Marine Generator Manual

Marine Generator Manual
Panda 5000i.Neo PMS
Super silent technology
230 V 50 Hz 5 kVA
120 V 60 Hz 5 kVA
110 V 60 Hz 5 kVA
Panda_5000i.Neo_PMS_eng.R03
13.4.17
Current revision status
Document
Actual:
Panda_5000i.Neo_PMS_eng.R03_13.4.17
Replace:
Panda_5000i.Neo_PMS_eng.R02
Revision
Page
120 V 60 Hz eingepflegt
110 V 60 Hz eingepflegt R03
Erstellt durch / created by
Fischer Panda GmbH - Leiter Technische Dokumentation
Otto-Hahn-Str. 32-34
33104 Paderborn - Germany
Tel.: +49 (0) 5254-9202-0
email: [email protected]
web: www.fischerpanda.de
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 of doubt.
Seite/Page 2 - Kaptitel/Chapter 1:
13.4.17
Inhalt / Contens
Marine Generator Manual ............................................................................................................................ ....... 1
Current revision status................................................................................................................................ ....... 2
3 General Instructions and Regulations .................................................................................................. ..... 10
3.1
Safety first!...................................................................................................................................... .... 10
3.2
Tools ............................................................................................................................................... .... 12
3.4
Customer registration and guarantee ............................................................................................. .... 14
3.4.1
Technical support ........................................................................................................... .... 14
3.4.2
Caution, important information for start-up! .................................................................... .... 14
3.5.1
Safe operation ................................................................................................................ .... 15
3.5.2
Observe safety instructions! ........................................................................................... .... 15
3.5.3
Personal protective clothing (PPE) ................................................................................. .... 15
3.5.4
Cleanliness ensures safety ............................................................................................. .... 15
3.5.6
Exhaust fumes and fire protection .................................................................................. .... 16
3.5.8
Protect your hands and body from rotating parts! .......................................................... .... 17
3.5.9
Anti-freeze and disposal of fluids .................................................................................... .... 17
3.6
Warning and instruction signs......................................................................................................... .... 18
3.6.1
Special instructions and hazards of generators .............................................................. .... 18
3.6.1.2 Protective conductor for Panda AC generators:............................................... .... 19
3.6.1.3 Switch off all loads while working on the generator ......................................... .... 19
3.6.1.4 Potential equalisation for Panda AGT DC generators...................................... .... 19
3.6.2
General safety instructions for handling batteries .......................................................... .... 20
4 In case of Emergency First Aid / Im Notfall - Erste Hilfe ..................................................................... ..... 21
5 Basics ...................................................................................................................................................... ..... 23
5.1
Intended use of the machine .......................................................................................................... .... 23
5.2
Purpose of the manual and description of the definitions of the trained persons/operators/users . .... 23
5.2.1
Trained persons .............................................................................................................. .... 23
5.2.2
Operator/Owner .............................................................................................................. .... 23
5.2.3
User ................................................................................................................................ .... 24
5.3
Components of the i-system ........................................................................................................... .... 24
5.4
Panda transport box ....................................................................................................................... .... 25
5.4.1
Bolted Fischer Panda transport box ............................................................................... .... 25
5.4.2
Fischer Panda transport box with metal tab closure ....................................................... .... 26
5.5
Opening the GFK sound insulation capsule ................................................................................... .... 26
5.6
Transport and loading/unloading .................................................................................................... .... 26
5.6.1
Transporting the generator ............................................................................................. .... 26
5.6.2
Loading/unloading of the generator ................................................................................ .... 27
5.7
Special service instructions and measures for extended machine downtimes and decommissioning 27
5.7.1
Instructions for the starter battery for extended downtimes ............................................ .... 27
5.7.2
Measures for short downtimes ....................................................................................... .... 28
5.7.3
Measures for medium term downtimes / hibernation ...................................................... .... 28
5.7.3.1 Courses for preservation:................................................................................. .... 28
5.7.3.2 Measures for removing surface protection after medium term downtimes (3 to 6
months). 29
5.7.4
Measures for extended downtimes / decommissioning .................................................. .... 29
5.7.4.1 Courses for preservation:................................................................................. .... 29
5.7.4.2 Measures for removing surface protection after extended downtimes / recommissioning
(over 6 months): 30
13.4.17
Inhalt/Contens
Seite/Page 3
Inhalt / Contens
6
Panda 5000i PMS generator .................................................................................................................. ..... 33
6.1
Type plate at the generator ............................................................................................................. .... 33
6.1.1
6.1.2
6.1.3
6.1.4
Right Side View .............................................................................................................. ....
Left Side View ................................................................................................................. ....
Front View ....................................................................................................................... ....
Back View ....................................................................................................................... ....
34
35
36
37
6.2
Details of function units ................................................................................................................... .... 38
6.2.1
The Panda iControl2 panel ............................................................................................. .... 38
6.2.2
Components of the Cooling System ............................................................................... .... 39
6.2.3
Components of the Fuel System .................................................................................... .... 40
6.2.4
Components of the Electrical System ............................................................................. .... 41
6.2.5
Components of the Oil Circuit ......................................................................................... .... 42
6.2.6
Sensors and switches for operating surveillance ............................................................ .... 42
6.3
Operation Instructions - see separate iControl panel manual ......................................................... .... 44
6.3.1
Daily routine checks before starting - See iControl manual. ........................................... .... 44
6.3.2
Starting Generator - See iControl manual. ..................................................................... .... 44
6.3.3
Stopping the Generator - See iControl manual. .............................................................. .... 44
7 Installation Instructions.......................................................................................................................... ..... 45
7.1
Personal requirements .................................................................................................................... .... 45
7.1.1
Hazard notes for the installation ..................................................................................... .... 45
7.2
Place of installation ......................................................................................................................... .... 47
7.2.1
Preliminary remark .......................................................................................................... .... 47
7.2.2
Preparing the base - placement ...................................................................................... .... 47
7.2.3
Advice for optimal sound insulation ................................................................................ .... 48
7.3
Generator Connections ................................................................................................................... .... 48
7.4
Installation of the cooling system - raw water ................................................................................. .... 49
7.4.1
General information ........................................................................................................ .... 49
7.4.2
Installation of the through hull fitting in Yachts - scheme ................................................ .... 49
7.4.3
Quality of the raw water sucking in line .......................................................................... .... 49
7.4.4
Generator installation above waterline ........................................................................... .... 50
7.4.5
Generator installation below waterline ............................................................................ .... 50
7.4.5.1 Raw water installation scheme ......................................................................... .... 51
7.4.6
First filling and ventilation of the internal cooling water circuit ........................................ .... 52
7.4.6.1 Anti-freeze in the cooling water circuit.............................................................. .... 53
7.4.7
Temperature check for controlling the cooling water circuit ............................................ .... 53
7.5.1
Installation of the standard exhaust system .................................................................... .... 54
7.6
.Installation of the waterlock............................................................................................................ .... 54
7.6.1
Possible cause for water in the exhaust hose ................................................................ .... 55
7.6.1.1 Possible cause: exhaust hose .......................................................................... .... 55
7.6.1.2 Possible cause: cooling water hose ................................................................. .... 55
7.6.2
Installation area of the waterlock .................................................................................... .... 55
7.6.3
The volume of the waterlock ........................................................................................... .... 56
7.6.3.1 Ideal position of the waterlock .......................................................................... .... 56
7.6.3.2 Example of the installation of the waterlock off-center and possible effects: ... .... 58
7.7
Exhaust / water separator ............................................................................................................... .... 59
7.8
Installation exhaust water separator ............................................................................................... .... 60
7.9
Fuel system installation................................................................................................................... .... 61
Seite/Page 4
Inhalt/Contens
13.4.17
Inhalt / Contens
7.9.1
7.9.2
7.9.3
The following items need to be installed: ........................................................................ .... 61
Connection of the fuel lines at the tank .......................................................................... .... 62
Position of the pre-filter with water separator ................................................................. .... 63
7.11 Generator DC system installation ................................................................................................... .... 64
7.11.1 Connection of the starter battery block ........................................................................... .... 64
7.11.2 Connection of the remote control panel - See Panda iControl panel manual ................. .... 67
7.11.3 Installation of the iControl panel - See iControl Manual ................................................. .... 67
7.12 Generator AC System Installation .................................................................................................. .... 67
7.12.1 Installation PMGi inverter - See separate PMGi 5000 inverter manual .......................... .... 68
7.12.2 Power source selector .................................................................................................... .... 68
7.13 Checking and filling of the oil circuit................................................................................................ .... 70
7.14 Isolation test.................................................................................................................................... .... 70
7.15 Initial operation ............................................................................................................................... .... 70
8 Maintenance Instructions....................................................................................................................... ..... 71
8.1
Personal requirements.................................................................................................................... .... 71
8.2
Personal requirements.................................................................................................................... .... 71
8.3
Hazard notes for the maintenance and failure................................................................................ .... 71
8.4
Environmental protection ................................................................................................................ .... 73
8.5
General maintenance instructions .................................................................................................. .... 73
8.5.1
Maintenance parts .......................................................................................................... .... 73
8.5.2
Checks before each start ................................................................................................ .... 74
8.6
Maintenance interval....................................................................................................................... .... 74
8.6.1
Check of Hoses and Rubber Parts in the sound insulated capsule ................................ .... 74
8.7
Oil Change Intervals ....................................................................................................................... .... 74
8.8
Checking oil-level............................................................................................................................ .... 74
8.8.1
Refilling oil ...................................................................................................................... .... 75
8.8.2
After the oil level check and refilling the oil ..................................................................... .... 76
8.9
Replacement of engine oil and engine oil filter ............................................................................... .... 76
8.9.1
After the oil change ........................................................................................................ .... 78
8.10 Verifying the starter battery and (if necessary) the battery bank .................................................... .... 78
8.10.1 Battery ............................................................................................................................ .... 78
8.10.1.1 Check battery and cable connections .............................................................. .... 78
8.11.1 Exchange of the Fuel Filter ............................................................................................. .... 79
8.11.2 De-aerating the fuel system ............................................................................................ .... 79
8.11.3 Replacement of the air filter ............................................................................................ .... 80
8.12 De-aerating of the coolant circuit / freshwater ................................................................................ .... 81
8.13 The raw water circuit....................................................................................................................... .... 81
8.13.1 Clean raw water filter ...................................................................................................... .... 81
8.13.2 Causes with frequent impeller waste .............................................................................. .... 81
8.13.3 Replacement of the impeller ........................................................................................... .... 82
9 Generator Tables .................................................................................................................................... ..... 85
9.1
Diameter of conduits....................................................................................................................... .... 85
9.2
Technical Data................................................................................................................................ .... 85
9.4
Engine oil ........................................................................................................................................ .... 86
9.4.1
Engine oil classification .................................................................................................. .... 86
13.4.17
Inhalt/Contens
Seite/Page 5
Inhalt / Contens
9.5
Fuel ................................................................................................................................................. .... 86
9.6
Coolant specifications ..................................................................................................................... .... 86
9.6.1
Coolant mixture ratio ....................................................................................................... .... 87
10 Inverter Panda PMGi 5000 ..................................................................................................................... ..... 89
10.1 Safety instruction ............................................................................................................................ .... 90
10.2 Type plate ....................................................................................................................................... .... 90
10.3 Front side/connection side .............................................................................................................. .... 92
10.3.1 Socket pins of the PMGi 5000 ........................................................................................ .... 93
10.4 Back side - Top side ....................................................................................................................... .... 94
10.5.1 Settings in the Victron VE Configure II Software - General ............................................ .... 95
10.5.1.1 Uninterrupted AC power (UPS function) .......................................................... .... 95
10.5.1.2 Dynamic current limiter..................................................................................... .... 95
10.5.2 Settings in the Victron VE Configure II Software - Inverter ............................................. .... 96
10.5.2.1 Assist current boost factor ................................................................................ .... 96
10.6.1 Primary remarks / Winter operation ................................................................................ .... 97
10.6.2 Load at the PMGi ............................................................................................................ .... 97
10.6.3 Automatic start ................................................................................................................ .... 97
10.7 Status LED´s ................................................................................................................................... .... 97
10.8 Cooling of the PMGi ........................................................................................................................ .... 97
10.9.1 Electrical connection. ...................................................................................................... .... 98
10.9.1.1 Connection to a system with RCD.................................................................... .... 98
10.9.1.2 Connection to a system with isolation control .................................................. .... 99
10.10 Technical data................................................................................................................................. .... 99
10.10.1 General data ................................................................................................................... .... 99
10.10.2 Generator spezification ................................................................................................... .... 99
10.10.4 Overload - switch point ................................................................................................... .. 101
10.10.5 Short circiut ..................................................................................................................... .. 101
Panda iControl2............................................................................................................................................ ... 103
Current revision status ................................................................................................................................ ... 104
Hardware ....................................................................................................................................................... ... 104
11 Safety instructions for the Panda iControl2 ......................................................................................... ... 105
11.1 Personnel ........................................................................................................................................ .. 105
11.2 Safety instructions........................................................................................................................... .. 105
12 General operation ................................................................................................................................... ... 107
12.1 The Panda iControl2 panel ............................................................................................................. .. 107
12.2 Starting preparation / Checks (daily)............................................................................................... .. 108
12.2.1 Marine version ................................................................................................................ .. 108
12.2.2 Vehicle version ............................................................................................................... .. 108
12.3 Operation ........................................................................................................................................ .. 109
12.3.1 Switching the controller on and off .................................................................................. .. 109
12.3.2 The default display screen .............................................................................................. .. 109
12.3.3 Operating modes ............................................................................................................ .. 110
12.3.3.1 Stand-by mode ................................................................................................. .. 110
12.3.3.2 Start-up mode................................................................................................... .. 111
12.3.3.3 Override mode.................................................................................................. .. 112
12.3.3.4 Operation mode................................................................................................ .. 112
Seite/Page 6
Inhalt/Contens
13.4.17
Inhalt / Contens
12.4.1
12.4.3
12.4.4
12.4.5
12.4.6
12.4.7
12.4.8
12.4.9
12.3.3.5 Panda i-Generator with electro-magnet Clutch (optional) ................................ ..
12.3.3.7 Autostart mode................................................................................................. ..
Set-up menu ................................................................................................................... ..
The configuration menu ("config") .................................................................................. ..
The network ID ............................................................................................................... ..
Saving settings and exiting the set-up menu ("Save & Exit") ......................................... ..
Activating/deactivating the autostart function ("Autostart") ............................................. ..
Resetting the service interval ("Service") ....................................................................... ..
Priming the fuel system ("Prime Fuel") ........................................................................... ..
Selecting and saving a unit for the temperature value output ........................................ ..
114
115
117
119
119
119
119
121
122
122
13 Installation ............................................................................................................................................... ... 125
13.1 Personnel........................................................................................................................................ .. 125
13.1.1 Hazard warnings for installation ..................................................................................... .. 125
13.2 Disposal of the components ........................................................................................................... .. 126
13.2.1 Panda iControl2 panel with installation housing ............................................................. .. 127
13.2.2 Terminal assignments on the Panda iControl2 panel ..................................................... .. 127
13.3 Dimensions ..................................................................................................................................... .. 128
13.4 Wiring of the Panda iControl2 controller ......................................................................................... .. 129
13.4.1 Terminal assignments on the Panda iControl2 controller ............................................... .. 130
13.4.1.1 Terminal assignment of 18-pin connector ........................................................ .. 130
13.4.1.2 Fischer Panda standard bus ............................................................................ .. 130
13.4.1.3 Fischer Panda CAN bus................................................................................... .. 130
13.5 Master and Slave Panels................................................................................................................ .. 131
14 Maintenance ............................................................................................................................................ ... 133
14.1 Maintenance of the iControl2 controller .......................................................................................... .. 133
14.1.1 Cleaning the iControl2 controller .................................................................................... .. 133
14.2 Maintenance of the iControl2 remote control panel ........................................................................ .. 133
14.2.1 Cleaning the iControl2 controller .................................................................................... .. 133
15 Annex ....................................................................................................................................................... ... 135
15.1 Technical data ................................................................................................................................ .. 135
15.1.1 Technical data for iControl2 control unit ......................................................................... .. 135
15.1.2 Technical data for iControl2 remote control panel .......................................................... .. 135
16 Warnings and error messages .............................................................................................................. ... 137
16.1 Warnings......................................................................................................................................... .. 137
16.1.1 Examples of warnings on the display: ............................................................................ .. 137
16.2 Faults .............................................................................................................................................. .. 138
16.2.2 Warning and fault thresholds .......................................................................................... .. 139
16.2.3 Bus errors ....................................................................................................................... .. 141
16.3 The error memory of the iControl 2 Panel ...................................................................................... .. 141
16.3.1 How to get to the error memory of the iControl2 Panel? ................................................ .. 141
16.3.2 How are stored errors displayed? ................................................................................... .. 141
16.3.3 How do I exit the error memory after having read the entries? ...................................... .. 142
16.3.4 Can I delete the error memory? ...................................................................................... .. 142
16.3.5 Where are the errors stored? ......................................................................................... .. 142
16.3.6 In which language are the stored errors displayed? ....................................................... .. 142
16.3.7 Is it possible to upgrade an old iGenerator model by the error memory? ....................... .. 142
13.4.17
Inhalt/Contens
Seite/Page 7
Inhalt / Contens
Seite/Page 8
Inhalt/Contens
13.4.17
Dear Customer,
Thank you for purchasing a Fischer Panda Generator and choosing Fischer Panda as your partner for mobile power
on board. With your generator, you now have the means to produce your own power – wherever you are - and
experience even greater independence. Not only do you have a Fischer Panda generator on board, you also have
worldwide support from the Fischer Panda Team. Please take the time to read this and find how we can support you
further.
Installation Approval and Warranty
Every generator has a worldwide warranty. You can apply for this warranty through your dealer when the installation
is approved. If you have purchased an extended warranty, please ensure that it is kept in a safe place and that the
dealer has your current address. Consult your dealer about warranty options especially if you have purchased a
used generator. He will be able to advise about authorised Fischer Panda Services worldwide.
Service and Support
To ensure that your generator operates reliably, regular maintenance checks and tasks as specified in this manual
must be carried out. Fischer Panda can supply Service Kits which are ideal for regular servicing tasks. We only
supply the highest quality components which are guaranteed to be the RIGHT parts for your generator. Service
“Plus” Kits are also available and ideal for longer trips where more than one service interval may be required.
If you require assistance – please contact your Fischer Panda Dealer. Please do not attempt to undertake any repair
work yourself, as this may affect your generator warranty. Your dealer will also be able to assist in finding your
nearest Fischer Panda service station. Your nearest service station can also be found in our Global Service Network
which can be downloaded from our homepage.
Product Registration
Please take the time to register your Fischer Panda Generator on our website at
http://www.fischerpanda.de/mypanda
By registering, you will ensure that you will be kept up to date on any technical upgrades or specific information on
the operation or servicing of your generator. We can even let you know about new Fischer Panda products –
especially helpful if you are planning to upgrade or expand your installation at a later date.
Fischer Panda Quality - Tried and Tested
DIN-certified according DIN ISO 9001
Thank you for purchasing a Fischer Panda Generator.
Your Fischer Panda Team
13.4.17
Kapitel/Chapter 3:
- Seite/Page 9
General Instructions and Regulations
3. General Instructions and Regulations
3.1
Safety first!
These symbols are used throughout this manual and on labels on the machine itself to warn of the possibility of
personal injury of lethal danger during certain maintenance work or operations. Read these instructions carefully.
Can cause acute or chronic health impairments or death
even in very small quantities if inhaled, swallowed, or
absorbed through the skin.
WARNING: Hazardous materials
This warning symbol draws attention to special warnings,
instructions or procedures which, if not strictly observed, may
result in damage or destruction of equipment.
WARNING: Important information!
Warning of materials that may ignite in the presence of an
ignition source (cigarettes, hot surfaces, sparks, etc.).
WARNING: Fire hazard
In the environment described / during the work specified,
smoking is prohibited.
PROHIBITED: No smoking
Fire and naked light are ignition sources that must be
avoided.
PROHIBITED: No fire or naked light
The equipment shall not be activated or started up while work
is in progress.
PROHIBITED: Do not activate/start up
Touching of the corresponding parts and systems is
prohibited.
PROHIBITED: Do not touch
Danger for life! Working at a running generator can
result in severe personal injury.
DANGER: Automatic start-up
The generator can be equipped with a automatic start device.
This means, an external signal may trigger an automatic
start-up. To avoid an unexpected starting of the generator,
the starter battery must be disconnected before working at
the generator.
This danger symbol refers to the danger of electric shock and
draws attention to special warnings, instructions or
procedures which, if not strictly observed, may result in
severe personal injury or loss of life due to electric shock.
Seite/Page 10 - Kaptitel/Chapter 3: General Instructions and Regulations
WARNING: Hazardous electric voltage
13.4.17
General Instructions and Regulations
General warning of a hazard area
WARNING: General warning
Can cause acute or chronic health impairments or death
even in very small quantities if inhaled or ingested.
WARNING: Danger due to inhalation and/or
ingestion
Warning of live parts that may cause electric shock upon
contact. Especially dangerous for persons with heart
problems or pacemakers.
WARNING: Risk of electric shock upon contact
Danger of injury due to being pulled into equipment. Bruising
and torn off body parts possible. Risk of being pulled in when
touching with body part, loose-fitting clothing, scarf, tie, etc.
WARNING: Danger due to rotating parts
Warning of substances that may cause an explosion under
certain conditions, e.g. presence of heat or ignition sources.
WARNING: Explosion hazard
Warning of hot surfaces and liquids. Burn/scalding hazard.
WARNING: Hot surface
Warning of substances that cause chemical burns upon
contact. These substances can act as contaminants if
introduced into the body.
WARNING: Danger due to corrosive substances,
potential contamination of person
When the system is opened, the pressure can be relieved
abruptly and expel hot gases and fluids. Risk of injury due to
parts flying about, burn hazard due to liquids and gases.
WARNING: System may be pressurised!
Warning of hearing damages.
WARNING: Hearing damage
Warning of magnetic field.
WARNING: Magnetic field
Warning of overpressure.
WARNING: Overpressure
13.4.17
Kapitel/Chapter 3: General Instructions and Regulations - Seite/Page 11
General Instructions and Regulations
Wearing the applicable snugly fitting protective clothing
provides protection from hazards and can prevent damage to
your health.
MANDATORY INSTRUCTION: Wear snugly fitting
protective clothing (PPE).
Wearing hearing protection provides protection from acute
and gradual hearing loss.
MANDATORY INSTRUCTION: Wear hearing
protection (PPE).
Wearing safety goggles protects the eyes from damage.
Optical spectacles are not a replacement for the
corresponding safety goggles.
M A N D ATO RY I N S T R U C T I O N : We a r s a f e t y
goggles (PPE).
Wearing protective gloves provides the hands from hazards
like friction, graze, punctures or deep cuts and protects them
from contact with hot surfaces.
MANDATORY INSTRUCTION: Wear protective
gloves (PPE).
Compliance with the instructions in the manual can avert
danger and prevent accidents. This will protect you and the
generator.
M A N D ATO RY I N S T R U C T I O N : O b s e r v e t h e
instructions in the manual.
Environmental protection saves our living environment. For
you and for your children.
MANDATORY INSTRUCTION: Comply with
environmental protection requirements.
3.2
Tools
These symbols are used throughout this manual to show which tool must be used for maintenance or installation.
Spanners
W.A.F X = width across flats of X mm
Hook wrench for oil filter
Screw driver, for slotted head screws and for Phillips head screws
Multimeter, multimeter with capacitor measuring unit
Seite/Page 12 - Kaptitel/Chapter 3: General Instructions and Regulations
13.4.17
General Instructions and Regulations
Socket wrench set
Hexagon socket wrench set
Clamp-on ammeter (DC for synchronous generators; AC for asynchronous
generators)
Torque wrench
13.4.17
Kapitel/Chapter 3: General Instructions and Regulations - Seite/Page 13
General Instructions and Regulations
3.3
Manufacturer declaration in accordance with the Machinery Directive
2006/42/EC
Manufacturer declaration in accordance with the Machinery Directive 2006/42/EC
The generator was designed in such a way that all assemblies correspond with the CE guidelines. If Machinery
Directive 2006/42/EC 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 complies with the Machinery Directive 2006/42/EC. This
includes the exhaust system, cooling system and electrical installations.
The evaluation of “protection against contact“ must be carried out when installed, in conjunction with the respective
system. This also includes correct electrical connections, a safe ground wire connection, foreign body and humidity
protection, protection against moisture due to excessive condensation, as well as overheating through appropriate
and inappropriate use of the equipment in its installed state. The responsibility for implementing these measures lies
with those who undertake the installation of the generator in the final system.
3.4
Customer registration and guarantee
Use the advantages of registering your product:
• you will receive a Guarantee Certificate after approval of your installation data
• you will receive extended product information that may be relevant to safety.
• You will receive free upgrades as necessary.
Additional advantages:
Based on your complete data record, Fischer Panda technicians can provide you with fast assistance, since 90 % of
the disturbances result from defects in the periphery.
Problems due to installation errors can be recognized in advance.
3.4.1 Technical support
Technical Support via the Internet:
[email protected]
3.4.2 Caution, important information for start-up!
1. The commissioning log shall be filled in immediately after initial operation and shall be confirmed by signature.
2. The commissioning log must be received by Fischer Panda GmbH at Paderborn within 4 weeks of initial
operation.
3. After receiving the commissioning log, Fischer Panda will make out the official guarantee certificate and send it to
the customer.
4. If warranty claims are made, the document with the guarantee certification must be submitted.
If the above requirements are not or only partly fulfilled, the warranty claim shall become void.
Seite/Page 14 - Kaptitel/Chapter 3: General Instructions and Regulations
13.4.17
General Instructions and Regulations
3.5
Safety Instructions - Safety First!
3.5.1 Safe operation
Careful handling of the equipment is the best insurance against an accident. Read the manual diligently,
and make sure you understand it before starting up the equipment. All operators, regardless of their
experience level, shall read this manual and additional pertinent manuals before commissioning the
equipment or installing an attachment. The owner shall be responsible for ensuring that all operators
receive this information and are instructed on safe handling practices.
3.5.2 Observe safety instructions!
Read and understand this manual and the safety instructions on the generator before trying to start up and operate
the generator. Learn the operating practices and ensure work safety. Familiarise yourself with the equipment and its
limits. Keep the generator in good condition.
3.5.3 Personal protective clothing (PPE)
For maintenance and repair work on the equipment, do not wear loose, torn, or ill-fitting clothing that may
catch on protruding parts or come into contact with pulleys, cooling disks, or other rotating parts, which can
cause severe injury.
Wear appropriate safety and protective clothing during work.
Do not operate the generator while under the influence of alcohol, medications, or drugs.
Do not wear head phones or ear buds while operating, servicing, or repairing the equipment.
3.5.4 Cleanliness ensures safety
Keep the generator and its environment clean.
Before cleaning the generator, shut down the equipment and secure it against accidental start-up. Keep
the generator free from dirt, grease, and waste. Store flammable liquids in suitable containers only and
ensure adequate distance to the generator. Check the lines regularly for leakage and eliminate leaks
immediately as applicable.
13.4.17
Kapitel/Chapter 3: General Instructions and Regulations - Seite/Page 15
General Instructions and Regulations
3.5.5 Safe handling of fuels and lubricants
Keep fuels and lubricants away from naked fire.
Before filling up the tank and/or applying lubricant, always shut down the generator and secure it against
accidental start-up.
Do not smoke and avoid naked flame and sparking near fuels and the generator. Fuel is highly flammable
and may explode under certain conditions.
Refuel in well-ventilated open spaces only. If fuel/lubricant was spilled, eliminate fluids immediately.
Do not mix diesel fuel with petrol or alcohol. Such a mixture can cause fire and will damage the generator.
Use only approved fuel containers and tank systems. Old bottles and canisters are not adequate.
3.5.6 Exhaust fumes and fire protection
Engine fumes can be hazardous to your health if they accumulate. Ensure that the generator exhaust
fumes are vented appropriately (leak-proof system), and that an adequate fresh air supply is available for
the generator and the operator (forced ventilation).
Check the system regularly for leakage and eliminate leaks as applicable.
Exhaust gases and parts containing such fumes are very hot; they may cause burns under certain circumstances.
Always keep flammable parts away from the generator and the exhaust system.
To prevent fire, ensure that electrical connections are not short-circuited. Check regularly that all lines
and cables are in good condition and that there is no chafing. Bare wires, open chafing spots, frayed
insulation, and loose cable connections can cause dangerous electric shocks, short-circuit, and fire.
The generator shall be integrated in the existing fire safety system by the operating company.
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.
Seite/Page 16 - Kaptitel/Chapter 3: General Instructions and Regulations
13.4.17
General Instructions and Regulations
3.5.7 Safety precautions against burns and battery explosions
The generator and its cooling agents and lubricants as well as the fuel can get hot while the generator is
operated. Use caution around hot components such as parts containing exhaust fumes, radiator, hoses,
and engine block during operation and after the generator was shut down.
The cooling system may be pressurised. Open the cooling system only after letting the engine and the
coolant cool down. Wear appropriate protective clothing (e.g. safety goggles, gloves).
Prior to operation, ensure that the cooling system is sealed and that all hose clamps are tightened.
The battery represents an explosion hazard, this applies both to the starter battery and the battery bank
of the AGT generators. While batteries are being charged, a hydrogen-oxygen mixture is generated,
which is highly explosive (electrolytic gas).
Do not use or charge batteries if the fluid level is below the MINIMUM marking. The life span of the
battery is significantly reduced, and the risk of explosion increases. Refill to a fluid level between maximum and
minimum level without delay.
Especially during charging, keep sparks and naked fire away from the batteries. Ensure that the battery
terminals are tightly connected and not corroded to avoid sparking. Use an appropriate terminal grease.
Check the charge level with an adequate voltmeter or acid siphon. Contact of a metal object across the
terminals will result in short-circuiting, battery damage, and high explosion risk.
Do not charge frozen batteries. Heat the batteries to +16 °C (61 °F) prior to charging.
3.5.8 Protect your hands and body from rotating parts!
Always keep the capsule closed while operating the generator.
To check the V-belt tension, always shut down the generator.
Keep your hands and body away from rotating parts such as V-belt, fans, pulleys, and flywheel. Contact
can cause severe injury.
Do not run the engine without the safety devices in place. Prior to start-up, mount all safety devices securely and
check for proper attachment and function.
3.5.9 Anti-freeze and disposal of fluids
Anti-freeze contains toxic substances. To prevent injury, wear rubber gloves and wash off any anti-freeze
immediately in case of skin contact. Do not mix different anti-freeze agents. The mixture may cause a
chemical reaction generating harmful substances. Use only anti-freeze that was approved by Fischer
Panda.
Protect the environment. Collect drained fluids (lubricants, anti-freeze, fuel), and dispose of them
properly. Observe the local regulations for the respective country. Ensure that no fluids (not even very
small quantities) can drain into the soil, sewers, or bodies of water.
13.4.17
Kapitel/Chapter 3: General Instructions and Regulations - Seite/Page 17
General Instructions and Regulations
3.5.10 Implementation of safety inspections and maintenance
Disconnect the battery from the engine before performing service work. Affix a sign to the control panel both the main and the corresponding slave panel - with the instruction “DO NOT START UP MAINTENANCE IN PROGRESS“ to prevent unintentional start-up.
To prevent sparking due to accidental short-circuiting, always remove the earthing cable (-) first and
reconnect it last. Do not start work until the generator and all fluids and exhaust system parts have cooled down.
Use only suitable tooling and appliances and familiarise yourself with their functions to prevent secondary
damage and/or injury.
Always keep a fire extinguisher and a first aid box handy while performing maintenance work.
3.6
Warning and instruction signs
Keep warning and instruction signs clean and legible.
Clean the signs with water and soap and dry them with a soft cloth.
Immediately replace damaged or missing warning and instruction signs. This also applies to the installation of spare
parts.
3.6.1 Special instructions and hazards of generators
The electrical installations may only be carried out by trained and qualified personnel!
The generator must not be operated with the cover removed.
If the generator is being installed without a sound insulation capsule, it must be ensured that all rotating
parts (belt-pulley, 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 easily visible signs must
show that the generator must only be switched on while the capsule is closed.
All servicing, maintenance, or repair work may only be carried out when the motor is not running.
Electrical voltages above 50 volts are always dangerous to life. The rules of the respective regional
authority must be adhered to during installation. For safety reasons, only an electrician may carry out the installation
of the electrical connections of the generator.
Seite/Page 18 - Kaptitel/Chapter 3: General Instructions and Regulations
13.4.17
General Instructions and Regulations
3.6.1.1 Protective conductor and potential equalisation:
Electric voltage above 50 V may be life-threatening. Fort this reason systems are grounded with a protective
conductor. In connection with a RCD the current supply will be disconnected in case of a failure.
Appropriate safety precautions like the RCD and corresponding fuses have to be provided by the customer
to guarantee a save operation of the generator.
3.6.1.2 Protective conductor for Panda AC generators:
The generator is earthed“ as a standard (centre and ground are interconnected in the generator terminal
box by a shunt). This is a basic first-level safety measure, which offers protection as long as no other
measures are installed. Above all, it is designed for delivery and a possible test run.
This „neutralisation“ (Protective Earthing Neutral - PEN) is only effective if all parts of the electrical
system are jointly „earthed“ to a common potential. The shunt can be removed if this is necessary for technical
reasons and another protective system has been set up instead.
While the generator is being operated, the full voltage is applied to the AC control box, as well.
Therefore, it is essential to ensure that the control box is closed and secured against touch while
the generator is running.
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 started up unintentionally.
3.6.1.3 Switch off all loads while working on the generator
All loads must be disconnected prior to working on the generator to avoid damage to the devices. In addition, the
semiconductor relays in the AC control box must be disconnected in order to avoid the booster capacitors being
activated during set-up. The negative terminal of the battery must be disconnected.
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 store electrical energy. High voltages may remain across the capacitor contacts even after they have
been disconnected from the mains. As a safety precaution, do not touch the contacts. If the capacitors must be
replaced or inspected, the contacts shall be short-circuited by connecting an electrical conductor to discharge
potentially remaining potential differences.
If the generator is switched off normally, the working capacitors are automatically discharged via the winding of the
generator. The booster capacitors are discharged by means of internal discharge resistors.
For safety reasons, all capacitors must be discharged through short-circuiting before work is carried out on the AC
control box.
3.6.1.4 Potential equalisation for Panda AGT DC generators
For further information specific to your generator, see the chapter installation.
13.4.17
Kapitel/Chapter 3: General Instructions and Regulations - Seite/Page 19
General Instructions and Regulations
3.6.1.5 Safety instructions concerning cables
Cable types
It is recommended to use cables that are in compliance with the standard UL 1426 (BC-5W2) with type 3 (ABYC
section E-11).
Cable cross-section
The cable shall be selected taking into account the amperage, cable type, and conductor length (from the positive
power source connection to the electrical device and back to the negative power source connection).
Cable installation
It is recommended to install a self-draining cable conduit classified as V-2 or higher in compliance with UL 94 in the
area of the cable guide inside the capsule. It must be ensured that the cable guide is not routed along hot surfaces
such as the exhaust manifold or the engine oil drain screw but instead is installed free from any influence due to
friction and crushing.
3.6.2 General safety instructions for handling batteries
These instructions shall apply in addition to the instructions of the battery manufacturer:
• While you are working on the batteries, a second person should be within earshot to help you if
necessary.
• Keep water and soap ready in case battery acid is burning your skin.
• Wear eye protection and protective clothing. Do not touch your eyes while handling batteries.
• If you have acid splashes on the skin or clothing, wash them out with lots of water and soap.
• If acid sprays into your eyes, immediately flush them with clean water until no more burning is felt.
Immediately seek medical assistance.
• Do not smoke near the batteries. Avoid naked fire. The area around batteries is a potentially explosive
atmosphere.
• Ensure that no tools are dropped on the battery terminals; cover them as necessary.
• Do not wear jewellery or watches on your arms during installation that might short-circuit the battery.
Otherwise, there is a risk of skin burns.
• Protect all battery contacts against accidental contact.
• For battery banks: Use only deep cycle batteries. Starter batteries are not suitable. Lead-acid gel batteries
are recommended. They are maintenance-free, cycle stable, and do not release gases.
• Never charge a frozen battery.
• Avoid battery short-circuits.
• Ensure proper ventilation of the battery to vent gases that may be released.
• Battery connection terminals must be checked for proper seating before operation.
• Battery connection cables shall be installed with utmost care and shall be checked for excessive heating
under load. Check the battery near vibrating components regularly for chafing and insulation defects.
ATTENTION! For battery charger generators (Fischer Panda AGT-DC)!
Prior to installation, verify that the voltage of the battery bank complies with the output voltage of
the generator.
Seite/Page 20 - Kaptitel/Chapter 3: General Instructions and Regulations
13.4.17
In case of Emergency First Aid / Im Notfall Erste Hilfe
4. In case of Emergency First Aid / Im Notfall - Erste Hilfe
First Aid in case of accidents by electrical shocks
5 Safety steps to follow if someone is the victim of electrical shock
Do not touch the injured person while the generator is running.
1
Switch off the generator immediately.
12
13
If you cannot switch off the generator, pull, push, or lift the person to safety using a
wooden pole, rope or some nonconducting material.
Call an emergency doctor as soon as possible.
14
Immediately start necessary first aid procedures.
15
13.4.17
Kapitel/Chapter 4: In case of Emergency First Aid / Im Notfall - Erste Hilfe - Seite/Page 21
In case of Emergency First Aid / Im Notfall Erste Hilfe
4.1
WHEN AN ADULT STOPS BREATHING
DO NOT attempt to perform the rescue breathing
techniques provided on this page, unless certified.
Performance of these techniques by uncertified
personnel could result in further injury or death to the
victim.
Warning:
1
Does the Person Respond?
Tap or gently shake victim.
Shout, “Are you OK?“
2
Shout, “Help!“
Call people who can phone for help.
3
Roll Person onto Back.
Roll victim towards you by pulling slowly.
4
Open Airway.
Tilt head back, and lift chin.
Shout, “Are you OK?“
5
Check for Breathing.
Look, listen, and feel for breathing for 3 to 5
seconds.
6
Give 2 Full Breaths.
Keep head tilted back.
Pinch nose shut.
Seal your lips tight around victim's mouth.
Give 2 full breaths for 1 to 1½ seconds each.
Check for Pulse at side of Neck.
Feel for pulse for 5 to 10 seconds.
7
Phone EMS for Help.
Send someone to call an ambulance.
9
Recheck Pulse Every Minute.
Keep head tilted back.
Feel for pulse for 5 to 10 seconds.
If victim has pulse, not breathing, continue
rescue breathing. If no pulse, begin CPR.
Begin Rescue Breathing.
Keep head tilted back.
Lift chin.
Pinch nose shut.
Give 1 full breath every 5 seconds.
Look, listen, and feel for breathing between breaths.
Seite/Page 22 - Kaptitel/Chapter 4: In case of Emergency First Aid / Im Notfall - Erste Hilfe
8
10
13.4.17
Basics
5. Basics
5.1
Intended use of the machine
The Fischer Panda generator is made to produce electrical energy out of diesel fuel.
The diesel fuel is converted to mechanical energy by the diesel engine. This mechanical energy drives the
generator. In the genset, the mechanical energy is converted to electrical energy. This process is controlled by
(sometimes external) components, the remote control panel and the voltage control system.
Sufficient amount of fuel and combustion air is necessary for this process. Arising exhaust and heat must be
conducted according to the specification.
If the electrical power is fed to a local net, the regulations and installation instructions of the system operator and the
regional authorities with reference to the power network/shipboard power supply system must be respected. Safety
applications and safety devices (including lightening conductor, personal protection switch, ect.) have to be installed.
Misapplication of the product can damage and destroy the product and the electrical net inclusive all load which is
attached to the net, and contain hazards like short circuit, ect. It is not allowed to modify the product in any case.
Never open the sound cover during operation! The safety and hazard notes of the manual must be respected!
5.2
Purpose of the manual and description of the definitions of the trained
persons/operators/users
This manual contains the working instructions and operating guidelines for the owner and user of Fischer Panda
generators.
The manual is the base and the guideline for the correct installation and maintenance of Fischer Panda generators.
It does not substitute the technical evaluation and should be used as an example guide only. The installation must
be undertaken and proved by a suitable qualified/trained person and should be in accordance with the law as
required by the country and special situation. All work has to be undertaken according to the state of the technology.
5.2.1 Trained persons
Qualified persons for the mechanical components are motor mechanics or persons with similar
qualification and training.
Trained persons for the electrical components are electricians or persons with similar qualification and
training.
After the installation the trained person has to instruct the operator/owner about the operation and maintenance of
the generator. This must include the hazards of the generator use.
5.2.2 Operator/Owner
The operator is responsible for the operation of the generator.
After the installation, the operator/owner must be instructed concerning the operation and maintenance of the
generator. This has to include the hazards during operation of the generator, different operating conditions, and
instructions for the maintenance.
The operator/owner must read and follow the manual and must respect the hazard notes and safety instructions.
13.4.17
Kapitel/Chapter 5: Basics - Seite/Page 23
Basics
5.2.3 User
Users are persons, established by the operator/owner, to operate the generator.
The operator/owner has to ensure that the user has read and understood the manual and that all hazard notes and
safety instructions are respected. The user must be instructed by the operator/owner regarding his activity at the
generator, especially concerning the maintenance.
5.3
Components of the i-system
1. Panda i-generator
Fig. 5.3-1: Panda i generator
Permanent magnet generator
2. Panel Panda iControl with electronic board at the
generator
Seite/Page 24 - Kaptitel/Chapter 5: Basics
Fig. 5.3-2: iControl panel
13.4.17
Basics
3. Panda PMGi inverter AC/AC
4. Fischer Panda manual
Fig. 5.3-3: PMGi inverter
Fig. 5.3-4: Manual
The Fischer Panda manual contains the following
components:
• Transparent sheet with general information, guarantee
conditions, installation inspection, and service list.
• Generator manual
• Spare parts catalogue „Installation & Service Guide“
• Engine manual from the engine manufacturer
• Wiring diagram of the generator
Optional components
Optional components could be for example:
• fuel pump
• installation kits
5.4
Panda transport box
5.4.1 Bolted Fischer Panda transport box
1. Remove the bolts for cover / sidewalls
2. Remove the cover
3. Remove the loose accessories
4. Remove the bolts for sidewalls / floor pallet
5. Remove the sidewalls
6. Open the generator attachment
13.4.17
Kapitel/Chapter 5: Basics - Seite/Page 25
Basics
5.4.2 Fischer Panda transport box with metal tab closure
1. Bend up the metal tab closures on the transport box lid
2. Remove the cover
3. Remove the loose
4. Bend open the metal tab closures at the bottom of the transport box
5. Remove the sidewalls
6. Open the generator attachment
5.5
Opening the GFK sound insulation capsule
GFK sound insulation capsule with lash closures
Fig. 5.5-1: Lash closures
To open the lash closures pull the handle in arrow
direction and lift the lash of the closure pin. After lifting
off the lashes, the sound isolation cover upper part can
be removed.
Fig. 5.5-2: Lash closures
5.6
Transport and loading/unloading
5.6.1 Transporting the generator
• The generator must always be upright for transport.
• For transport, the Fischer Panda transport box shall be used for the generator. The generator shall be securely
attached to the bottom of the box.
Seite/Page 26 - Kaptitel/Chapter 5: Basics
13.4.17
Basics
• For loading/unloading, an adequate industrial truck shall be used.
• Depending on the transport distance (e.g. air cargo), the generator fluids (coolant, engine oil, fuel) may have to be
drained. The corresponding instructions and warnings must be fitted to the transport packaging.
5.6.2 Loading/unloading of the generator
For loading/unloading the generator, appropriate ring eye bolts shall be installed in the holes in the support rails. The
load bearing capacity of each ring eye bolt must at least equal the generator weight.
An adequate lifting yoke shall be used for transport/
loading.
5.7
Fig. 5.6.2-1: Lifting yoke (example)
Special service instructions and measures for extended machine
downtimes and decommissioning
The decommissioning and storage must be undertaken and
proved regarding the operation and storage situation.
Note:
Fischer Panda takes no responsibility for damages
through wrong decommissioning and storage.
Downtimes are categorised in the following groups:
• Short downtime (1 to 3 months)
• Medium term downtime / hibernation (3 to 6 months)
• Extended downtime / decommissioning (more than 6 months)
5.7.1 Instructions for the starter battery for extended downtimes
Starter batteries
Note: Information starter battery
Self-discharge of batteries is a physical and chemical
process and cannot be avoided even if the battery is
disconnected
• For extended downtimes, the battery shall be disconnected from the genset.
• Charge battery regularly. Observe instructions of the battery manufacturer.
Depending on the battery type, check the acid level before charging and refill each cell up to the marking using
distilled water as necessary.
13.4.17
Kapitel/Chapter 5: Basics - Seite/Page 27
Basics
Modern starter batteries are typically maintenance-free.
Deep discharge will damage the battery and can render it unusable.
Keep battery clean and dry. Clean battery poles (+ and -) and terminals regularly and coat with acid-free and acidresistant grease. During assembly, ensure good contact of the terminal connections.
General limits for lead-acid batteries:
2.1 V / cell corresponds with full battery (charged).
1.95 V / cell corresponds with empty battery - recharge.
For a 12 V battery, the following applies:
- 11.7 V lower open-circuit voltage (battery empty), recharge battery.
- 12.6 V upper open-circuit voltage (full battery) - trickle charge full battery at 13.2 V.
For a 24 V battery, the following applies:
- 23.4 V lower open-circuit voltage (battery empty), recharge battery.
- 25.2 V upper open-circuit voltage (full battery) - trickle charge full battery at 26.4 V.
These values are based on a battery temperature of 20-25 °C. Observe the instructions from the battery
manufacturer.
Fischer Panda recommends:
Note: Starter battery recommendation
• Install battery circuit breaker and switch to OFF on the
machine. (Cutting the battery circuit.)
• Secure the battery plus terminal close to the battery.
• Regularly check contacts for corrosion.
5.7.2 Measures for short downtimes
Short downtime (1 to 3 months)
• Measure battery charge status based on open-circuit voltage.
• During downtimes >7 days, disconnect battery (e.g. battery main switch to position 0).
• Check the battery within 2 months and allow the engine to warm up for min. 10 min.
• Fill fuel tank to 100% (level to full).
5.7.3 Measures for medium term downtimes / hibernation
Medium term downtimes (3 to 6 months)
5.7.3.1 Courses for preservation:
• Check battery charge status and recharge regularly, roughly every 2 months, as necessary. Observe instructions
of the battery manufacturer.
• Check cooling water anti-freeze level and refill as necessary.
The anti-freeze agent must not be older than 2 years. The anti-freeze content shall be between 40 % and 60 % to
ensure corrosion protection of the cooling water circuit. Top off coolant if necessary.
If the cooling water is drained, e.g. after engine surface protection is applied, no water may remain inside the
engine during the downtime. The control unit must be marked accordingly with a note specifying “NO COOLING
WATER“.
• Drain engine oil as specified. Refill engine with preservative oil to the max. level on the oil dipstick.
Seite/Page 28 - Kaptitel/Chapter 5: Basics
13.4.17
Basics
• Drain diesel from tank and refill with a protective mixture (90 % diesel and 10 % preservative oil) (level to full).
Crank engine without start.
• Dismount V-belt as specified, wrap and store in a dry location. Protect against UV radiation.
Cover alternator apertures.
Attention!
Cleaning fluids and preservatives must not enter the
alternator. Risk of destroying the alternator.
• Clean engine as per manufacturer's instructions.
• Spray engine parts and V-belt disks with preservative.
• Clean air filter housing and spray with preservative (metal housing only).
• Close off intake and exhaust apertures (e.g. with tape or end caps).
Before recommissioning, remove preservatives and
protective measures.
Attention!
5.7.3.2 Measures for removing surface protection after medium term downtimes (3 to 6
months).
• Check battery charge status and recharge if necessary. Observe instructions of the battery manufacturer.
• Check cooling water anti-freeze level and cooling water level and refill as necessary.
• Drain engine oil. Replace oil filter and engine oil as per the specification.
• Remove preservatives from the engine with petroleum spirit.
• Degrease V-belt disks and mount V-belt according to instructions. Check V-belt tension!
• If applicable, open turbocharger oil pressure line and fill clean engine oil into channel.
• Hold engine stop lever in zero delivery position and crank engine manually several times.
• Clean air filter housing with petroleum spirit, check air filter and replace if necessary.
• Remove covers from exhaust aperture and intake apertures.
• Connect battery. Close battery main switch.
• Hold stop lever on generator motor in neutral position and crank starter for approx. 10 seconds. Then, pause for 10
seconds. Repeat this procedure 2 times.
• Perform visual check of the generator similar to initial commissioning and start up generator.
5.7.4 Measures for extended downtimes / decommissioning
Downtimes (more than 6 months)
5.7.4.1 Courses for preservation:
• Check battery charge status and recharge regularly, roughly every 3 months, as necessary. Observe instructions
of the battery manufacturer.
• Check cooling water anti-freeze level and refill as necessary.
The anti-freeze agent must not be older than 2 years. The anti-freeze content shall be between 40 % and 60 % to
ensure corrosion protection of the cooling water circuit. Top off coolant if necessary.
If the cooling water is drained, e.g. after engine surface protection is applied, no water may remain inside the
13.4.17
Kapitel/Chapter 5: Basics - Seite/Page 29
Basics
engine during the downtime. The control unit must be marked accordingly with a note specifying “NO COOLING
WATER“.
• Drain engine oil as specified. Refill engine with preservative oil to the max. level on the oil dipstick.
• Drain diesel from tank and refill with a protective mixture (90 % diesel and 10 % preservative oil) (level to full).
Crank engine without start.
• Dismount V-belt as specified, wrap and store in a dry location. Protect against UV radiation.
• Disconnect battery. Coat terminals with acid-free grease.
Cover alternator apertures.
Attention!
Cleaning fluids and preservatives must not enter the
alternator. Risk of destroying the alternator.
• Clean engine as per manufacturer's instructions.
• Spray engine parts and V-belt disks with preservative.
• Clean air filter housing and spray with preservative (metal housing only).
• Spray preservative on intake and exhaust side of exhaust turbocharger (where applicable) and reconnect the lines.
• Remove valve cover and spray inside of valve cover, valve stems, springs, rocker, etc. with preservative oil.
• Remove injection nozzle and coat cylinder surface with preservative oil. Hold stop lever in zero delivery position
and crank engine manually several times. Refit injection nozzles with new seals (at an operation hour of min. 100
hours after the last change). Observe torque values.
• Spray radiator cover and tank cover or radiator cover on expansion tank lightly with preservative oil and refit.
• Close off intake and exhaust apertures (e.g. with tape or end caps).
For storage for more than 12 months, the preservation
measures shall be checked annually and supplemented
as necessary.
Note:
Before recommissioning, remove preservatives and
protective measures.
Attention!
5.7.4.2 Measures for removing surface protection after extended downtimes /
recommissioning (over 6 months):
• Check battery charge status and recharge if necessary. Observe instructions of the battery manufacturer.
• Check cooling water anti-freeze level and cooling water level and refill as necessary.
• Drain engine oil. Replace oil filter and oil as per the specification.
• Remove preservatives from the engine with petroleum spirit.
• Degrease V-belt disks and mount V-belt according to instructions. Check V-belt tension!
• If applicable, open turbocharger oil pressure line and fill clean engine oil into channel.
• Hold engine stop lever in zero delivery position and crank engine manually several times.
• Clean air filter housing with petroleum spirit, check air filter and replace if necessary.
• Remove covers from exhaust aperture and intake apertures.
• Connect battery. Close battery main switch.
• Hold stop lever on generator motor in neutral position and crank starter for approx. 10 seconds. Then, pause for 10
Seite/Page 30 - Kaptitel/Chapter 5: Basics
13.4.17
Basics
seconds. Repeat this procedure 2 times.
• Perform visual check of the generator similar to initial commissioning and start up generator.
Fischer Panda recommends:
Note:
After extended downtimes, a full 150 h inspection as per the
inspection list should be performed.
13.4.17
Kapitel/Chapter 5: Basics - Seite/Page 31
Basics
Leere Seite / Intentionally blank
Seite/Page 32
Kapitel/Chapter 5: Basics
13.4.17
Panda 5000i PMS generator
6.
Panda 5000i PMS generator
6.1
Type plate at the generator
Fig. 6.1-1: Type plate
Fig. 6.1-2: Discription type plate
13.4.17
Kapitel/Chapter 6: Panda 5000i PMS generator - Seite/Page 33
Panda 5000i PMS generator
Description of the Generator
6.1.1 Right Side View
Fig. 6.1.1-1: Right side view
10
09
08
01
11
02
07
03
04
05
01)
02)
03)
04)
05)
06)
Actuator (servo)
Raw water pump
Oil pressure switch
Oil filter
Oil drain hose
Dip stick
Seite/Page 34 - Kaptitel/Chapter 6: Panda 5000i PMS generator
06
07)
08)
09)
10)
11)
Housing with iControl electronic board (DO NOT OPEN)
Air filter housing
Lifting eye
Oil filler cap
Injection pump
13.4.17
Panda 5000i PMS generator
6.1.2 Left Side View
Fig. 6.1.2-1: Left side view
09
08
07
01
12
02
03
04
01)
02)
03)
04)
05)
13.4.17
Air filter housing with air filter
DC main fuse
Generator housing with coil
Solenoid switch for starter motor
Starter motor
05
06)
07)
08)
09)
06
Electrical fresh water pump
Temperature sensor at cylinder head
Thermostat housing
Bleeding screw at thermostat housing
Kapitel/Chapter 6: Panda 5000i PMS generator - Seite/Page 35
Panda 5000i PMS generator
6.1.3 Front View
Fig. 6.1.3-1: Front side view
17
01
02
03
16
04
15
14
05
01)
02)
03)
04)
05)
06)
07)
08)
09)
06
Valve cover
Thermo sensor at cylinder head
Raw water injection nozzle
Fresh water pump
Coolant feed line from external expansion tank
Coolant bleeding line to external expansion tank
Exhaust out
Connection for external ventilation valve
Fuel return line
Seite/Page 36 - Kaptitel/Chapter 6: Panda 5000i PMS generator
07
08
09
10)
11)
12)
13)
14)
15)
16)
17)
10
11
12 13
Fuel feed line
Cable for fuel pump
Oil drain hose
Raw water in
Oil filter
Raw water pump
Actuator (servo)
Oil filler cap
13.4.17
Panda 5000i PMS generator
6.1.4 Back View
Fig. 6.1.4-1: Back side view
01
02
10
03
04
09
08
05
01)
02)
03)
04)
05)
13.4.17
06
Lifting eye
Air filter
Housing with iControl electronic board (DO NOT OPEN)
Generator housing back cover
Cable for Power out to inverter
07
06)
07)
08)
09)
10)
Cable Control to inverter
Cable for remote control panel
Passage for starter battery cable
Passage for starter battery cable
DC main fuse
Kapitel/Chapter 6: Panda 5000i PMS generator - Seite/Page 37
Panda 5000i PMS generator
6.2
Details of function units
6.2.1 The Panda iControl2 panel
The "Panda iControl2 panel" control panel is the control and display unit for the Panda iControl2 control system and
represents the interface between the user and the Panda iControl2 controller. The integrated display serves to
present the most important data of the system as well as warnings and error messages.
The control panel is equipped with four buttons for operating the Panda iControl2 controller:
Fig. 6.2.1-1: Panda iControl 2 panel
1. On/Off button: Switching the Panda iControl2 controller on and off
2. Start/Stop button: Starting and stopping the generator, confirming values in selection menus (Enter key)
3. Cursor-up button Switching between display screens (up), counting values up in selection menus
4. Cursor-down button Switching between display screens (down), counting values down in selection menus.
See remote control panel data sheet for details!
Seite/Page 38 - Kaptitel/Chapter 6: Panda 5000i PMS generator
Notice!:
13.4.17
Panda 5000i PMS generator
6.2.2 Components of the Cooling System
Fig. 6.2.2-1: Cooling System
13.4.17
Kapitel/Chapter 6: Panda 5000i PMS generator - Seite/Page 39
Panda 5000i PMS generator
6.2.3 Components of the Fuel System
Fig. 6.2.3-1: Components of the Fuel System
Seite/Page 40 - Kaptitel/Chapter 6: Panda 5000i PMS generator
13.4.17
Panda 5000i PMS generator
6.2.4 Components of the Electrical System
Fig. 6.2.4-1: Components of the Electrical System
13.4.17
Kapitel/Chapter 6: Panda 5000i PMS generator - Seite/Page 41
Panda 5000i PMS generator
6.2.5 Components of the Oil Circuit
Fig. 6.2.5-1: Components of the Oil Circuit
6.2.6 Sensors and switches for operating surveillance
Thermo-sensor at engine
Fig. 6.2.6-1: Thermo.sensor at engine
The thermo-sensor at the engine is used for monitoring the
engine temperature.
Seite/Page 42 - Kaptitel/Chapter 6: Panda 5000i PMS generator
13.4.17
Panda 5000i PMS generator
Thermo-switch at exhaust connection
Fig. 6.2.6-2: TThermo-switch at exhaust connection
If the impeller pump drops out and delivers no more
seawater, the exhaust connection becomes extremely hot.
Thermo-sensor coil
Fig. 6.2.6-3: Thermo-switch coil
One thermo sensor is located in the stator winding
1
Oil pressure switch
Fig. 6.2.6-4: Oil pressure switch
In order to be able to monitor the lubricating oil system, an oil
pressure switch is built into the system.
13.4.17
Kapitel/Chapter 6: Panda 5000i PMS generator - Seite/Page 43
Panda 5000i PMS generator
6.3
Operation Instructions - see separate iControl panel manual
6.3.1 Daily routine checks before starting - See iControl manual.
6.3.2 Starting Generator - See iControl manual.
6.3.3 Stopping the Generator - See iControl manual.
Seite/Page 44 - Kaptitel/Chapter 6: Panda 5000i PMS generator
13.4.17
Installation Instructions
7. Installation Instructions
All connections (hoses, wires etc.) and installation
instructions are designed and suited for “standard”
installation situations.
Attention!: Adapt system correctly.
In situations where Fischer Panda has no detailed
information concerning certain installation requirements
(such as vehicle specifications, maximum vehicle speed and all other conditions concerning special operating
situations) the installation instructions should be used as an
example guide only. The installation must be undertaken and
proved by a suitable qualified/trained person and should be
in accordance with the law as required by the country and
special situation.
Damages caused by faulty or incorrect installation are not
covered by the warranty.
7.1
Personal requirements
The described installation must be done by a technical trained person or a Fischer Panda service point.
7.1.1 Hazard notes for the installation
Follow the general safety instruction at the front of this
manual.
Notice:
DANGER TO LIFE! - Incorrect handling may lead to
health damage and to death.
.Warning!:
Automatic start
Always disconnect the battery bank (first negative terminal
than positive terminal) before you work at the generator or
the electric system of the generator so that the generator
may not be started unintentionally.
Improper installation can result in severe personal
injuries or material damage. Therefore:
Warning!: Risk of injury
• Always undertake installation work when the generator is
switched off.
• Ensure there is sufficient installation clearance before start
working.
• Ensure tidiness and cleanliness at the workplace. Loose
components and tools lying around or on top of each other
are sources of accidents.
• Only perform installation work using commercially available
tools and special tools. Incorrect or damaged tools can
result injuries.
13.4.17
Kapitel/Chapter 7: Installation Instructions - Seite/Page 45
Installation Instructions
Oil and fuel vapours can ignite at contact with ignition
sources. Therefore:
Warning!: Danger of fire
• No open flames during work on the generator.
• Do not smoke.
• Remove oil and fuel residues from the generator and floor.
Contact with engine oil, antifreeze and fuel can result in
damage to health. Therefore:
Danger!: Danger of poisoning
• Avoid skin contact with engine oil, fuel and antifreeze.
• Remove oil and fuel splashes and antifreeze from the skin
immediately.
• Do not inhale oil and fuel vapours.
DANGER TO LIFE! - Improper handling can result in
severe personal injury and death.
Attention!: Danger to Life - High voltage
Electrical voltages above 60 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.
Generator, oil and antifreeze can be hot during/after
operation. Risk of severe burns!
Warning!: Hot surface/material
During operation an over pressure in the cooling system may
be established.
Batteries contain corrosive acids and bases.
Warning: Danger of chemical burns
Improper handling can lead to heating of the batteries and
bursts. Corrosive acids and bases may leak. Under bad
conditions it may lead to an explosion.
Consider the instructions of the battery manufacturer.
During installation/maintenance personal protective
equipment is required to minimize the health hazards:
Instruction!: Personal protective equipment
necessary
• Protective clothing
• Safety boots
• Protective gloves
• Ear defender
• Safety glasses
Disconnect all load during the work at the generator to
avoid damages at the load.
Seite/Page 46 - Kaptitel/Chapter 7: Installation Instructions
Attention!: Disconnect all load.
13.4.17
Installation Instructions
7.2
Place of installation
7.2.1 Preliminary remark
• There must be sufficient fresh air supply for the combustion air.
• It has to be ensured that the cooling air supply from underneath or sidewise is sufficient.
• During operation the sea cock has to be opened.
• The generator may only be opened by a technical trained person.
• The generator may only be operated by a trained person.
7.2.2 Preparing the base - 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. plywood). 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.
As the generator sucks in its combustion air via several drill holes in the capsule base, the capsule base must be
installed with sufficient space to the basement so that the air supply is guaranteed (at least 12 mm/½“)
The generator sucks its air from the surrounding engine room. Therefore it must be ensured that sufficient ventilation
openings are present, so that the generator cannot overheat.
The Power out of the generator based on the following data:
Ambient temperature: 20 °C
Air pressure: 1000 mbar (100 m above normal Zero)
Raw water temperature: 20 °C
Rel. áir moisture: 30 % reg. the ambient temperature
Fuel temperature: bis zu 20 °C
Exhaust backpressure: 80 mbar (at the exhaust out of the sound isolation cover)
Any differents to this data, for example an ambient temperature of 40 °C because of the build inside a maschine
room/vehicle with a bad ventilation, will cause in a lower Power out (Derating).
13.4.17
Kapitel/Chapter 7: Installation Instructions - Seite/Page 47
Installation Instructions
7.2.3 Advice for optimal sound insulation
The convenient base consists of a stable framework, on
which the generator is fastened by means of shockmounts. Since the aggregate is „free“ downwards, the
combustion air can be sucked in unhindered. In addition
the vibrations are void which would arise with a closed
capsule base.
7.3
Fig. 7.2.3-1: Generator base
Generator Connections
All electrical wires are connected within the capsule tightly to the motor and the generator. 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.
Before working (installation) on the System read the
section „Safety Instructions“ in this manual.
ATTENTION!
Fig. 7.3-1: Connection at the Generator - sample
1
2
1. Feed line from external expansion tank
2. Bleeding line to external expansion tank
3. Exhaust out
4. Connection for external ventilation valve
5. Fuel return line
Seite/Page 48 - Kaptitel/Chapter 7: Installation Instructions
3
4
5
6
7
8
9
6. Fuel feed line
7. Cable for fuel pump
8. Raw water in
9. Oil drain hose
13.4.17
Installation Instructions
Fig. 7.3-2: Connection at the Generator - sample
1
2
3
1. Cable Power out to PMGi inverter
2. Cable Control to PMGi inverter
7.4
3. Cable for remote control panel
Installation of the cooling system - raw water
7.4.1 General information
The genset should have its own raw water (coolant water) inlet and should not be connected to any other engine
systems. Ensure that the following installation instructions are complied with:
7.4.2 Installation of the through hull fitting in Yachts - scheme
It is good practice for yachts to use a through hull fitting
with an integrated strainer. The through hull fitting (raw
water intake) is often mounted against the sailing
direction to induce more water intake for cooling.
Fig. 7.4.2-1: Position of the through hull fitting
For Panda generators, the through 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.
7.4.3 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 must have an inner
diameter of at least 1" (25 mm).
This applies also to installation components such as through-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). For the flow
13.4.17
Kapitel/Chapter 7: Installation Instructions - Seite/Page 49
Installation Instructions
rate see section 9.2, “Technical data,” on page 118.
7.4.4 Generator installation above waterline
The Panda is equipped with a water intake pump mounted on the motor. Since the intake pump is an impeller pump
there are wearing parts which are likely to require replacement after a period of time. Ensure that the genset is
installed so that the intake pump can be easily accessed. 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.With the installation of a
non return valve in the raw water inlet line, which is under the waterline, this problem can be restricted.
When starting the generator you should always consider when raw water runs out of the exhaust system. If this
takes longer than 5 seconds you should replace the impeller pump because it sucks in air for too long before it
delivers raw water. The impeller has lost its effect and cannot suck in raw water anymore. This results to an
overheating of the motor. If the impeller is not exchanged early enough the impeller blades may break into pieces
and plugging the cooling water cycle. It is very important to exchange the impeller after a couple of months.
If the raw water line is too long for the impeller pump or the
generator installed too high above the water line a electrical
pump can be installed into the raw water line. In this case the
impeller should be removed out of the impeller pump.
NOTE:
Contact Fischer Panda for further information.
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.
NOTE:
Replacement impeller and also a spare pump should always
be on board. The old pump can be sent back to Fischer
Panda for cost-effective repair.
7.4.5 Generator installation below waterline
If the generator cannot be attached at least 600 mm
above the waterline, a vent valve must be installed at the
raw water line.
Fig. 7.4.5-1: Vent valve
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 capsule.
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, 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.
If the valve jams the cool water line cannot be de-aerated
after stopping the generator, the water column is not
discontinued and water can penetrate into the combustion
chamber of the engine. This will lead to damage the engine in
a short term!
Seite/Page 50 - Kaptitel/Chapter 7: Installation Instructions
13.4.17
Installation Instructions
Fig. 7.4.5-2: Rubber hose for vent valve - example
The rubber hose for the external vent valve will be cut...
...and bend upwards.
Fig. 7.4.5-3: Split rubber hose for vent valve
Both hose ends will be extended respectively with a
hose and connected with a vent valve 600 mm over the
waterline.
Example
7.4.5.1 Raw water installation scheme
Fig. 7.4.5.1-1: Raw water installation schema
13.4.17
Kapitel/Chapter 7: Installation Instructions - Seite/Page 51
Installation Instructions
7.4.6 First filling and ventilation of the internal cooling water circuit
The expansion tank is supplied with a pressure relief
valve in the cap with 500 mbar. It is possible when
operating the generator hot cooling water can leak here
if there is an overpressure. When working always wear
protective clothing and ensure an adequate installation
location.
ATTENTION!: Risk of scalding.
1. Fill up the external cooling water expansion tank with
coolant.
Fig. 7.4.6-1: Expansion tank
ATTENTION: Maximum fill level = „max.“- marking
The cover of the external expansion tank must be opened
temporarily (all other closures are now closed!).
Sample picture
2. Start the water pump.
The electrical water pump can be started with the „Prime
Fuel“ option in the iControl panel, see “Priming the fuel
system ("Prime Fuel")” on page 122.
3. Open venting screw at the thermostat housing. Close the
vent screw when air free water comes out.
Fig. 7.4.6-2: Venting screw at the thermostat housing
Check the water level in the expansion tank during the
venting. Fill up if necessary.
10
4. Start the generator
After filling the generator must be started. During this first phase of start-up, the generator may not be loaded.
Switch off the generator after approx. 10 seconds of operation!
5. Repeat the steps 1-4 till no more air comes out of the venting screw at the thermostat housing.
Close the venting screws.
6. Run the generator at idle speed till the cooling water temperature at the engine reach 60°C. Stop the generator.
Fill up the expansion tank up to max. marking.
Close the expansion tank.
7. Re-ventilating process 10 operating hours after the first start-up (and if necessary).
Also after the first initial operation a small amount of air may reside in the cooling circuit. To ensure an immaculate
und actual operation 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
Seite/Page 52 - Kaptitel/Chapter 7: Installation Instructions
13.4.17
Installation Instructions
stood still for a long time.
During the ventilating process repeated checks must be made
to check the cooling water is indeed circulating. If there are air
bubbles in the internal cooling water pump, it is possible that
the cooling water is not circulating. The generator will heat up
very quickly and switch off, because of overheating.
ATTENTION: Check circulation
7.4.6.1 Anti-freeze in the cooling water circuit
In the interest of safety, the concentration of the coolant should be checked on a regular basis. Be sure that the
coolant/antifreeze mixture is good for at least -15 °C (5 °F) which is recommended by the manufacturer. If your
genset experiences lower temperatures, for example during storage or transportation, then the entire cooling system
should be drained. The coolant also serves as corrosion protection of the engine.
7.4.7 Temperature check for controlling the cooling water circuit
Check with an IR-thermometer if a temperature difference exists between cooling water in-flow and cooling water
return flow.
The cooling water in-flow line can be measured directly at the internal cooling water pump.
The cooling water return pipe can be measured either at the outlet of the water-cooled exhaust elbow or at the side
where this pipe enters the heat exchanger.
The temperature difference between in-flow and return should be approx 2-3 °C at nominal rating.
13.4.17
Kapitel/Chapter 7: Installation Instructions - Seite/Page 53
Installation Instructions
7.5
Installation of the water cooled exhaust system
7.5.1 Installation of the standard exhaust system
The generator exhaust system must remain completely independent and separate from the exhaust system of any
other unit(s) on board. The water lock must be installed at the lowest point of the exhaust system. An optional noise
insulated water lock can also be installed. The exhaust hose descends from the capsule to the water lock. 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. In order that the back pressure inside the exhaust is not to high, the total length of
the exhaust system should not exceed 6,3 m.
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.
Fig. 7.5.1-1: Installation Scheme Standard Exhaust System
7.6
.Installation
of the waterlock
Pay attention to the right flow direction throught the
waterlock.
Note!:
Unfortunately, it can occasionally occur that, because of an disadvantageous mounting position of the waterlock, sea
water gets into the diesel engines’ combustion chamber. This disables the diesel engine by irreversible damages.
Quite frequently, this leads to discussions during which the parties involved in the yachts’ construction or the
installation of the generator have to explain themselves.
One point in this situation can be clarified definitely:
If sea water gets into the inner section of the engine, this is not possible due to constructional defects of the
generator or to malfunctions on the engine itself. It can only reach the combustion chamber via the exhaust hose
and thus get into the engine.
Seite/Page 54 - Kaptitel/Chapter 7: Installation Instructions
13.4.17
Installation Instructions
Thereby, the position of the generator and the waterlock, as well as the arrangement of the cooling water and
exhaust hoses play the decisive role.
If the waterlock is arranged in an unfavourable position, the cooling water flowing back in the exhaust hose can rise
so high, that it reaches the exhaust stack. Since at least one discharge valve is always open when the engine is shut
off, the sea water has free access to the combustion chamber. By capillary action, this sea water then flows past the
cocks and even reaches the engine oil in that way. (In fact, a surprisingly high oil level is a first indication of an
upcoming catastrophe).
If an usual high oil level can be detected and/or the oil is of a greyish colour, the engine must not be used
anymore. This is a certain sign for cooling water that got into the oil pan. If the engine is started under these
conditions, the water and the oil are mixed into an emulsion. The oil will quickly become so viscous that one
will have to call it a paste. In this phase the fine oil hoses are blocked and a few moments later the machine
gets destroyed because of insufficient lubrication. Before this happens, an immediate oil change should be
made. Since the water can only reach the engine via the combustion chamber, it can be assumed that the
compression rings will start to corrode. These effects have to be discussed with an engine expert. It will
certainly be reasonable to immediately inject plenty penetrating oil through the intake stack and to slowly
turn the engine with the starter motor.
The cooling water can reach the exhaust area via the exhaust hose as well as via the cooling water feed.
7.6.1 Possible cause for water in the exhaust hose
7.6.1.1 Possible cause: exhaust hose
If the cause is the exhaust hose itself, the following points are to be checked at the hose:
a) Position of the waterlock is too high. The water reaches the exhaust hose.
b) Position of the waterlock is too far away from the middle of the generator. The water reaches the exhaust hose in
tilted position.
c) The waterlock is too small relating to the length of the exhaust hose.
7.6.1.2 Possible cause: cooling water hose
If the generator is not clearly installed 600 mm over the water line, the cooling water feed must be equipped with a
„venting valve“ which is at least led out 600 mm over the water line. (This position must also be assured in every
tilted position. Therefore, the venting valve should be located in the ships’ center line, so that it cannot move in tilted
position).
a) Position of the venting valve is too low. The water flows into the exhaust area when the ship is tilted.
b) Position of the venting valve is too far from the ships’ center line. The water reaches the exhaust area when the
ship is tilted.
c) The venting valve does not work, because it jams or it is clotted. (The venting valve’s function needs to be
checked regularly.)
As it consistently happens that functioning risks are not realised during the laying of the exhaust hose, the following
explanations refer explicitly to the exhaust hose. Here, the location, the size and the position of the „waterlock“ play
a very decisive role:
7.6.2 Installation area of the waterlock
Concerning a water-cooled exhaust system, it must be regarded that - under no circumstances - cooling water from
the exhaust hose can get into the exhaust elbow area at the engine. If this happens, the cooling water can get into
the combustion chamber via an open discharge valve. This would lead to irreparable damage at the engine.
In addition to that, one has to reckon with possible tilted positions of sailing yachts, which makes the position of the
waterlock even more important. In general one could say that:
13.4.17
Kapitel/Chapter 7: Installation Instructions - Seite/Page 55
Installation Instructions
The deeper the waterlock is located underneath the generator, the better the protection from entering water into the
combustion chamber.
The picture below shows that the distance between the critical point at the exhaust elbow and the maximum
permissible water level in the exhaust hose is stated with 600 mm. This distance should be understood as a
minimum distance.
7.6.3 The volume of the waterlock
The waterlock must be measured so large, that it can take the entire amount of water flowing back from the exhaust
hose. The amount of water depends on the hoses’ length (L) and its cross section. While the diesel engine is
running, cooling water is continuously injected into the exhaust system and is carted outside with the emissions by
the exhaust gas pressure. When the engine is turned off, the number of revolutions sinks quite fast. By doing so, the
point is reached where the exhaust gas pressure does not suffice anymore to cart the cooling water out. All cooling
water remaining in the hose at that point flows back into the waterlock. At the same time, the diesel engine itself
continues to cart cooling water through the cooling water pump, as long as it keeps on rotating.
The waterlock must necessarily be measured large enough that it can take the entire amount of cooling
water and, at the same time, does not exceed the prescribed vertical height of 600 mm up to the critical
point at the exhaust elbow.
Fig. 7.6.3.0-1: Volume of the waterlock
If there are any doubts, a verification can easily be made
by temporarily using a clear-sighted hose (1) as exhaust
hose. In that way, the cooling water level can be checked
very easily.
Fig. 7.6.3.0-2: Testing the cooling water level
1
7.6.3.1 Ideal position of the waterlock
The ideal position of the waterlock would be in center
underneath the generator.
Important Note!
Only in this position it is assured that the water level cannot
change drastically in tilted position by the waterlock moving
out of the center line.
See the following pictures:
Seite/Page 56 - Kaptitel/Chapter 7: Installation Instructions
13.4.17
Installation Instructions
In Fig. 7.6.3.1-1, the waterlock is mounted in center
underneath the generator.
Fig. 7.6.3.1-1: Ideal position of the waterlock
When the ship tilts, the position of the waterlock related to the
critical point at the exhaust hose, changes only slightly.
Tilted position 15 degrees - Fig. 7.6.3.1-2
Fig. 7.6.3.1-2: Tilted position 15 degrees
The distance from the exhaust elbow to the hydrostatic head
has derated to 540 mm.
Tilted position 30 degrees - Fig. 7.6.3.1-3
Fig. 7.6.3.1-3: Tilted position 30 degrees
The distance of the water level, even in ideal position,
changes that only 458 mm distance remain. So the critical
distance is under-run already.
Tilted position 45 degrees - Fig. 7.6.3.1-4
Fig. 7.6.3.1-4: Tilted position 45 degrees
In this case the water level rise so high, that the distance
constitutes only 325 mm.
Even when the water lock is mounted in the ideal spot, at an
extremely tilted position of 45 degrees there is still the risk
that water can get straight into the discharge stack area
through strong rocking motions („sloshing“). This shows that
the distance of 600 mm represents a minimum size at which,
even when installed ideally, the water can slosh into the
exhaust elbow when the ship is very tilted or rocks very hard.
13.4.17
Kapitel/Chapter 7: Installation Instructions - Seite/Page 57
Installation Instructions
Summary:
The preset minimum height of 600 mm must be regarded unconditionally and is only valid if the waterlock is
mounted in its ideal position in center underneath the generator. A higher position is highly recommended if it has to
be reckoned with tilted positions of 45 degrees.
7.6.3.2 Example of the installation of the waterlock off-center and possible effects:
The following pictures are primarily relevant for an installation of the generator with the waterlock on sailing yachts.
A change in the mounting position caused by tilted position does not have to be reckoned concerning motor yachts.
Here it is only necessary to regard that the volume of the waterlock is measured so large that it can take the entire
amount of water flowing back, and at the same time, maintains the minimum distance of 600 mm.
A) Installation of the waterlock 500 mm next to the generator’s center line:
Installation of the waterlock 500 mm next to the
generator’s center line
Tilted position 45 degrees - Fig. 7.6.3.2-2
Fig. 7.6.3.2-1: waterlock, 500 mm next to the center line
Fig. 7.6.3.2-2: Tilted position 45 degrees
The water level is now at the same height as the critical point
at the exhaust elbow. If the ship is sailed in a tilted position of
45 degrees with an installation like this, the ingress of cooling
water into the combustion chamber is inevitable. Irreparable
damages are pre-programmed.
Seite/Page 58 - Kaptitel/Chapter 7: Installation Instructions
13.4.17
Installation Instructions
B) Installation distance between waterlock and the generator’s center line 1000 mm
Installation distance between waterlock and the
generator’s center line 1000 mm
Tilted position 30 degrees - Fig. 7.6.3.2-4
Fig. 7.6.3.2-3: waterlock, 1000 mm next to center line
Fig. 7.6.3.2-4: Tilted position 30 degrees
The water level and the critical point at the exhaust elbow are
at the same level now. If the ship is sailed in a tilted position
of 30 degrees with an installation like that, the infiltration of
cooling water into the combustion chamber is inevitable.
Irreparable damages are pre-programmed.
Summary:
Concerning sailing yachts it must be regarded, that the waterlock is mounted in center underneath the generator, at
least in reference to the ships’ center line. Thus the waterlock is prevented from „leaking“ very strongly when the
ship is tilted.
The „leaking“ of the waterlock leads to a rise of the water level which then gets too close to the exhaust elbow’s
critical point.
7.7
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 through-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“.
13.4.17
Kapitel/Chapter 7: Installation Instructions - Seite/Page 59
Installation Instructions
Fig. 7.7.0-1: Installation Scheme exhaust / water separator
7.8
Installation exhaust water separator
If the exhaust water separator was sufficiently highly installed, a goose neck is no longer necessary. The exhaust/
water separator fulfils the same function. If the „Super silent“ exhaust system were installed correctly, the generator
will not disturb your boat neighbour. The exhaust noise should be nearly inaudible. 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.
If the through-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 in the throughhull outlet. For such long exhaust routes, the exhaust hose diameter should also be increased, f.e. from NW40mm to
NW50mm in order to reduce the back-pressure. The exhaust may have a length of over 10 m (32 ft.) if the exhaust
hose diameter is increased. 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.
Seite/Page 60 - Kaptitel/Chapter 7: Installation Instructions
13.4.17
Installation Instructions
Fig. 7.8.0-1: Example for an unfavourable Installation
Example of an unfavourable installation:
- Water lock not far enough below the lowest level of the generator
- Distance water lock to gooseneck too large
7.9
Fuel system installation
7.9.1 The following items need to be installed:
• Fuel supply pump (DC)
• Pre-filter with water separator (not part of the delivery)
• Fine particle fuel filter
• Return fuel line to fuel tank (unpressurized)
The external Fuel pump should be installed near the fuel tank
Electrical fuel pump
Fig. 7.9.1-1: electrical fuel pump
With the Fischer Panda generator is usually supplied an
external, electrical fuel pump (DC). The fuel pump must be
installed close at the fuel tank. The electrical connections is
prepared at the generator.
Some generators (f.e. with Deutz diesel engine) has an
engine driven internal fuel pump. At these generators the
electrical fuel pump is optional.
13.4.17
Kapitel/Chapter 7: Installation Instructions - Seite/Page 61
Installation Instructions
Fig. 7.9.1-2: Fuel system - schema
6
3
5
4
1
2
1. Fuel tank
2. External fuel pump
3. External fuel prefilter with water separator
4. Non return valve
5. External fuel fine filter
6. Generator
External fine filter
Fig. 7.9-3: externer Feinfilter
At generators with FP 320, Kubota EA 300 or Farymann
engines, the fine filter is delivered with the generator. This
fine filter should be installed in the fuel feed line next to the
generator.
7.9.2 Connection of the fuel lines at the tank
General fuel feed and return line must be connected to the
tank at separate connection points.
Note:
Connection of the return pipe to the tank
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
Seite/Page 62 - Kaptitel/Chapter 7: Installation Instructions
13.4.17
Installation Instructions
period, in order to preserve the starter battery.
Non-return valve for the fuel return pipe
ATTENTION!
If the fuel tank should be installed over the level of the
generator (e.g. daily tank), then a non-return valve must
be installed into the fuel return pipe to guarantee that
through the return pipe no fuel is led into the injection
pump.
7.9.3 Position of the pre-filter with water separator
Inside the generator capsule itself, there is the fuel filter installed (exception: Panda 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.
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. 7.9.3-1: Pre-filter with water separator
representative picture
13.4.17
Kapitel/Chapter 7: Installation Instructions - Seite/Page 63
Installation Instructions
7.10 Ventilating the fuel system
Normally, the fuel system is designed to ventilate air itself i.e. as soon as the electric starter motor starts operation
the fuel pump starts working and the fuel system will be de-aerated after some time automatically. It is nevertheless
essential to ventilate the system as follows prior to the first operation (as all hoses are empty):
Start the fuel pump
The external fuel pump can be started manual by an option in
the iControl2 panel. See iControl2 manual for details.
Note:
Ventilation Screw
4.) Open the ventilation screw located at the fuel solenoid valve. The
„START“ 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 „START“
button be released.
5.) Switch the panel „OFF“.
This procedure must be repeated several times, until fuel
(nonporously) withdraws perfectly at the ventilation
screw.
Injection nozzles
Pressing the starter button can now start the machine. The machine should
start after a short period.
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.
Switch main switch "OFF"
7.11 Generator DC system installation
The Panda 5000i.Neo has no DC alternator to charge the
Starter battery. The Starter battery must be charged by
an external device.
Note:
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.
7.11.1 Connection of the starter battery block
An own separate starter battery must be installed for the generator.
The positive cable (+) of the battery is attached directly at the solenoid switch of the starter motor (position 1). The
negative cable (-) of the battery is attached underneath the starter motor at the engine mount (position 2).
Seite/Page 64 - Kaptitel/Chapter 7: Installation Instructions
13.4.17
Installation Instructions
Make sure that the voltage of the starter battery fits to
the start system voltage
ATTENTION!
f.e. 12 V starter battery for a 12 V start system
f.e. 24 V starter battery for a 24 V start system (2x12 V
batteries in a row)
To avoid large voltage drops the battery should be
installed as near as possible to the generator. The
positive terminal of the battery is attached at the red
cable, the negative pole at the blue cable.
NOTE:
It must be guaranteed that first the cables are attached at the
generator and then at the battery.
Attention!: Consider correct connection
sequence
Battery connection
Attention!: Right connection of the battery.
Wrong connection of the battery bank can cause a shortcircuit and fire.
Install an appropriate fuse and a battery circuit breaker in the plus pole cable of the battery, but with a distance to the
battery of up to 300 mm (12 inch) at maximum.
The cable from the battery to the safety device must be secured with protective pipe/sleeve against chafing through.
For the connection use self-extinguishing and fire-protected cables, which are appropriate for temperatures up to
90 °C, 195 °F.
The batteries must be installed in such a way that they do not chafe through or other mechanical load can be
stripped.
The battery poles must be secured against unintentional short-circuit.
The positive battery cable within the generator must be shifted in such a way that it is protected against heat and
vibrations by appropriate sleeve/protective pipe. It must be shifted in such a way that it does not affect rotary parts or
parts, that become hot in operation, e.g. wheel, exhaust elbow union, tail pipe and the engine. Do not lay the cable
too tautly, since otherwise it could be damaged.
Make a test run after the installation and check the laying of the batteries during the test run and afterwards. If
necessary, correct the laying.
Examine regularly the cable laying and the electrical connections.
DC Starter Motor
Fig. 7.11.1-1: DC Starter Motor
All Panda generators are equipped with an independent DC
starter motor.
1. Solenoid switch for starter motor
1
2. Starter motor
2
13.4.17
Kapitel/Chapter 7: Installation Instructions - Seite/Page 65
Installation Instructions
Positive battery cable
Fig. 7.11.1-2: Positive Battery Cable
The positive (+) battery cable is connected directly to the
solenoid switch of the starter.
Negative battery cable
Fig. 7.11.1-3: Negative Battery Cable
The negative (-) battery cable is connected to the engine
foot.
Note! The battery negative pole may not be connected
with the boat ground.
Fig. 7.11.1-4: Connection starterbattery 12V - schema
1. Generator
2. Battery block
Seite/Page 66 - Kaptitel/Chapter 7: Installation Instructions
3. Fuse
4. Battery main switch
13.4.17
Installation Instructions
7.11.2 Connection of the remote control panel - See Panda iControl panel manual
7.11.3 Installation of the iControl panel - See iControl Manual
7.12 Generator AC System Installation
Before the electrical system is installed, READ the
SAFETY INSTRUCTIONS of this manual FIRST! Be sure
that all electrical installations (including all safety
systems) comply with all required regulations of the
regional authorities. This includes lightening conductor,
personal protection switch etc.
ATTENTION!
All electrical safety installations have to be made on board.
Required cable cross-sections
The following recommended electrical cable dimensions
(cross sections) are the minimum required sizes for a
safe installation (see “Diameter of conduits” on
Page 85).
13.4.17
Kapitel/Chapter 7: Installation Instructions - Seite/Page 67
Installation Instructions
Fig. 7.12-1: Electrical installation - example
1
1
3
2
4
1. Generator
2. Electrical fuel pump DC
3. PMGi 5000 inverter
4. iControl panel
5. Starter battery DC
7.12.1 Installation PMGi inverter - See separate PMGi 5000 inverter manual
All electrical safety installations have to be made on board.
7.12.2 Power source selector
A power source selector switch must be installed between the PMGi power out and the ship's electrical supply
system. 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.
Seite/Page 68 - Kaptitel/Chapter 7: Installation Instructions
13.4.17
Installation Instructions
3-Way Cam Switch
Fig. 7.12.2-1: 3-Way Cam Switch
A 3-way cam switch should be used. This switch basic
positions: „Shore power“ - „OFF“ - „Generator“. If an (DC-AC)
inverter is used, a fourth position will be required.
0. OFF
I. Generator
II. Shore power connection
III. Inverter
The cam-type switch must have 2 poles, so that „MP“ and „phase“ can be switched off.
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 9.1, “Diameter of conduits,” auf Seite 85
Required cable cross-sections
The following recommended electrical cable dimensions (cross sections) are the minimum required sizes for a safe
installation. (siehe Tabelle 9.1, “Diameter of conduits,” auf Seite 85)
13.4.17
Kapitel/Chapter 7: Installation Instructions - Seite/Page 69
Installation Instructions
7.13 Checking and filling of the oil circuit
Check oil and fill the oil circuit as described in the service chapter.
7.14 Isolation test
After installation, before bringing into service and
handover of the generator to the customer, an isolation
test has to be accomplished as follows:
ATTENTION!
1. Switch off all electrical load.
2. Start the generator.
3. 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 50 mV (millivolt).
4. Once the safety systems have been installed, they must be checked. If a leakage current relay (RCD) has been
installed, it also has to be tested in order to ensure that all contacts are connected properly. The individual
phases have to be checked against each other, and between phase and ground. An additional 4th phase (L1’)
also needs to be checked at generators with DVS winding.
5. If the generator is protected by a ground connection, it has to be ensured that ALL electrical devices must also be
connected to this „common“ ground (usually ground contacts are attached to the device’s metallic housing).
The electrical system installation must also comply with the hook-up requirements of the shore current grid.
Generally a leakage current relay (RCD) is sufficient for safe electrical operation; how ewer, this must be confirmed
by the electrical safety standard in the region where the system is attached to a main land power grid. The release
current of the relay (RCD) has to meet the installation circumstances.
7.15 Initial operation
After successful installation an initial operation has to be performed.
For this purpose the initial operation record has to be completely filled out by the installing expert. The filled record
has to be handed out to the owner.
The owner has to be instructed regarding handling, servicing and risks of the generator. This applies to the service
steps and risks mentioned in the manual as well as further risks which may arise from the specific installation and
the connected components.
The original initial operation record has to be sent to
Fischer Panda to receive the complete guarantee. Please
make a copy for your own documentation.
Seite/Page 70 - Kaptitel/Chapter 7: Installation Instructions
Note:
13.4.17
Maintenance Instructions
8. Maintenance Instructions
8.1
Personal requirements
All maintenance work - if not specially marked - can be made by the trained persons.
Further maintenance work must only be made by Technical personel or Fischer Panda service points.
8.2
Personal requirements
All maintenance, if not special marked, can be done by the trained persons.
Further maintenance must be done by technical personal or Fischer Panda service points.
8.3
Hazard notes for the maintenance and failure
Follow the general safety instruction at the front of this
manual.
Notice!:
Danger for life! - The generator can be equipped with a
automatic start device. This means the generator can be
started by an external signal. To avoid an unexpected
starting of the generator, the starter battery must be
disconnected before start working at the generator.
Warning!: Automatic start
Working at a running generator can result in severe
personal injury. Therefore before starting work at the
generator:
Warning!: Risk of injury
Make sure that the generator is stopped and the starter
battery is disconnected to guarantee that the generator
cannot be inadvertently started.
Do not run the generator with removed sound isolation cover
Improper installation/maintenance can result in severe
personal injuries or material damage.
Warning!: Risk of injury
• Always undertake installation/maintenance work when the
generator is switched off.
• Ensure there is sufficient installation clearance before start
working.
• Ensure tidiness and cleanliness at the workplace. Loose
components and tools lying around or on top of each other
are sources of accidents.
• Only perform installation work using commercially available
tools and special tools. incorrect or damaged tools can
result injuries.
13.4.17
Kapitel/Chapter 8: Maintenance Instructions - Seite/Page 71
Maintenance Instructions
Oil and fuel vapours can ignite on contact with ignition
sources. Therefore:
Warning!: Danger of fire
• No open flames during work on the generator.
• Do not smoke.
• Remove oil and fuel residues from the generator and floor.
Contact with engine oil, antifreeze and fuel can result in
damage to health. Therefor:
Danger!: Danger of poisoning
• Avoid skin contact with engine oil, fuel and antifreeze.
• Remove oil and fuel splashes and antifreeze from the skin
immediately.
• Do not inhale oil and fuel vapours.
Danger for Life. Improper handling, operation, installation and maintenance can result in severe personal
injury and/or material damage.
ATTENTION!: Danger to Life - High voltage
Electrical voltages above 60 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.
Generator, oil and antifreeze can be hot during/after
operation. Risk of severe burns.
Warning!: Hot surface/material
During Installation/maintenance personal protective
equipment is required to minimize the health hazards.
Instruction!: Personal protective equipment
necessary.
• Protective clothing
• safety boots
• protective gloves
• Ear defender
• safety glasses
Disconnect all load during the work at the generator to
avoid damages at the load.
Attention!: disconnect all load
Batteries contains acid or alkalis.
Warning!:
Improper handling can result in battery explosion and
leakage. Acid or alkalis can run out. An explosion of the
battery is possible.
See the operation and safety instruction from your battery
manufacturer.
Batteries contain corrosive acids and lyes.
Improper handling can cause the batteries to heat up and
burst. Corrosive acid/lye may leak. Under unfavorable
conditions, the battery may explode.
Seite/Page 72 - Kaptitel/Chapter 8: Maintenance Instructions
13.4.17
Maintenance Instructions
Observe the instructions from your battery manufacturer.
8.4
Environmental protection
Danger to the environment due to mishandling!
Environmental protection.
Significant environmental damage can occur, particularly for
incorrect disposal, if environmentally hazardous operating
materials are mishandled. Therefore:
• Always observe the instructions mentioned below.
• Take immediate action if environmentally hazardous
materials reach the environment. Inform the responsible
local authorities about the damage in the case of doubt.
The disposal must be performed by a specialist disposal company.
8.5
General maintenance instructions
8.5.1 Maintenance parts
Fig. 8.5.1-1: Maintenance Parts
FP Art No.
Maintenance Part
0015567
Valve Cover Gasket
0015560
Air Filter Fischer Panda G1
0000651
Impeller set for pump F35B with O-seal and
gasket
0003990
Fuel in line filter 8mm plastic housing
0004666
Oil Filter for FP-320
Fig. 8.5.1-2: Maintenance Kits
Art No 0015691
Service Kit PMS NEO (standard kit for 150h service)
Qty
0015567
Valve Cover Gasket
1
0004666
Oil Filter for FP-320
1
0003990
Fuel in line filter 8mm plastic housing
1
0015560
Air Filter Fischer Panda G1
1
0000651
Impeller set for pump F35B with O-seal and gasket
1
Storage box
Art No
Service Kit Plus PMS NEO (advanced kit for 4x 150h service)
Qty
0015567
Valve Cover Gasket
4
0004666
Oil Filter for FP-320
5
0003990
Fuel in line filter 8mm plastic housing
4
0015560
Air Filter Fischer Panda G1
4
0000651
Impeller set for pump F35B with O-seal and gasket
2
0000650
Service Kit for F35B-8
1
Fuse strip DIN 72581/2 030A, 41x11 mm
3
0003675
Storage box
13.4.17
Kapitel/Chapter 8: Maintenance Instructions - Seite/Page 73
Maintenance Instructions
8.5.2 Checks before each start
• Oil level
• Leaks in the Cooling system
• Visual check for any changes, leaks in the oil drain system,
v-belt, cable connections, hose clips, air filter, fuel lines
8.6
Maintenance interval
For the maintenance interval, please see the „General information for PMS generators“ which are attached to this
manual.
At generator with dynamic operation hours (f.e. Generators with iControl2 system) the maintenance interval can may
be extended.
With the dynamic operation hours the service interval can be
raised up to 30 % (200 h max.). Make sure that the dynamic
operation hours are not reset accidently between the service
interval.
Note:
8.6.1 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 out 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 the front seal cover at the generator.
8.7
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 150 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.
For filling quantity, see „Technical Data“ at page 107.
8.8
Checking oil-level
You require:
paper towels / cloth for the oil dipstick
The generator must be placed at level.
• with marine generators: Measure the oil-level when the ship is not lop-sided.
Generator, coolant and engine oil can be hot during and
after operating.
Caution: Burn hazard!
Wear personal protective equipment. (Gloves, protective
goggles, protective clothing and safety shoes)
• Assure generator against accidental start.
Seite/Page 74 - Kaptitel/Chapter 8: Maintenance Instructions
13.4.17
Maintenance Instructions
• Open the generator casing.
• Screw the oil dipstick out of the check rail.
• Clean oil dipstick.
• Put the oil dipstick back into the check rail, do not screw it in
and wait for 10 seconds.
Fig. 8.8-1: Oil dipstick
• Pull the oil dipstick out of the check rail and read off the oil-level at the lower end of the stick.
Oil dipstick FP320 Engine
Fig. 8.8-2: Oil dipstick
The oil-level is to be checked by means of the oil dipstick.
The prescribed filling level must not cross the „Max“-mark.
We recommend an oil-level of 90%.
Oil Max.
Oil Min.
90% Suggestion
Oil should be refilled, if the oil-level is under 50% between the minimum and the maximum mark.
Fischer Panda recommends an oil-level of 90% between the minimum and the maximum mark.
If the oil-level is under the MIN-mark, check how many operating hours went by since the last oil change, by means
of your service manual or an existing oil change tag. - with operating hours between 50 and 150 hours it is only
necessary to refill oil. See „Refilling oil“ on page 2.
• with 150 operating hours or more the oil should be changed (See your generators’ service table)
• if the oil-level is under the minimum mark by less than 50h, there might be a technical problem! In that case, we
recommend going to a shop or a Fischer Panda service point.
• if the oil is cloudy or even „creamy“, coolant might have mixed with the oil. See a garage or a Fischer Panda service
point immediately.
8.8.1 Refilling oil
You require:
Engine oil
1. Check oil-level as described under section 8.8, “Checking oil-level,” on page 74.
2. Oil dipstick is pulled out of the check rail.
3. Open the oil filler cap.
4. Fill in oil (approx. 0,1 litre) and wait for about 2 min. so this it can flow into the oil pan.
13.4.17
Kapitel/Chapter 8: Maintenance Instructions - Seite/Page 75
Maintenance Instructions
5. Wipe off the oil dipstick and put it into the check rail.
6. Pull the oil dipstick out of the check rail and check the oil-level. See section 8.8, “Checking oil-level,” on page 74.
If oil-level is still too low (under 2/3): repeat steps 4-6.
8.8.2 After the oil level check and refilling the oil
• Screw the oil dipstick back into the check rail.
• Close the oil filling cap.
• Remove potential oil stains and splashes from the generator and surroundings.
• Close the generator casing.
• Remove lock against accidental generator start.
8.9
Replacement of engine oil and engine oil filter
You require:
- Engine oil. See attachment.
- New oil filter (not with generators with EA300
engines)
- Sealing for oil drain screw
- Personal protective gear
- Container to collect used oil (heat resistant and
of sufficient size)
- Open-ended wrench for oil drain screw
- Paper towels and cloth
- Oil filter wrench
- Oil resistant mat, so prevent used oil from
getting into underground water
The generator must be placed at level.
• with marine generators: Change the oil when the ship is not lop-sided.
Run the generator till the engine temperature reach 60°C to ensure that the engine is warm.
Generator and coolant can be hot during and after
operating.
Caution: Burn hazard!
Wear personal protective equipment. (Gloves, protective
goggles, protective clothing and safety shoes)
1. Prepare generator.
- Assure generator against accidental start.
- Open the generator casing.
- Release the oil drain hose from the mounting.
Place an oil resistant mat under the oil drain hose area and prepare the container.
Seite/Page 76 - Kaptitel/Chapter 8: Maintenance Instructions
13.4.17
Maintenance Instructions
2. Loosen oil filling cap
Fig. 8.9-1: Oil filling cap
Unscrew the oil filling cap. This is necessary, because
otherwise a vacuum will form and the oil can not
completely drain off.
3. Open oil drain screw.
Fig. 8.9-2: Oil drain hose
Unscrew the oil drain screw by means of the open-ended
wrench from the oil drain hose (rotating direction left).
Use a second open-ended wrench to lock. Make sure to
do this over the container.
Use spanner size 17 mm.
4. Discharge used oil.
Let the entire amount of oil drain out of the engine. This can take several minutes.
5. Remove used oil filter / clean oil screen
Fig. 8.9-3: Oil filter
Release the oil filter by turning the filter wrench
counterclockwise. The filter might be full of oil. Make sure
to not spill anything and avoid skin contact.
Sample picture
6. Preparing a new filter
Fig. 8.9-4: Oil screen sealing ring
Clean the engines’ filter holder brush a thin oil layer on the
sealing of the new filter.
7. Mounting the new filter
Carefully screw in the new filter by hand. It must not be tightened too much. Screw in the oil drain screw again
and tighten is with the wrench. Use a new sealing for the oil drain screw.
8. Fill in oil. (oil fill capacity: see attachment)
13.4.17
Kapitel/Chapter 8: Maintenance Instructions - Seite/Page 77
Maintenance Instructions
Fill the engine oil into the engine via feed hopper. Check oil-level after every 0,75 litres with the oil dipstick.
9. Check proper filling level. See section 8.8, “Checking oil-level,” on page 74.
When the proper filling level is reached, screw in the oil cap again. Run the engine for 10 minutes and then turn it
off. Check the oil-level once more after several minutes with the oil dipstick. If it is too low, refill some oil.
10. Clean up
Wipe off all oil splashes from the generator and make sure that the drain screw has no leak.
8.9.1 After the oil change
• Screw the oil dipstick back into the check rail.
• Close the oil filling cap.
• Remove potential oil stains and splashes from the generator and surroundings.
• Close the generator casing.
• Remove lock against accidental generator start.
• Duly dispose of used oil and filter.
Used oil is very toxic and must not be disposed with domestic waste. It is prohibited to dispose used oil with
waste water! Make sure that used oil is disposed properly (e.g.: where oil is bought or at collection stations).
8.10 Verifying the starter battery and (if necessary) the battery bank
Check the condition of the battery. Proceed here as prescribed by the battery manufacturer.
If from the battery manufacturer not otherwise mentioned.
8.10.1 Battery
8.10.1.1 Check battery and cable connections
• Keep battery clean and dry.
Fig. 8.10.1.1-1: Battery
• Remove dirty clamps.
• Clean terminal posts (+ and -) and clamps of the battery,
and grease with acid-free and acid-resistant grease.
• When reassembling, ensure that clamps make good
contact. Tighten clamp bolts hand-tight.
Seite/Page 78 - Kaptitel/Chapter 8: Maintenance Instructions
13.4.17
Maintenance Instructions
8.11 Checking the water separator in the fuel supply
The pre-filter with water separator has a cock underneath, by
which means the water can be drained.
Fig. 8.11-1: Pre-filter with water separator
This water sinks to the bottom, due to the difference in the
densities of water and fuel. Water is heavier than the diesel
Sample picture
8.11.1 Exchange of the Fuel Filter
Exchanging the filter, depending upon fuel contamination,
should take place after 300 operational hours at the very
least.
Fig. 8.11.1-1: Fuel Filter
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.
8.11.2 De-aerating the fuel system
Normally, the fuel system is designed to bleed out air itself i.e. as soon as the electric starter motor starts operation
the fuel pump starts working and the fuel system will be de-aerated after some time automatically. It is nevertheless
essential to bleed the system as follows prior to the first operation (as all hoses are empty) and after a fuel filter
replacement:
13.4.17
Kapitel/Chapter 8: Maintenance Instructions - Seite/Page 79
Maintenance Instructions
1. Put a container under the fuel return pipe to catch running
out fuel to catch.
Fig. 8.11.2-1: Fuel return pippe
2. Switch the panel „ON“.
3. Activate the the fuel pump prime function in the panel
menue.
4. Let the pump run till the fuel runs bleed free out of the
return line. (about three times activation of the fuel pump
prime function)
This procedure must be repeated several times, until fuel
(nonporously) withdraws perfectly at the fuel return pipe.
Fig. 8.11.2-2: iControl
5. Switch the panel „OFF“.
8.11.3 Replacement of the air filter
Open the air suction housing by turning the cap about
20° anti clockwise. Remove the cap.
Fig. 8.11.3-1: Air filter
8
Seite/Page 80 - Kaptitel/Chapter 8: Maintenance Instructions
13.4.17
Maintenance Instructions
Remove the air filter.
Fig. 8.11.3-2: Air filter
Clean the air filter housing.
Replace the air filter and close the cover again.
8.12 De-aerating of the coolant circuit / freshwater
The Panda 5000i PMS is self de-aerating.
8.13 The raw water circuit
8.13.1 Clean raw water filter
The raw water filter should be released regularly from arrears. In
each case the water cock must be closed before. It is mostly
sufficient to beat the filter punnet.
If water should seep through the cover of the raw water filter, this
may be sealed in no case with adhesive or sealant. Rather must be
searched for the cause for the leakage. In the simplest case the
sealing ring between caps and filter holders must be exchanged.
Fig. 8.13.1-1: Raw water filter
8.13.2 Causes with frequent impeller waste
The impeller of the cooling water pump must be regarded as wearing part. The life span of the impeller can be
extremely different and exclusively depends on the operating conditions. The cooling water pumps of the PANDA
generators are laid out in such a way that the number of revolutions of the pump lies low compared with other
aggregates. This is for the life span of the pump a positive effect.
Unfavorably affects the life span of the impeller, if the cooling water sucking in way is relatively long or the supply is
handicapped, so that the cooling water sucking in range develops a negative pressure. This can reduce first of all
the power of the cooling water pump extremely that the wings of the impeller are exposed to very strong loads. This
13.4.17
Kapitel/Chapter 8: Maintenance Instructions - Seite/Page 81
Maintenance Instructions
can shorten the life span extremely.
Further the operation of the impeller pump loaded in waters with a high portion of suspended matters. The use of the
impeller pump is particularly critical in coral waterbodies. Cases are well-known, which a impeller pump had so
strongly run after 100 hours already that the lip seal on the wave was ground in. In these cases sharp crystal parts of
the coral sand assess in the rubber seal and affect like an abrasive the high-grade steel shank of the impeller pump.
If the generator were mounted over the water level it is particularly unfavorable for the impeller pump. After the first
start some seconds will pass by, until the impeller can suck in cooling water. This short unlubricated operation time
damages the impeller. The increased wear can lead after short time to the loss. (see special notes: "Effects on the
impeller pump, if the generator is mounted over the waterline").
8.13.3 Replacement of the impeller
Close the raw water stop cock.
Raw water pump on the front side of the genset.
Seite/Page 82 - Kaptitel/Chapter 8: Maintenance Instructions
Fig. 8.13.3-1: Raw water stop cock
Fig. 8.13.3-2: Raw water pump
13.4.17
Maintenance Instructions
Remove the cover of the raw water pump by loosen the
wing screws from the housing.
Pull to the impeller with a multigrip pliers of the wave.
Fig. 8.13.3-3: Raw water pump
Fig. 8.13.3-4: Impeller
Mark the impeller, to make sure that these is used in the
correct position at re-installation.
Check to the impeller for damage and replace it if
necessary.
Fig. 8.13.3-5: Impeller
Before the reinsertion into the housing the impeller should
have been lubricated with glycerin or with a non-mineral oil
based lubricant e.g. silicone spray.
The impeller is attached to the pump wave (if the old
impeller is used, pay attention to the before attached
marking).
Fig. 8.13.3-6: TImpeller seal
Fastening the cover and use a new seal.
13.4.17
Kapitel/Chapter 8: Maintenance Instructions - Seite/Page 83
Maintenance Instructions
Seite/Page 84 - Kaptitel/Chapter 8: Maintenance Instructions
13.4.17
Generator Tables
9. Generator Tables
9.1
Diameter of conduits
Fig. 9.1-1: Diameter of conduits
Generator type
Panda 5000i PMS
9.2
Ø Cooling water
pipe
Ø Cooling water
pipe external
expansion tank
Raw water
[mm]
Feed /Bleeding
[mm]
12
10/8
Ø Exhaust hose
[mm]
40
Ø Fuel hose
Supply
[mm]
Return
[mm]
8
8
Technical Data
Fig. 9.2-1: Technical Data generator
Type
Panda 4200 FC
FPE-320
Panda 5000i Neo
FPE-320
Panda 4000S neo
FPE-320
Rpm control
mecanical
I Control 2
mecanical
Automatik Startbooster
no
no
no
Cylinder
1
1
1
Bore
78 mm
78 mm
78 mm
Stroke
64 mm
64 mm
64 mm
Stroke volume
306 cm³
306 cm³
306 cm³
max. Power (DIN 6270-NB) at 3000rpm
4,4kW @3600rpm
4,4kW @3600rpm
4,0kW @3000rpm
Rated speed
3600rpm
3250rpm
3000rpm
Idle speed running
--
2500rpm
--
Valve clearance (engine cold)
in:0,15 ; ex: 0,15
in:0,15 ; ex: 0,15
in:0,15 ; ex: 0,15
Lubrication oil capacity
2,1l
2,1l
2,1l
Fuel consumption
-
on request
-
Oil consumption
max. 1 % of Fuel consumption
Lubrication oil spezification
SAE 15W-40
ACEA A3/B3
Permissible max. permanent tilt of engine
Recommend starter battery size
Recommend cable cross size starter battery
cable
Length 4 meter max.
Max. exhaust back pressure
13.4.17
SAE 15W-40
ACEA A3/B3
SAE 15W-40
ACEA A3/B3
recommend:
recommend:
Castrol GTX
Castrol GTX
a) 20° gegen die Motorachse
b) 20° in der Motorachse
12 V 55 Ah
12 V 55 Ah
recommend:
Castrol GTX
12 V 55 Ah
Min 35 mm²
recommend 55mm²
Min 35 mm²
recommend 55mm²
Min 35 mm²
recommend 55mm²
9,3 kPa
93 Millimbar
9,3 kPa
93 Millimbar
9,3 kPa
93 Millimbar
Kapitel/Chapter 9: Generator Tables - Seite/Page 85
Generator Tables
9.3
Types of coil
HP3 delta connection
9.4
Fig. 9.3-1: HP3 delta connection
Engine oil
9.4.1 Engine oil classification
Full mineral engine oil SAE15W-40 ACEA A3/B3
Fischer Panda recommend Castrol GTX
9.5
Fuel
Use a clean Diesel fuel oil according to DIN590:1999 or better. For Generators with common rail or particle filter use
DIN590:2009 or better.
Do not use alternative fuel, because its quality is unknown or it may be inferior in quality. Kerosene, which is very low
in cetane rating, adversely effects the engine.
9.6
Coolant specifications
Use a mixture of water and antifreeze. The antifreeze needs to be suitable for aluminium. The antifreeze
concentration must be regularly checked in the interests of safety.
Fischer Panda recommend to use the product: GLYSANTIN PROTECT PLUS/G 48
Engine coolant automotive industry Product description
Product name
GLYSANTIN ® PROTECT PLUS / G48
Chemical nature
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
Seite/Page 86 - Kaptitel/Chapter 9: Generator Tables
7,1 – 7,3
13.4.17
Generator Tables
9.6.1 Coolant mixture ratio
Water/antifreeze
Temperature
70:30
-20 °C
65:35
-25 °C
60:40
-30 °C
55:45
-35 °C
50:50
-40 °C
13.4.17
Kapitel/Chapter 9: Generator Tables - Seite/Page 87
Generator Tables
Seite/Page 88 - Kaptitel/Chapter 9: Generator Tables
13.4.17
Inverter Panda PMGi 5000
10. Inverter Panda PMGi 5000
Art Nr.
Bez.
Document
Actual:
R03
Replace:
R02
13.4.17
0000793
0006781
Panda PMGi 5000
Hardware
Software
Kapitel/Chapter 10: Inverter Panda PMGi 5000 - Seite/Page 89
Inverter Panda PMGi 5000
10.1 Safety instruction
The generator may not be taken into use with the cover removed.
The rotating parts (belt-pulley, belts, etc) must be covered and protected so that there is no danger to life and body!
If a sound insulation cover must be produced at the place of installation, then well-placed signs must show that the
generator can only be switched on with a closed capsule.
All servicing-, maintenance or repair work may only be carried out, when the motor is not running.
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.
Electrical power: DANGER TO LIVE!
Before start working at the Panda i-series Generator
(service, repair ect), disconnect the starter battery (First
minus cable, then positive cable). This avoid unexpected
start of the generator.
10.2 Type plate
1. Location of the type plate
Fig. 10.2-1: Location Type plate
1
Seite/Page 90 - Kaptitel/Chapter 10: Inverter Panda PMGi 5000
13.4.17
Inverter Panda PMGi 5000
Fig. 10.2-2: Type plate 230 V 50 Hz version
Fig. 10.2-3: Type plate 110 V 60 Hz version
13.4.17
Kapitel/Chapter 10: Inverter Panda PMGi 5000 - Seite/Page 91
Inverter Panda PMGi 5000
10.3 Front side/connection side
To connect the PMGi 5000 use the prepared cable with the
4pin plug and connect to socket 3 (PMGi in-450 V/400 Hz)
Fig. 10.3-1: Connection side 230 V Version
3
Connect your termination box with the socket 1.
Do not cover the Air out grille (2)
1
1. Socket for Load
2. Air out grille
3. Socket for generator connection
4
4. FP- Bus socket connection to generator
2
Seite/Page 92 - Kaptitel/Chapter 10: Inverter Panda PMGi 5000
13.4.17
Inverter Panda PMGi 5000
Fig. 10.3-2: Connection side 110V and 120 V Version
3
1
4
2
10.3.1 Socket pins of the PMGi 5000
Socket 1 - 230 V / 50 Hz AC - PMGi out
Fig. 10.3-1: Socket 1
1. Ground (cable green/yellow)
2. Live (cable brown)
3
1
3. Neutral (cable blue)
Connecting the Phase with the earth pin will destroy the
PGMi
13.4.17
2
Attention!
Kapitel/Chapter 10: Inverter Panda PMGi 5000 - Seite/Page 93
Inverter Panda PMGi 5000
10.4 Back side - Top side
Fig. 10.4-1: Back side
1
Inside of the PMGi a fan is mounted. The air holes and air grille should not be covered.
1. Air holes
Inside of the PMGi are up to 550 VAC. The cover of the
PMGi should only be opened by special trained persons!
!Danger for Live!
Attention!
Make sure that the connection between the generator
and the PMGi is secured. Never connect or disconnect
the PMGi while the generator is running. This will
destroy the PMGi (it may burn or explode).
Attention!
Seite/Page 94 - Kaptitel/Chapter 10: Inverter Panda PMGi 5000
13.4.17
Inverter Panda PMGi 5000
10.5 Settings for the use of iGenerators with power inverter
For the use of power inverter with the PMGi, the settings of
the power inverter must be modified.
ATTENTION: Wrong settings can destroy the
PMGi
Wrong settings can damage or destroy the PMGi.
The settings for the Victron power inverter must be adapted for the power inverters of other brands.
10.5.1 Settings in the Victron VE Configure II Software - General
Fig. 10.5.1-1: Settings in the Victron VE configure II Software
10.5.1.1 Uninterrupted AC power (UPS function)
Due to the fact that the power inverter connects the shore power immediately to the domestic grid (to fast), the PMGi
gets overloaded and shut down with an error.
UPS Function must be deactivated.
10.5.1.2 Dynamic current limiter
With inductive load the dynamic current limiter will raise up the Voltage in the DC circuit. These over voltage can
damage or destroy the PMGi.
Dynamic current limiter must be deactivated.
13.4.17
Kapitel/Chapter 10: Inverter Panda PMGi 5000 - Seite/Page 95
Inverter Panda PMGi 5000
10.5.2 Settings in the Victron VE Configure II Software - Inverter
Fig. 10.5.2-1: Settings in the Victron VE configure II Software
10.5.2.1 Assist current boost factor
To reduce the action of the power inverter on the iGenerator, the Assist current boost factor must be reduced from
2.0 to 1.3. Wrong settings will cause bad rpm control of the generator.
Seite/Page 96 - Kaptitel/Chapter 10: Inverter Panda PMGi 5000
13.4.17
Inverter Panda PMGi 5000
10.6 Operation manual
10.6.1 Primary remarks / Winter operation
The PMGi can operate in the range of -20 °C to +40 °C.
10.6.2 Load at the PMGi
Do not overload the PMGi. It will go on error.
10.6.3 Automatic start
The generator can start (depending on the remote control panel) by an external signal (automatic start)
If you use this option make sure that the load is connected to the PMGi after the output has reached the nominal
230 V / 50 Hz and not to overload the PMGi (some electronic devices, such like air conditions, need an higher start
current). May use a relay which connect the load at 230 V.
10.7 Status LED´s
Red - Green
LED - Red
Red LED lights for the very first seconds (about 10 sec) after the running of the engine. During this time no output is
provided by the PMGi.
Red LED starts to blink when an overload condition is reached. During this time the green LED continiues to light.
When an overload condition stays for too long the red LED stops blinking and stays permanently switched on, while the
green LED switch off.
LED-Green
Green LED permanently lights alone when the PMGi output is available and it value stays in the spacification
10.8 Cooling of the PMGi
Inside of the PMGi a fan is mounted.
Do not cover the air holes and grille.
The heat sink and the fan of the PMGi may become dirty as a consequence of the use of the generator, and so the
unit can loose a part of their heat transfer characteristic. Every 6 months it is necessary to visual inspect the heat
sinks and clean it with compressed air. At every Generator service the fan of the PMGi should be cleaned by the
special trained person.
13.4.17
Kapitel/Chapter 10: Inverter Panda PMGi 5000 - Seite/Page 97
Inverter Panda PMGi 5000
10.9 Installation of the PMGi
The PMGi must be mounted vertical, with the electrical connection down. So you can read the writing on the PMGi.
The surface where the PMGi is mounted should be smoothed and support the heat transfer. The Air holes and Air
grille must be not covered and enough cooling air must be pleasant at any time for the PMGi.
To mount the PMGi use the fixing holes diameter 6,5mm.
See the safety instruction in your Generator and iControl
Manual.
Note!
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.
10.9.1 Electrical connection.
Only special trained persons are allowed to make the electrical connection.
When an extension cable is required, be sure to use a though rubber sheeted flexible and fireproof cable. Limit
length of extension cables depends on the voltage drop along the cable. This drop must be less than 2,5 % value of
the nominal output voltage.
Pay attention to the right pin assignment. See “Socket pins of the PMGi 5000” on page 93.
10.9.1.1 Connection to a system with RCD
The PMGi is prepared for the use in a RCD protected grid.,
The PMGi out must be connected 1:1 (PE,N,L) to the customers electrical cabinet. The Life wire and neutral wire will
be connected to the RCD. The PE will be connected to the PE of the electrical cabinet. After installation the function
of the RCD must be tested.
Seite/Page 98 - Kaptitel/Chapter 10: Inverter Panda PMGi 5000
13.4.17
Inverter Panda PMGi 5000
PE-N Bridge
Fig. 10.9-1: PE-N bridge
Inside of the PMGi a PE-N bridge
1
10.9.1.2 Connection to a system with isolation control
For the use of the PMGi with an isolation controlled grid, the internal PWE-N Bridge must be disconnected.
A Manual for this modification can be downloaded under:
http://www.fischerpanda.de/images/gensets/M_AC_50_INV_PMS_8000i/operatormanual/PMGi/
Modification_PMGi_isolation_control.eng.pdf
10.10Technical data
10.10.1 General data
PMGi is part of the Panda i-series generator. It´s not allowed to be used with other generators or aplications.
Storage temperature
PMGi
-20 °C to +55 °C
Working temperature
PMGi
Minimum: -20 °C
Maximum: +40 °C
Maximale internel temperature of the PMGi:
+60 °C
10.10.2 Generator spezification
PMG Generator out
3 phase
Voltage Phase
minimum 140 V AC
Maximum 250 V AC
Frequency
minimum 250 Hz
Maximum 400 Hz
13.4.17
Kapitel/Chapter 10: Inverter Panda PMGi 5000 - Seite/Page 99
Inverter Panda PMGi 5000
10.10.3 PMGi out
Fig. 10.10.3-1: Technische Daten PMGit / Technical data PMGi / PMGi Out
PMGi 5000 230 V
PMGi 5000 110 V
Nominale
Ausgangsspannung
Nominal Voltage
Tension de sortie nominale:
NOVAC
230 V VAC +/- 5 % ohne 110 V VAC +/- 5 % ohne
Last / without Load / sans Last / without Load / sans
charge
charge
Regelung
Regulation
Réglage
R
5%
5%
Stabilität (Kurzzeit (30sec))
Stability (short term (30sec))
Stabilité (courte durée (30s))
Ds
5%
5%
Stabilität (Langzeit (4h))
Stability (Long term (4h))
Stabilité (longue durée (4h))
Dl
5%
5%
Spannungsabweichung
Voltage offset
Divergence de tension
Voffset
+-5 V -20 °C bis +40 °C
+-5 V -20 °C to +40 °C
+-5 V -20 °C à +40 °C
+-5 V -20 °C bis +40 °C
+-5 V -20 °C to +40 °C
+-5 V -20 °C à +40 °C
Stromstärke
Current
Courant
StromstärkeNominal
CurrentNominal
CourantNominal
17,4 A @230Veff.
36,4 A @110 Veff.
StromstärkeMaximum
CurrentMaximum
CourantMaximum
22 A @ cos phi 0,8
@230 Veff.
22 A @ cos phi 0,8
@230 Veff.
Nominal
Nominal power
Nominale
5,0 kVA
5,0 kVA
Dauer
Long term
3,6 kW
3,6 kW
Nominale Frequenz
Nominal Frequency
Fréquence nominale
50 Hz +/-2 %
60 Hz +/-2 %
Regulierung
Regulation
Réglage
4%
4%
Stabilität (Kurzeitig) (30 s))
Stability (short term (30 s))
Stabilité (courte durée
(30 s))
3%
3%
Stabilität (Langzeit (4 h))
3%
Stability (Long term (4 h))
Stabilité (longue durée (4 h))
3%
Leistung
Power
Puissance
Frequenz
Frequency
Fréquence
Krestfaktor 1)
Crestfactor 1)
Facteur de crête
3:1
3:1
Empfohlene Absicherung
Recommend protection fuse
Sécurisation recommandée
25 A
50 A
Empfohlener
Kabelquerschnitt
Recommend cable cross
Section de câble recommandée
2,5 mm²
10 mm²
Umgebungstemperatur max.
Ambient temperature
40 °C
40 °C
1) Peak Strom darf den 3-fachen Nennstrom erreichen
1) Peak current is allowed to reach 3 times of the nominal current
Seite/Page 100 - Kaptitel/Chapter 10: Inverter Panda PMGi 5000
13.4.17
Inverter Panda PMGi 5000
10.10.4 Overload - switch point
Output type
Max. current
Comments
230VAC
30,0 A +/- 0.5 A
When protection takes place the engine must be switched off and all appliances
detached
10.10.5 Short circiut
To operate the short circuit protection a fuse must be put in series with the live wire. The minimum requested feature
for this fuse are the following.
Rated current
1.2
1.5
2.75
4.0
10.0
26A
>1 h
<30 min
5 ms to 150 ms
2 ms to 15 ms
<2 ms
The electrical Data refer to the system running in
accordance with all the limits defined in the
„General Specification“ table.
13.4.17
Note!
Kapitel/Chapter 10: Inverter Panda PMGi 5000 - Seite/Page 101
Inverter Panda PMGi 5000
Seite/Page 102 - Kaptitel/Chapter 10: Inverter Panda PMGi 5000
13.4.17
Panda iControl2
Operating Manual
Open-loop and closed-loop control system for Fischer Panda generators
Panda iControl2_eng.R08
13.4.17
Current revision status
Document
Current:
Panda iControl2_eng.R08_13.4.17
Replaces:
Panda iControl2_eng.R07
Revision
Page
Kontrolltätigkeiten vor dem Start eingefügt
Emergency stop, Fehlerspeicher, Master Slave eingepflegt R08
Hardware
Generator
Revision
Modification Strike Plate
Date
Upgrade
Created by
Fischer Panda GmbH - Head of Technical Documentation
Otto-Hahn-Str. 32-34
33104 Paderborn - Germany
Phone: +49 (0) 5254-9202-0
E-mail: [email protected]
web: www.fischerpanda.de
Copyright
Reproduction and modification of the manual is permitted only after agreement with the manufacturer!
Fischer Panda GmbH, 33104 Paderborn, reserves all rights regarding text and graphics in this document. Details
are given to the best of our knowledge. No liability is accepted for correctness. Please note: technical modifications
aimed at improving the product may be implemented without prior notice. Therefore, it must be ensured prior to
installation that the pictures, diagrams and related material are applicable to the genset supplied. In case of doubt,
verify upon delivery that documentation and equipment match.
Fischer Panda GmbH
Otto‐Hahn‐Str. 40
D‐33104 Paderborn
Germany
Tel.
Fax.
Hotline
Email
Web
:
:
:
:
:
+49 (0)5254 9202‐0
+49 (0)5254 9202‐550
+49 (0)5254 9202‐767
[email protected]
www.fischerpanda.de
Safety instructions for the Panda iControl2
11. Safety instructions for the Panda iControl2
11.1 Personnel
The settings described here can be performed by the operator unless highlighted differently.
The installation should be implemented by specially trained technical personnel or by authorised workshops (Fischer
Panda Service Points), only.
11.2 Safety instructions
Ensure compliance with the safety instructions in the
Fischer Panda genset manual.
NOTE:
If these instructions are not on hand, they can be requested
from Fischer Panda GmbH, 33104 Paderborn, Germany.
An external signal may trigger an automatic start-up.
WARNING: Automatic start-up
The generator must not be operated with the cover
removed.
WARNING:
If the generator is being installed without a sound insulation
capsule, it must be ensured that all rotating parts (belt pulley,
belts etc.) are covered and protected so that there is no
danger to life and body!
If a sound insulation capsule will be produced at the place of
installation, then well-placed signs must show that the
generator can only be switched on with the capsule closed.
All service, maintenance, or repair work may only be carried
out when the unit is not running.
Electric voltage - DANGER TO LIFE!
WARNING: Electric voltage
Electric voltages of more than 60V are potentially lethal in
any situation. The rules of the respective regional authority
must be adhered to for installation and maintenance.
For safety reasons, only an electrician may carry out the
installation of the electrical connections of the generator.
Disconnect battery before working on the generator
WARNING:
The battery must always be disconnected (first the negative
terminal, then the positive terminal) if work on the generator
or electrical system is to be carried out, so that the generator
cannot be unintentionally started.
This applies in particular to systems with an automatic startup function. The automatic start-up function shall be
deactivated before starting work.
13.4.17
Kapitel/Chapter 11: Safety instructions for the Panda iControl2 - Seite/Page 105
Safety instructions for the Panda iControl2
The flooding valve must be closed. (For PMS version only.)
Also observe the safety instructions for the other
components of your system.
Seite/Page 106 - Kaptitel/Chapter 11: Safety instructions for the Panda iControl2
NOTE:
13.4.17
General operation
12. General operation
12.1 The Panda iControl2 panel
The "Panda iControl2 panel" control panel is the control and display unit for the Panda iControl2 control system and
represents the interface between the user and the Panda iControl2 controller. The integrated display serves to
present the most important data of the system as well as warnings and error messages.
The control panel is equipped with four buttons for operating the Panda iControl2 controller:
Fig. 12.1-1: Panda iControl 2 panel
1. On/Off button: Switching the Panda iControl2 controller on and off
2. Start/Stop button: Starting and stopping the generator, confirming values in selection menus (Enter key)
3. Cursor-up button Switching between display screens (up), counting values up in selection menus
4. Cursor-down button Switching between display screens (down), counting values down in selection menus.
13.4.17
Kapitel/Chapter 12: General operation - Seite/Page 107
General operation
12.2 Starting preparation / Checks (daily)
12.2.1 Marine version
1. Oil level control (ideal level: 2/3 MAX).
The level should be about 2/3 of the maximum level of a cold engine.
Further, if installed, the oil level of the oil-cooled bearing must be controlled before each start - see sediment bowl
at generator front cover!.
2. State of cooling water.
The external expansion tank should be filled up to 1/3 of the maximum in a cold state. 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 reopened 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 (on).
12.2.2 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.
Close battery main switch (on).
Seite/Page 108 - Kaptitel/Chapter 12: General operation
13.4.17
General operation
12.3 Operation
12.3.1 Switching the controller on and off
The Panda iControl2 controller is switched on and off with the On/Off button on the Panda iControl2 panel. Press
and hold the On/Off button until the start screen with the panda bear appears on the display. The controller is
switched off by actuating the On/Off button once more.
On the start screen, the hardware version, the generator
type, and the software version are shown at the bottom
left.
Fig. 12.3.1-1: .Panda iControl2 start screen
Fig. 12.3.1-2: Hardware version, generator type, and software version in default display
Example:
Note:
Hardware version: 2 -> iControl2 controller
Generator type: 01 -> Panda 5000i PMS
Software version: 2.0 -> iControl2, compatible with iControlPanel2
12.3.2 The default display screen
Five seconds after the controller is switched on, the display will change to the default display screen. On the default
display screen, you will find information on the battery voltage, operating hours of the generator, temperatures of
cylinder head, exhaust manifold, and winding, RPM, and the oil pressure status. Also, a bar graph display at the right
hand edge of the display shows the utilisation of the generator in percent.
Data output on the default display screen:
• Battery voltage (supply voltage)
• Status field for operating modes (stand-by, pre-heat, starting, override, running, autostart, stopping)
• Operating hours of the generator
13.4.17
Kapitel/Chapter 12: General operation - Seite/Page 109
General operation
• Oil pressure status
• Cylinder head temperature
• Temperature of exhaust manifold
• Winding temperature
• Speed/RPM
• Utilisation in percent
Fig. 12.3.2-1: Default display screen
The Display shows the iControl board input voltage.
Note:
At generator systems with 12 V starter system these is equal
with the starter battery voltage.
At generator system with 24 V starter system the starter
battery voltage can not be displayed.
12.3.3 Operating modes
The Panda iControl2 controller offers different operating modes.
12.3.3.1 Stand-by mode
After the controller is switched on with the On/Off button, the system is in stand-by mode. This is indicated by the
output "STANDBY" in the status field in the top right corner of the default display screen. In this operating mode, the
system can be switched off with the On/Off button, and the generator can be started up with the Start/Stop button.
With the cursor buttons, the service information screen can be accessed.
Seite/Page 110 - Kaptitel/Chapter 12: General operation
13.4.17
General operation
Fig. 12.3.3.1-1: Service information screen
The total operating hours of the generator are given on the default display screen and on the service information
screen. By actuating the cursor-up and cursor-down button in stand-by mode, the service screen can be accessed.
This screen is marked with a screwdriver/spanner symbol. Here, the time until the next service is given. By actuating
the cursor-up or cursor-down button, you can return to the default screen.
With the dynamic operation hours the service interval can be
raised up to 30 % (200 h max.). Make sure that the dynamic
operation hours are not reset accidently between the service
interval. see “Resetting the service interval ("Service")” on
page 121.
Note:
In the set-up menu of the controller, you can reset the service interval after performing maintenance. Siehe “Set-up
menu” auf Seite 117.
12.3.3.2 Start-up mode
The start-up mode represents the transition from stand-by mode to operation mode, i.e., generator operation. By
actuating the Start/Stop button in stand-by mode, you can initiate the start-up process of the generator.
The pre-heating is the first step. During this stage, the status field at the top right of the default display screen shows
the word "PREHEAT".
The pre-heating is always implemented for a duration of
10 seconds, regardless of the cylinder head temperature.
Fig. 12.3.3.2-1: Default display screen during pre-heating
In temperatures below 0°C, the pre-heating time is always 40
seconds.
After pre-heating, the starter is initiated, accompanied by
the text output "STARTING" in the status field of the
default display screen.
13.4.17
Fig. 12.3.3.2-2: Default display screen during start-up
Kapitel/Chapter 12: General operation - Seite/Page 111
General operation
The controller will only perform one starting attempt. If
the generator could not be started, the text output
"STARTING FAILS" informs you of the failure of the
generator starting attempt.
Note:
Acknowledging the message with the cursor-up, cursor-down, or the Start/Stop button on the Panda iControl2 panel
will return the system to stand-by mode.
If there is difficulty in starting - close the seacock (Panda
Marine Generators only)
ATTENTION:
If the generator engine does not start immediately and further start attempts are necessary, then the seacock MUST
be closed (i.e. for ventilating the fuel lines ect.) The cooling water impeller pump turns automatically and draws cooling water as long as the motor is turning. If the diesel motor is running, the cooling water is blown out by the exhaust
system gases. The cooling water cannot be pressed through the exhaust as long as the diesel motor does not run at
sufficient speed. This leads to severe motor damage.
Open the sea valve as soon as the generator is started.
12.3.3.3 Override mode
The override mode follows directly after the successful start-up of the generator. In this mode, no fault analysis is
performed. The duration of the override mode is 10 seconds. The status indicator on the display reads
"OVERRIDE".
Fig. 12.3.3.3-1: Default display screen in override mode
12.3.3.4 Operation mode
Operation mode signifies the operating mode in which the generator is running and all operating data are within their
normal range. The status field of the default display screen shows "RUNNING".
In operation mode, the electrical load is given on the
right hand side of the default display screen and in the
inverter screen as a bar graph. The bar graph merely
provides a guide value for the load of the generator and
gives the values as a percentage.
Seite/Page 112 - Kaptitel/Chapter 12: General operation
Fig. 12.3.3.4-1: Default display screen in operation mode
13.4.17
General operation
Display screen for single phase generators
With the single phase i-series generators, there is an
additional screen in operation mode for the inverter data.
This screen provides the current inverter output voltage
and the inverter temperature. You can access the
inverter screen by actuating the cursor-up button while
in operation mode.
Fig. 12.3.3.4-2: Inverter screen in operation mode
Display screens for 3-phase generators
With the 3-phase i-series generators, there are 5 additional
screen in operation mode for the inverter data. This screen
provides the inverter coil-voltage and the conductor current.
You can access the inverter screen by actuating the cursorup button while in operation mode.
Fig. 12.3.3.4-3: Inverter screen coil-voltage and conductor current
This screen provides the latest inverter phase voltages. You
can access the inverter screen by actuating the cursor-up
button while in operation mode.
Fig. 12.3.3.4-4: Inverter screen phase voltages
This screen provides the latest inverter output voltage of the
single phases with the matching conductor current and the
circuit board temperature. The inverter will be switched off at
a circuit board temperature of 75 °C. You can access the
inverter screen by actuating the cursor-up button while in
operation mode.
Fig. 12.3.3.4-5: Phase voltage L1
This screen provides the latest inverter output voltage of the
single phases with the matching conductor current and the
circuit board temperature. The inverter will be switched off at
a circuit board temperature of 75 °C. You can access the
inverter screen by actuating the cursor-up button while in
operation mode.
Fig. 12.3.3.4-6: Phase voltage L2
13.4.17
Kapitel/Chapter 12: General operation - Seite/Page 113
General operation
This screen provides the latest inverter output voltage of the
single phases with the matching conductor current and the
circuit board temperature. The inverter will be switched off at
a circuit board temperature of 75 °C. You can access the
inverter screen by actuating the cursor-up button while in
operation mode.
Fig. 12.3.3.4-7: Phase voltage L3
12.3.3.5 Panda i-Generator with electro-magnet Clutch (optional)
During the activation of the electro-magnetic clutch, the
icontrol raise the generator speed to maximum.
Attention!:
After the clutch is released, the generator speed will drop to normal.
Seite/Page 114 - Kaptitel/Chapter 12: General operation
13.4.17
General operation
12.3.3.6 Stop mode
By activating the Start/Stop button in operation mode, i.e., while the generator is running, you will stop the generator.
After stopping the generator, the system will return to stand-by mode. The display status field reads "STOPPING".
If the icontrol system detect a high cylinder head temperature (for example after a long time running with high load)
the icontrol start a stopping delay timer. The Display shows „Cooldown“ and a countdown.
During this timer the icontrol system will shut of the PMGi and run the engine at idle speed. During the delay time an
automatic start request will be ignored.
After the delay time, the generator will be stopped automatically.
You can interrupt the delay time by pressing the start/stop button. (Not recommend by Fischer Panda. The Engine
may overheat)
Fig. 12.3.3.6-1: Delay time
Never use an emergency stop switch for a regular stop
of the generator.
Attention:
The engine may overheat and can be damaged/destroyed
If the generator is manually started up and stopped while in
automatic start-up mode, it will switch to stand-by mode for
safety reasons.
Note: Manual start in autostart mode
If necessary, the autostart mode must be reactivated.
12.3.3.7 Autostart mode
The Panda iControl2 panel is equipped with an autostart function. A jumper between pin 6 (UBAT) and pin 7
(USTARTI of the Phoenix jack of the control panel starts up the generator with a delay of 5 seconds when the
autostart function is active. Removing the jumper will stop the generator - also with a delay of 5 seconds.
To activate the autostart function, you must first check the "Autostart" flag in the set-up menu. To activate the
autostart function, read Siehe “Activating/deactivating the autostart function ("Autostart")” auf Seite 119.
The display status field reading "AUTOSTART" indicates
that the autostart function is active, or, if it reads
"STANDBY", this means that the autostart function was
deactivated.
13.4.17
Fig. 12.3.3.7-1: Default display screen in autostart mode
Kapitel/Chapter 12: General operation - Seite/Page 115
General operation
The autostart function will remain active even after the
controller is switched off and on again with the On/Off
button. To deactivate the autostart function, the flag in
the EEPROM must be reset with "Disable". Siehe
“Activating/deactivating the autostart function
("Autostart")” auf Seite 119.
.Warning!:
Automatic start-up
If the generator is manually started up and stopped while
in automatic start-up mode, it will switch to stand-by
mode for safety reasons.
Note: Manual start in autostart mode
If necessary, the autostart mode must be reactivated.
Seite/Page 116 - Kaptitel/Chapter 12: General operation
13.4.17
General operation
12.4 Other operating functions
12.4.1 Set-up menu
In the set-up menu, a series of parameters can be modified directly using the control panel. To access the set-up
menu, you have to actuate the cursor-down button immediately after switching on the controller with the On/Off
button and while the start screen with panda bear is still being displayed. This will open a menu with the following
sub-items:
Fig. 12.4.1-1: Set-up menu
Menu item
Settings range for
backlight 1
Setting the brightness value for the standard backlighting to 0-9
backlight 2
Setting the brightness value for the dimmed backlighting to 0-9
Dimtime (dimming time)
Time until the display switches to dimmed mode, 0-225s, 0= function deactivated
Config
Password protected area for Fischer Panda associates and Fischer Panda service points
Network ID
Settings for the network ID of the panel
Save & Exit
Saving the values and exiting the set-up menu
Autostart
Activating and deactivating the automatic start-up function
Service
Resetting the "Operating hours to service" indication
Prime fuel
Activation of the fuel pump to prime the generator fuel system
Degree C/F
Switches the display between °C and °F
With the cursor-up and cursor-down buttons, you can
navigate through the menu. The currently selected menu
item is marked with two asterisks (*), e.g. "backlight 2":
Fig. 12.4-2: Set-up menu
Set-up menu with item highlighted: *backlight 2*
The Start/Stop button is used for confirming a selection
in the set-up menu. If you confirm the row marked with
the * with the Start/Stop button, you will access the
selected sub-menu.
Set-up menu
13.4.17
Note:
Fig. 12.4-3: Set-up menu
Kapitel/Chapter 12: General operation - Seite/Page 117
General operation
12.4.2 Setting the brightness of the backlight ("backlight" and "dimtime")
The brightness of the display backlight of the Panda iControl2 panel can be varied in ten increments (0-9). Also, the
display can be dimmed with a timer if no button is actuated on the control panel for a parameter is able period. To
adjust the default brightness and the dimmed brightness, the set-up menu offers the items "backlight 1" (default
brightness) and "backlight 2" (dimmed brightness). These service menu screens are highlighted with the light bulb
symbol:
The period after which the backlight is to switch to the dimmed level can be specified with the menu item "dimtime".
In this screen, you can enter the time in seconds, values between 0s and 255s are
possible.
In the sub-menus, set the desired values with the cursor
buttons, and then confirm your settings with the Start/
Stop button.
Note:
After setting all parameters, you can exit the set-up menu with the menu item "Save & Exit". In doing so, all settings
entered in the sub-menus backlight 1, backlight 2, dimtime, and Network ID are saved to the EEPROM. Then, the
goodbye screen appears for 3 seconds, and the controller is switched off.
At the next start of the controller, the changes will take effect.
Seite/Page 118 - Kaptitel/Chapter 12: General operation
13.4.17
General operation
12.4.3 The configuration menu ("config")
Settings in this area must only be entered by Fischer
Panda associates and Fischer Panda service points.
STOP!
The "config" sub-menu is a password protected area in which the generator type can be selected, and generator
parameters in the EEPROM can be modified.
12.4.4 The network ID
Settings in this area must only be entered by Fischer
Panda associates and Fischer Panda service points.
STOP! Network ID must not be modified
Changing the network ID can result in malfunction.
12.4.5 Saving settings and exiting the set-up menu ("Save & Exit")
After setting all parameters, you can exit the set-up menu with the menu item "Save & Exit".
In doing so, all settings entered in the sub-menus
backlight 1, backlight 2, dimtime, and Network ID are
saved to the EEPROM.
Fig. 12.4.5-1: Saving the values to the EEPROM
Then, the goodbye screen appears for 3 seconds, and the controller is switched off. At the next start of the controller,
the changes will take effect.
12.4.6 Activating/deactivating the autostart function ("Autostart")
DANGER TO LIFE! - Improper operation can result in
health impairment and death.
WARNING: Automatic start-up
While the automatic start-up function is active, the generator
can start up automatically. Before activating it, ensure that
the generator capsule is closed and that the corresponding
warning signs are affixed to the generator.
13.4.17
Kapitel/Chapter 12: General operation - Seite/Page 119
General operation
To activate the autostart function, select the item
"Autostart" in the set-up menu using the cursor buttons
and confirm the selection with the Start/Stop button.
Fig. 12.4.6-1: Set-up menu
In the "Autostart" sub-menu, you can select between the
options "Enable" and "Disable" using the cursor
buttons:
Fig. 12.4.6-2: "Autostart" sub-menu
To activate the autostart function, select "Enable" and again
confirm your selection with the Start/Stop button.
To deactivate the function, use the menu item "Disable".
The Panda iControl will then confirm your input:
Message "Autostart enabled" after confirming the
selection
Fig. 12.4.6-3: Message "Autostart enabled" after confirming the
Message "Autostart disabled" after confirming the
selection
Fig. 12.4.6-4: Message "Autostart disabled" after confirming the
The activation/deactivation of the autostart function is
then saved to the EEPROM of the control panel.
Seite/Page 120 - Kaptitel/Chapter 12: General operation
selection
selection
Fig. 12.4.6-5: Selection is saved to the EEPROM
13.4.17
General operation
Then, the controller is shut down.
After switching the controller back on, the display status
field reading "AUTOSTART" indicates that the autostart
function is active, or, if it reads "STANDBY", this means
that the autostart function was deactivated:
The autostart function will remain active even after the
controller is switched off and on again with the On/Off
button. To deactivate the autostart function, the flag in
the EEPROM must be reset with "Disable" as described
above.
Fig. 12.4.6-6: Goodbye screen prior to shutting down
Fig. 12.4.6-7: Default display screen in autostart mode
.Warning!:
Automatic start-up
The autostart function of the Panda iControl2 is now ready. While the autostart function is active, you can manually
start and stop the generator with the Start/Stop button, as well.
If the generator is manually started up and stopped while
in automatic start mode, it will switch to stand-by mode
for safety reasons.
Note: Manual start in autostart mode
If necessary, the autostart mode must be reactivated.
12.4.7 Resetting the service interval ("Service")
As the indication of operating hours remaining until the
next service interval can be reset at any time, it serves
only as an orientation guide. The service intervals shall
be implemented using the actual operating hours and
shall be properly documented in the service log of the
generator.
Note
With the dynamic operation hours the service interval
can be raised up to 30% (200h max.). Make sure that the
dynamic operation hours are not reset accidently
between the service interval.
Note:
In the set-up menu, select the menu item "Service" and confirm as usual, using the Start/Stop button. This will open
the screen with the service information discussed above, supplemented with the instruction to actuate the Start/Stop
button to reset the service interval.
13.4.17
Kapitel/Chapter 12: General operation - Seite/Page 121
General operation
Resetting the time until the next service
Fig. 12.4.7-1: Resetting the time until the next service
By actuating the Start/Stop button again, you can reset the
service interval to the original interval. The service interval for
each generator type is stored in the software.
The controller is switched off after resetting the service
interval. After restart, the new value will be displayed in the
service screen.
12.4.8 Priming the fuel system ("Prime Fuel")
To prime the fuel system, the Panda iControl2 offers the option of separately activating the fuel pump. In the set-up
menu, select the menu item "Prime fuel" and confirm your selection using the Start/Stop button.
Actuating the Start/Stop button again will switch on the
fuel pump for a duration of max. 30 seconds. After that,
the fuel pump will shut off automatically.
Fig. 12.4.8-1: Set-up menu
Naturally, you can also switch off the fuel pump manually.
For this purpose, confirm the menu item "Prime fuel" again,
and switch off the fuel pump using the Start/Stop button.
12.4.9 Selecting and saving a unit for the temperature value output
With the Panda iControl2 panel, you can output the temperature values on the display in degrees Celsius [°C] or in
degrees Fahrenheit [°F]. The unit can be switched with the control panel. In the set-up menu, select the menu item
"Degree C/F" and confirm your selection using the Start/Stop button.
Using the cursor buttons, select 0' for outputting all temperatures in degrees Celsius [°C] or 1' for outputting them in
degrees Fahrenheit [°F]. To confirm your selection, actuate the Start/Stop button.
You can enter additional settings in the set-up menu, or you can exit the set-up menu with "Save & Exit". Your
selections will then be saved to the EEPROM of the Panda iControl2 panel.
After restarting the system with the On/Off button, your settings will take effect, and all temperatures will be output
with the selected unit.
Settings options:
0 Output of all temperatures in degrees Celsius [°C]
1 Output of all temperatures in degrees Fahrenheit [°F]
Seite/Page 122 - Kaptitel/Chapter 12: General operation
13.4.17
General operation
12.5 iControl2-Emergency-Stop
The iControl2 is prepared for the connection of an emergency stop. The socket for the emergency stop is in the
cable harness integrated and bridged (1X1, optional emergency off). The bridge must be removed and the
emergency stop connected.
After the emergency stop is initiated, the servo drives to zero position, all out of the iControl controller are switched
off and the power supply to the inverter is switched off.
The Panel shows „Emergency Stop“.
Damit wird auch die Spannungsversorgung für den Inverter ausgeschaltet.
Das Panel zeigt nach der Betätigung „EMERGENCY STOP!“. The message disappear as soon as the emergency
switch is released.
Fig. 12.5-1: Not Stop bridge in the cable harness
Fig. 12.5-2: Panel shows Emergency Stop
13.4.17
Kapitel/Chapter 12: General operation - Seite/Page 123
General operation
Leere Seite / Intentionally blank
Seite/Page 124
Kapitel/Chapter 12: General operation
13.4.17
Installation
13. Installation
All connecting wires and instructions for installation are
designed and adequate for „standard“ installation
situations.
WARNING: Properly dimension your system.
As Fischer Panda does not know the specific installation and
operating situation (e.g. special vehicle shapes, high travel
speeds, and special application conditions, etc. ), this
installation specification can only serve as a guideline and
example. The installation must be adjusted and implemented
by a competent specialist based on the local conditions and
requirements.
If damage occurs due to wrong installation without adjusting
for specific conditions, it is not covered by the warranty.
13.1 Personnel
The installation described herein must be implemented by specially trained technical personnel or by authorised
workshops (Fischer Panda Service Points), only.
13.1.1 Hazard warnings for installation
Ensure compliance with the general safety instructions
at the beginning of this manual.
Note:
DANGER TO LIFE! - Improper operation can result in
health impairment and death.
.Warning!:
Automatic start-up
The battery must always be disconnected (first the negative
terminal, then the positive terminal) if work on the generator
or electrical system is to be carried out, so that the generator
cannot be unintentionally started.
Improper installation can cause severe injury and/or
substantial property damage. Therefore:
WARNING: Risk of injury!
• Always turn off motor to perform installation work.
• Ensure adequate space for assembly prior to starting work.
• Ensure order and cleanliness at the work place! Parts and
tools loosely stacked or lying on the floor represent accident
hazards.
• Use only standard tools and special tools for installation
work. Incorrect or damaged tooling can result in injury.
DANGER TO LIFE! - Improper operation can result in
health impairment and death.
WARNING: Electric voltage
Electric voltages of more than 60 V are potentially lethal in
any situation. The rules of the respective regional authority
must be adhered to during installation. For safety reasons,
13.4.17
Kapitel/Chapter 13: Installation - Seite/Page 125
Installation
only an electrician may carry out the installation of the
electrical connections of the generator.
Generator and cooling water may be hot during and after
operation. Burn/scalding hazard!
WARNING: Hot surface/material
During operation, overpressure may build up in the cooling
system.
For installation work, personal protective equipment is
compulsory. This includes:
M A N D AT O RY I N S T R U C T I O N : P r o t e c t i v e
equipment required
• Tightly fitting protective clothing
• Safety shoes
• Safety gloves
• Hearing protection
• Safety goggles if applicable
All loads must be disconnected prior to working on the
generator to avoid damage to the devices.
WARNING: Switch off all loads.
13.2 Disposal of the components
Electronics components are hazardous to the
environment and contain rare raw materials.
M A N D ATO RY I N S T R U C T I O N : P r o t e c t t h e
environment.
Collect and properly dispose of components that are no
longer needed!
The iControl2 board is typically pre-installed on the generator, and the corresponding connecting lines for connecting
it to the iControl2 panel and the PMGi are prepared. See generator manual.
Seite/Page 126 - Kaptitel/Chapter 13: Installation
13.4.17
Installation
13.2.1 Panda iControl2 panel with installation housing
Fig. 13.2.1-1: Panda iControl2 panel with panel connecting cable and closed housing
13.2.2 Terminal assignments on the Panda iControl2 panel
The Panda iControl2 panel is connected via a 7-pin Phoenix jack.
Fig. 13.2.2-1: Terminal assignment on the Panda iControl2 panel
Terminal
Terminal description
Cable colour
Function
1
UBUS
white (WH)
Bus supply voltage
2
GND
brown + shielding (BN)
Fischer Panda bus ground, ground connection
between Panda iController and Panda iControl panel
3
REIZ
green (GN)
Exciter wire, is switched to ground if the controller is to
switch on
4
DATA-A
pink (PK)
Fischer Panda bus data line A
5
DATA-B
Grey (GY)
Fischer Panda bus data line B
6
UBATT
--
Autostarta
7
USTART/STOPP
--
Autostartb
a.
b.
A jumper between terminal 6 and 7 closes the autostart contact.
A jumper between terminal 6 and 7 closes the autostart contact.
Use only original Fischer Panda connecting cables.
13.4.17
Note:
Kapitel/Chapter 13: Installation - Seite/Page 127
Installation
13.3 Dimensions
Fig. 13.3-1: Housing of the Panda iControl2 panel
Seite/Page 128 - Kaptitel/Chapter 13: Installation
13.4.17
Installation
Due to the terminals being exposed, the protection class
IP 04 applies to the iControl2 panel.
Please note!
If properly installed with a seal (e.g. Sikaflex), up to IP66
can be achieved.
13.4 Wiring of the Panda iControl2 controller
Fig. 13.4-1: Wiring of the Panda iControl2 controller
The Panda iControl2 controller is connected to the wire harness with the 18-pin jack. The centre 6-pin jack is
designed for the Fischer Panda standard bus. The Panda iControl2 panel is connected to this jack. The Fischer
Panda CAN bus is connected to the 6-pin jack at the bottom right of the circuit board. The configuration of the
connectors is given in the subsequent tables. See “Terminal assignments on the Panda iControl2 controller” on
page 130.
01. Connecting jack for wire harness, 18-pin
02. Connecting jack, 6-pin, Fischer Panda standard bus
03. Connecting jack, 6-pin, Fischer Panda CAN bus for optional use
04. Connecting bolt for phase L3 (load output to inverter) and input from winding L3
05. Connecting bolt for phase L2 (load output to inverter) and input from winding L2
06. Connecting bolt for winding L1
07. Connecting bolt for phase L1 (load output to inverter)
08. Input for supply voltage +12V
09. Pre-heating output
13.4.17
Kapitel/Chapter 13: Installation - Seite/Page 129
Installation
13.4.1 Terminal assignments on the Panda iControl2 controller
13.4.1.1 Terminal assignment of 18-pin connector
Fig. 13.4.1.1-1: Terminal assignment of 18-pin connector
Terminal
IN / OUT
Function
1
--
Actuator (optional)
2
I
Cylinder head temperature
3
IN
Exhaust manifold temperature
4
IN
Winding temperature
5
IN
Reserve temperature
6
IN
Oil pressure
7
IN
Emergency stop
8
--
GND, ground for all temperature sensors
9
--
GND
10
--
Actuator (optional)
11
--
+5V servo motor (red wire)
12
OUT
PWM servo motor (yellow wire)
13
OUT
Booster (optional, depending on generator type)
14
OUT
Fuel pump
15
OUT
Fuel pump
16
OUT
Electric starter
17
OUT
Electric starter
18
OUT
Electric starter
13.4.1.2 Fischer Panda standard bus
Fig. 13.4.1.2-1: Fischer Panda standard bus terminal assignment
Terminal
Terminal description
Function
1
UBUS
Bus supply voltage
2
GND
Fischer Panda bus ground, ground connection between Panda iControl2 controller and
Panda iControl2 panel
3
REIZ
Exciter line, is switched to ground by the panel if the controller is to switch on
4
DATA+
Fischer Panda bus data line A
5
DATA-
Fischer Panda bus data line B
6
UBAT
Battery voltage
13.4.1.3 Fischer Panda CAN bus
Fig. 13.4.1.3-1: Fischer Panda CAN bus terminal assignment
Terminal
Terminal description
Function
1
UBUS
Bus supply voltage
2
GND
Fischer Panda bus ground, ground connection between iControl2 controller and Panda
iControl2 panel
3
REIZ
Exciter line, is switched to ground by the panel if the controller is to switch on
4
CAN-L
CAN-Low
5
CAN-H
CAN-High
6
UBAT
Battery voltage
Seite/Page 130 - Kaptitel/Chapter 13: Installation
13.4.17
Installation
13.5 Master and Slave Panels
With the iControl2 it is possible to have up to four remote control panels at one iGenerator. (One Master + three
Slave)
The standard iControl panel has the Art. No. 21.02.02.131P. This Panel has integrated termination resistors and is
the Master Panel.
The iControl2 Slave Panel has the Art. No. 21.02.02.132P. It is marked with a sticker „Slave Panel“ at the back side.
In a iControl system with Master and Slave panels, The Master must be the last one in the row, so that the
termination resistor is at the end of the FP-BUS.
The Slave Panel can not be used alone. The Slave Panels must be connected between the iControl controller (at the
iGenerator) and the Master Panel.
The Master Slave configuration can be used at iGenerators with software 2.3 at Controller and Panel.
All Panels (Master and Slave) has the Address „1“ as standard. The Address can be changed in the menu. Possible
are 1, 2, 3 and 4. Each Panel must have a unique address.
To use the automatic start option, the connection of the automatic start must be at the panel with the address „1“.
Activation or deactivation can be done at every panel.
Fig. 13.5-1: Master Slave configuration
PandaiControl 2MasterͲSlaveͲBetrieb
Up to four Panelwork parallel.TheMasterPanel(21.02.02.131P)mustbe the lastPanelinthe row,sothat the
termination resistor is atthe end.Please label the cabels according to this.
MasterͲPanel
SlaveͲPanel
iControl2
Controller
Slave
Sensors/
Actuators
Master
PMGi
SlaveͲPanel
SlaveͲPanel
Slave
13.09.2013
13.4.17
Slave
5
1
Kapitel/Chapter 13: Installation - Seite/Page 131
Installation
13.6 Start-up
After completing the installation, the system must be started up.
For this purpose, the start-up log for the generator is processed and filled in by the specialist installing the
equipment. The completed log shall be handed over to the operating company.
The operating company shall be instructed in the operation, maintenance, and hazards of the generator. This
applies to both the maintenance steps and hazards described in the manual and to additional steps and hazards that
result from the specific installation conditions and the connected components.
The original start-up log of the generator must be sent to
Fischer Panda to obtain the full warranty. Make sure that
you retain a copy for your records.
Note:
The corresponding forms are included in the generator
manual.
Seite/Page 132 - Kaptitel/Chapter 13: Installation
13.4.17
Maintenance
14. Maintenance
14.1 Maintenance of the iControl2 controller
The iControl2 controller is maintenance-free. The fuses of the controller are self-healing.
14.1.1 Cleaning the iControl2 controller
The housing shall be cleaned within the scope of the overall generator cleaning. The housing can be wiped off with
a soft, lightly dampened cloth. In doing so, it must be ensured that no moisture enters the jacks and the housing.
14.2 Maintenance of the iControl2 remote control panel
The iControl2 remote control panel is maintenance-free.
14.2.1 Cleaning the iControl2 controller
The display can be cleaned with a soft cloth dampened lightly with soapy water. Harsh cleaning agents are not
suitable and can cause the display film to turn dull.
13.4.17
Kapitel/Chapter 14: Maintenance - Seite/Page 133
Maintenance
Leere Seite / Intentionally blank
Seite/Page 134
Kapitel/Chapter 14: Maintenance
13.4.17
Annex
15. Annex
15.1 Technical data
15.1.1 Technical data for iControl2 control unit
Fig. 15.1.1-1: Technical data for iControl 2 control unit
iControl 2 control unit
Supply voltage
12 V-13.5 V (12 V automotive)
Current consumption, nominal
175 mA
Current consumption, stand-by
2.5 mA
Operating temperature
-20 °C to +85 °C
Storage temperature
-30 °C*to +85 °C
Current sensor Hall element
max. 20 A
max. tightening torque for connecting bolts
1.2 Nm
15.1.2 Technical data for iControl2 remote control panel
Fig. 15.1.2-1: Technical data for iControl2 remote control panel
iControl 2 control unit
Supply voltage
12 V-24 V (12 V or 24 V automotive)
Current consumption, off
0 mA
Current consumption, stand-by - backlight brightness 9
45 mA
Current consumption, stand-by - backlight brightness 4
33 mA
Current consumption, stand-by - backlight brightness 0
25 mA
Operating temperature
-20 °C to +70 °C
Storage temperature
-30 °C*to +80 °C
13.4.17
Kapitel/Chapter 15: Annex - Seite/Page 135
Annex
Leere Seite / Intentionally blank
Seite/Page 136
Kapitel/Chapter 15: Annex
13.4.17
Warnings and error messages
16. Warnings and error messages
To enable the safe operation of the generator, the Panda iControl2 controller is programmed with a series of
warnings and error messages that influence the generator operation.
16.1 Warnings
Warnings are issued when the variable being monitored, e.g. temperature, reaches a defined warning threshold.
The warnings are issued on the Panda iControl2 panel display via the cyclical display of the word „HIGH“ or „LOW“,
alternating with the measured value, e.g. the temperature. Warnings do not become active until the time between
reaching the threshold value and the defined delay has expired.
Warnings do not result in the generator or the controller
being switched off.
Note:
16.1.1 Examples of warnings on the display:
Warning: „Battery power too low“
Warning: „Winding temperature too high“
13.4.17
Fig. 16.1.1-1: Warning: „Battery power too low“
Fig. 16.1.1-2: Warning: „Winding temperature too high“
Kapitel/Chapter 16: Warnings and error messages - Seite/Page 137
Warnings and error messages
16.1.2 Warning messages
All warning messages defined for the Panda iControl 2 and the corresponding display output are compiled in the
subsequent table.
Fig. 16.1.2-1: Warning messages
Warning message on the display
Meaning of warning message
„HIGH“ flashes, alternating with the temperature value of the cylinder head
Cylinder head temperature is too high, the warning threshold
was reached
„HIGH“ flashes, alternating with the temperature value of the winding
Winding temperature is too high, the warning threshold was
reached
„HIGH“ flashes, alternating with the temperature value of the exhaust manifold
Exhaust manifold temperature is too high, the warning
threshold was reached
„LOW“ flashes, alternating with the voltage value of the starter battery
Starter battery voltage is too low, the warning threshold was
reached
16.2 Faults
Error messages are issued when the monitored variable, e.g. a temperature, reaches the defined fault threshold.
With the temperature sensors, a loose connection or a broken cable will result in a fault, as well, and cause the
generator to shut down.
An error message is typically preceded by a warning, as the warning threshold is reached before the fault threshold.
Error messages are output on the Panda iControl2 panel display in the form of the error text shown on a cleared
display page. Faults do not become active until the time between reaching the fault threshold and the defined delay
has expired.
Faults result in the generator shutting down. If a fault occurs due to the battery voltage being too low, the controller is
completely shut down to prevent the battery from discharging too much.
Examples of an error message on the display:
Fault: „Exhaust manifold temperature out of range“
Fig. 16.2-1: Fault: „Cylinder head temperature out of range“
(broken cable)
Fault: „Winding“, winding temperature too high
Fig. 16.2-2: Fault: „STARTING FAILS“, start-up process was not
successful
Seite/Page 138 - Kaptitel/Chapter 16: Warnings and error messages
13.4.17
Warnings and error messages
16.2.1 Error messages
All error messages defined for the Panda iControl 2 and the corresponding display texts are compiled in the
subsequent table.
Fig. 16.2.1-1: Error messages
Error message on the display
Meaning of error message
„OUT“ is output instead of a temperature
„Out of range“ - broken cable on corresponding temperature sensor
Fig. 16.2.1-2: Error codes
Error
code
Meaning
Error Message English
Error Message German
5
Starting failed
STARTING FAILS
STARTABBRUCH
9
Watchdog Error
WATCHDOG
WATCHDOG
12
Winding temperature fault
FAULT: WINDING
TEMP. WICKLUNG
13
Winding temperature out of range
OUT: WINDING
OUT: WICKLUNG
14
Exhaust temperature fault
FAULT: EXHAUST
TEMP. ABGAS
15
Exhaust temperature out of range
OUT: EXHAUST
OUT: ABGAS
16
Engine temperature fault
FAULT: CYL.HEAD
TEMP. MOTOR
17
Oil pressure fault
FAULT: OILPRESS
FEHLER: OELDRUCK
18
Battery voltage low
BATTERY LOW
BATTERIE ENTLADEN
19
unexpected stop/Problem with fuel supply
PROBLEM WITH / FUEL SUPPLY!
PROBLEM MIT DER /
KRAFTSTOFFVERS.!
22
Emergency stop
EMERGENCY STOP!
NOT-HALT!
23
Engine temperature out of range
OUT: CYL.HEAD
OUT: MOTOR
30
Inverter overtemp
Inverter overtemp
Inverter Uebertemp.
31
inverter overload
Inverter overload
Inverter Ueberlast
32
inverter communication lost
Inverter com. lost
Inverter Kom. defekt
33
inverter synchronisation lost
INV. SYNC. FAILED
INV. SYNC. FEHLER
34
Engine fault (EDC)
ENGINE FAULT
MOTOR FEHLER
35
CAN communication lost
CAN. COMM.LOST
CAN KOMM. FEHLER
36
inverter overload slave 1
L1 OVERLOAD
L1 UEBERLAST
37
inverter overload slave 2
L2 OVERLOAD
L2 UEBERLAST
38
inverter overload slave 3
L3 OVERLOAD
L3 UEBERLAST
39
inverter overload slave DC
DC OVERLOAD
DC UEBERLAST
40
Overvoltage
FAULT: OVERVOLTAGE
Fehler: Ueberspg.
41
Undervoltage
FAULT: LOWVOLTAGE
Fehler: Unterspg.
42
DC-Overvoltage
DC OVERVOLTAGE
DC UEBERSPG.
66
RedundantTempSwitchOff
NOTSTOP!
NOTSTOPP!
100
Communication Error
NO CONNECTION / BUS ERROR!
KEINE VERBINDUNG / BUS FEHLER!
207
Init failed (no generator type is selected)
INIT FAILED!
INIT FAILED!
Error messages can be acknowledged with the Start/Stop button, The controller will then return to stand-by mode.
16.2.2 Warning and fault thresholds
The threshold values resulting in triggering warnings and faults depend on the generator type and are compiled in
table below.
13.4.17
Kapitel/Chapter 16: Warnings and error messages - Seite/Page 139
Warnings and error messages
Fig. 16.2.2-1: Warning and fault thresholds for different generator types
Generator type
Warning/fault
Warning threshold
Fault threshold
5000i marine
Cylinder head temperature
Delay
85 °C
5s
95 °C
5s
Winding temperature
Delay
130 °C
5s
135 °C
5s
Exhaust manifold temperature
Delay
70 °C
1s
75 °C
1s
Cylinder head temperature
Delay
90 °C
5s
95 °C
5s
Winding temperature
Delay
130 °C
5s
135 °C
5s
Exhaust manifold temperature
Delay
100 °C
1s
105 °C
1s
Cylinder head temperature
Delay
90 °C
5s
95 °C
5s
Winding temperature
Delay
130 °C
5s
135 °C
5s
Exhaust manifold temperature
Delay
70 °C
1s
75 °C
1s
Cylinder head temperature
Delay
90 °C
5s
95 °C
5s
Winding temperature
Delay
130 °C
5s
135 °C
5s
Exhaust manifold temperature
Delay
100 °C
1s
105 °C
1s
Cylinder head temperature
Delay
90 °C
5s
95 °C
5s
Winding temperature
Delay
130 °C
5s
135 °C
5s
Exhaust manifold temperature
Delay
70 °C
1s
75 °C
1s
Cylinder head temperature
Delay
95 °C
5s
100 °C
5s
Winding temperature
Delay
160 °C
5s
165 °C
5s
Exhaust manifold temperature
Delay
100 °C
1s
105 °C
1s
Cylinder head temperature
Delay
90 °C
5s
95 °C
5s
Winding temperature
Delay
130 °C
5s
135 °C
5s
Exhaust manifold temperature
Delay
70 °C
2s
75 °C
2s
Cylinder head temperature
Delay
90 °C
5s
95 °C
5s
Winding temperature
Delay
130 °C
5s
135 °C
5s
Exhaust manifold temperature
Delay
95 °C
2s
100 °C
2s
Starter battery voltage low
Delay
11.8 V
30 s
10.8 V
30 s
Starter battery voltage high
15.0 V
5s
---
5000i vehicle
P8000i / P10000i marine
P8000i / P10000i vehicle
P8-P50 marine
P8-P50 vehicle
P15000i marine
P15000i vehicle
All generator types
Seite/Page 140 - Kaptitel/Chapter 16: Warnings and error messages
13.4.17
Warnings and error messages
16.2.3 Bus errors
If the communication connection is lost on the Fischer Panda bus, an error is output on the display after a period of
10 seconds:
This error will occur if at least one of the two data lines
of the Fischer Panda bus is disconnected. Once the
connection is restored, the error message can be
acknowledged with the Start/Stop button.
Fig. 16.2.3-1: Error: „NO CONNECTION“, error in the
communication (Fischer Panda bus)
If the communication connection is lost, the generator shall be secured (open battery disconnect switches), and all
plug-in connections and cables shall be checked for firm seating or damage.
16.3 The error memory of the iControl 2 Panel
From Software version PiC2_2.9 (control board) and PiP2_2.9 (control panel) the Panda iControl2 has got an error
memory which shows the last six errors in the plain text.
16.3.1 How to get to the error memory of the iControl2 Panel?
The error memory is easily accessible via the setup menu of the control panel which is open to every user.
The setup menu can be accessed as usual:
• To access the setup menu, please press the key "Cursor Down" directly after switching on the control while the
panda bear is displayed.
• Now you can see the setup menu and its menu items.
• You can navigate through the menu viy the keys
• „Cursor-Up“ und „Cursor-Down.
• The selected menu item is marked by two *symbols.
• The start/stop key is used for validation in the setup menu. If you select and validate the row marked by the * by
actuating the start/stop key, you will access the selected sub-menu.
• To display the error memory please select the menu item Error mem.
16.3.2 How are stored errors displayed?
The errors are displayed in the plain text. The error is preceded by the operating hour when the error occurred. The
fault having the highest operating hour will be displayed in the first row. Older error entries are displayed in the rows
below in descending order of the operation hour. If the memory contains already six errors, the oldest entry is
deleted.
Expample for displaying an error entry: 3045.2h COMMUNICATION
This means: In operating hour 3045.2 an error in the bus communication has occurred.
13.4.17
Kapitel/Chapter 16: Warnings and error messages - Seite/Page 141
Warnings and error messages
16.3.3 How do I exit the error memory after having read the entries?
You can return to the standby page via the start-stop-key.
16.3.4 Can I delete the error memory?
No, it is not possible to delete the error memory.
16.3.5 Where are the errors stored?
In the EEPROM of the panel or in the storage of the control board?
The errors are stored in the EEPROM of the control board. The control panel only displays the errors which are
stored there. If, for service reasons, the control panel has to be exchanged, the entries remain in the error memory.
16.3.6 In which language are the stored errors displayed?
The stored errors are displayed in the language which is set in the control panel. This can be English or German
depending on your settings.
16.3.7 Is it possible to upgrade an old iGenerator model by the error memory?
Yes, if the software of the control board and the panel is updated, it is possible to upgrade an existing system by this
function.
Seite/Page 142 - Kaptitel/Chapter 16: Warnings and error messages
13.4.17
Warnings and error messages
Fig. 16.3.7-1: Image: Display of the stored errors on the control panel
13.4.17
Kapitel/Chapter 16: Warnings and error messages - Seite/Page 143
Warnings and error messages
Leere Seite / Intentionally blank
Seite/Page 144
Kapitel/Chapter 16: Warnings and error messages
13.4.17