked on the printed circuit board (with jumper no. and at three-part jumper with solder area
no.).
X
= Jumper must be set as seen
XM = Jumper must be set as seen, function is selected on the master panel
M = Jumper must be set exactly the same, as on the master panel
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General operation
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A
B
C
6
175
5
195
185
5
4
105
4
Alle nicht
bemaßten Fasen
a=0,5 mm
25
Zust.
Panel Generator Control P6+ RE0703_Kunde_eng .R01 - Chapter B: Measurements
3
Änderungen
2
88
Datum Name
Schutzvermerk nach
DIN 34 beachten !
Allgemeintoleranzen nach
DIN ISO 2768-mK
Norm.
Gepr.
2
Datum
Name
Bearb. 06.03.2007 jschaefers
Ersatz für
Ersetzt durch
1
2D Zeichnungs Nr.
7067e00
Panel Generator Control
Gewicht:
Halbzeug:
3
Maßstab:
n
1
Material:
Artikel Nr.:
21.02.02.009H
Skizze für Lochbild
layout for hole pattern
177
185
Otto-Hahn-Str. 32-34 D-33104 Paderborn Tel.: (05254) 9202-0
Fax (05254) 85724 info@fischerpanda.de www.fischerpanda.de
3
95
n 4
4x
16.6.08
95
D
Q:\Zeichnungen\7067e00.idw
6
A3
Blatt
1
A
B
C
D
Measurements
B. Measurements
B.1 Hole pattern
Fig. B.1-1: Hole pattern
Page 145
87
Measurements
Intentionally Blank
Page 146
Panel Generator Control P6+ RE0703_Kunde_eng.R01 - Chapter B: Measurements
16.6.08
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