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Fischer Panda 5000i PMS User Manual

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Panda_5000i_PMS_eng.R01 9.12.10
Fischer Panda GmbH
Power - wherever you are
Generator manual
Panda 5000i PMS
Super silent technology
230V 50Hz 5kVA 120V 60Hz 5kVA
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Current revision status
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.
Document
Actual: Panda_5000i_PMS_eng.R01_9.12.10 Replace:
Revision Page
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Generator manual................................................................................................................... 1
Panda 5000i PMS.................................................................................................................... 1
Current revision status.......................................................................................................... 2
1 General References and Regulations .......................................................................... 9
1.1 Safety first symbols ....................................................................................................... 10
1.2 Tools ................................................................................................................................ 15
1.4 Customer registration and guarantee .......................................................................... 17
1.4.1 Technical Support ............................................................................................................. 17
1.4.2 Attention, important directions regarding operation! .......................................................... 17
1.5 Safety instructions - Safety first! .................................................................................. 18
1.5.1 Safe operation ................................................................................................................... 18
1.5.2 Observe safety instructions ............................................................................................... 18
1.5.3 Wear personal protective equipment (PPE) ...................................................................... 18
1.5.4 Cleanness protect ............................................................................................................. 18
1.5.5 Safe handling of fuel and lubricants - Keep away from fire ............................................... 19
1.5.6 Exhaust gases and fire prevention .................................................................................... 19
1.5.8 Keep hands away from rotating parts ................................................................................ 20
1.5.9 Anti-Freeze and disposal of fluids ..................................................................................... 20
1.6 Warning and caution labels ........................................................................................... 21
1.6.1 Safety instructions concerning operating the generator .................................................... 21
1.6.1.2 Ground wire............................................................................................................................... 22
1.6.1.3 Switch off all load when working on the generator.................................................................... 22
1.6.2 Recommended starter battery size ................................................................................... 23
1.6.3 Important Advice for Batteries - Starting batteries and Traction batteries ......................... 23
1.6.4 Safety Instructions for the Handling with Batteries ............................................................ 24
2 In case of Emergency First Aid / Im Notfall - Erste Hilfe......................................... 27
3 Basics ........................................................................................................................... 29
3.1 Intended use of the maschine ....................................................................................... 29
3.1.1 Purpose of the manual und description of the definitions trained person/operator/user ... 29
3.1.1.1 Trained persons........................................................................................................................ 29
3.1.2 Operator ............................................................................................................................ 29
3.1.2.1 User........................................................................................................................................... 29
3.2 Panda Transport Box ..................................................................................................... 30
3.2.1 Bolted Fischer Panda Transport Box ................................................................................ 30
3.2.2 Fischer Panda Transport Box with metal tab closure ........................................................ 30
3.2.3 Opening the MPL sound insulation capsule . .................................................................... 30
3.2.4 Opening the GFK sound insulation capsule ...................................................................... 31
3.3 Transport and Loading/Unloading ................................................................................ 32
3.3.1 Transporting the generator ................................................................................................ 32
3.3.2 Loading/unloading of the generator ................................................................................... 32
3.4 Special Service Instructions and Measures for Extended Machine Downtimes and De-
commissioning 33
3.4.1 Instructions for the starter battery for extended downtimes .............................................. 33
3.4.2 Measures for short downtimes .......................................................................................... 33
3.4.3 Measures for medium term downtimes / hibernation ........................................................ 34
3.4.3.1 Surface protection measures: ................................................................................................... 34
3.4.3.2 Measures for removing surface protection after medium term downtimes (3 to 6 months)...... 34
3.4.4 Measures for extended downtimes / decommissioning ..................................................... 35
3.4.4.1 Surface protection measures: ................................................................................................... 35
3.4.4.2 Measures for removing surface protection after extended downtimes / recommissioning (over 6 months): 36
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3.5 Components .................................................................................................................... 36
3.6 Range of operation ......................................................................................................... 37
3.6.1 Main features of the Panda 5000i ...................................................................................... 37
4 Panda 5000i PMS generator .......................................................................................39
4.1 Type plate at the generator ............................................................................................ 39
4.2 Description of the Generator.......................................................................................... 40
4.2.1 Right Side View ................................................................................................................. 40
4.2.2 Left Side View .................................................................................................................... 41
4.2.3 Front View ......................................................................................................................... 42
4.2.4 Back View .......................................................................................................................... 43
4.2.5 View from Above ............................................................................................................... 44
4.3 Details of function units ................................................................................................. 45
4.3.1 Remote control panel - see iControl manual ..................................................................... 45
4.3.2 Components of the Cooling System (Raw Water) ............................................................. 45
4.3.3 Components of the Cooling System (Fresh Water) ........................................................... 46
4.3.4 Components of the Fuel System ....................................................................................... 47
4.3.5 Components of Combustion Air ......................................................................................... 48
4.3.6 Components of the Electrical System ................................................................................ 49
4.3.7 Components of the Oil Circuit ............................................................................................ 50
4.3.8 Sensors and switches for operating surveillance .............................................................. 50
4.4 Operation Instructions - see separate control panel manual ..................................... 52
4.4.1 Daily routine checks before starting - See iControl manual. .............................................. 52
4.4.2 Starting Generator - See iControl manual. ........................................................................ 52
4.4.3 Stopping the Generator - See iControl manual. ................................................................ 52
5 Installation Instructions...............................................................................................53
5.1 Personal requirements ................................................................................................... 53
5.1.1 Hazard notes for the installation ........................................................................................ 53
5.2 Preparing the base - Placement ...................................................................................54
5.2.1 Advice for optimal sound insulation ...................................................................................55
5.3 Generator Connections .................................................................................................. 55
5.4 Cooling System Installation - Raw water ..................................................................... 55
5.4.1 General References .......................................................................................................... 55
5.4.2 Installation of the thru-vessel fitting in Yachts ................................................................... 56
5.4.3 Quality of the raw water sucking in line ............................................................................. 56
5.4.4 Installation above waterline ............................................................................................... 56
5.4.5 Installation below waterline ................................................................................................ 57
5.5 The Freshwater - Coolant Circuit .................................................................................. 58
5.5.1 De-aerating at the first filling of the internal cooling water circuit ...................................... 58
5.6 Watercooled Exhaust System ....................................................................................... 59
5.6.1 Installation of the standard exhaust system ...................................................................... 59
5.6.2 Installation of the water collector ....................................................................................... 60
5.6.3 Possible cause: Exhaust duct ............................................................................................ 61
5.6.4 Possible cause: Coolant duct ............................................................................................ 61
5.6.5 Installation area of exhaust water collector ....................................................................... 61
5.6.5.1 The volume of the exhaust water collector............................................................................... 62
5.6.6 Exhaust / water separator .................................................................................................. 68
5.6.7 Installation exhaust/water separator .................................................................................. 69
5.7 Installation of the fuel system .......................................................................................70
5.7.1 General references ............................................................................................................ 70
5.7.2 The Electrical Fuel Pump .................................................................................................. 71
5.7.3 Connection of the fuel lines at the tank ............................................................................. 71
5.7.4 Position of the pre-filter with water separator .................................................................... 72
5.7.5 Ventilating air from the fuel system ................................................................................... 72
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5.8 Generator DC system installation ................................................................................. 73
5.8.1 Connection of the starter battery block .............................................................................. 73
5.8.2 Connection of the DC starter battery ................................................................................. 74
5.8.3 Fuse .................................................................................................................................. 76
5.8.4 Installation of the iControl panel - See iControl Manual .................................................... 76
5.9 Generator AC System Installation ................................................................................ 76
5.9.1 Installation PMGi inverter - See separat PMGi 5000 inverter manual ............................... 77
5.9.2 Power source selector ....................................................................................................... 77
5.9.3 Insulation test .................................................................................................................... 79
6 Maintenance Instructions............................................................................................ 81
6.1 Personal requirements .................................................................................................. 81
6.2 Hazard notes for this chapter ........................................................................................ 81
6.3 Environmental protection .............................................................................................. 83
6.4 General maintenance instructions ............................................................................... 83
6.4.1 Checks before each start .................................................................................................. 83
6.4.2 Check of Hoses and Rubber Parts in the sound insulated capsule .................................. 83
6.5 Oil Change Intervals ....................................................................................................... 83
6.5.1 Checking oil-level .............................................................................................................. 84
6.5.2 Refilling Oil ........................................................................................................................ 85
6.5.3 After the oil level check and refilling the oil ....................................................................... 85
6.6 Exchanging engine oil and engine oil filter ................................................................. 86
6.6.1 After the oil change ........................................................................................................... 88
6.7 Verifying the starter batterie and (if necessary) the battery bank ............................. 89
6.7.1 Battery ............................................................................................................................... 89
6.7.1.1 Check battery and cable connections ....................................................................................... 89
6.7.1.2 Check electrolyt level................................................................................................................ 89
6.7.1.3 Check electrolyt density............................................................................................................ 89
6.8.1 Exchange of the Fuel Filter ............................................................................................... 91
6.8.1.1 Optional fuel filter with sight glass............................................................................................. 92
6.8.2 De-aerating the fuel system .............................................................................................. 93
6.8.3 Replacement of the air filter .............................................................................................. 94
6.9 De-aerating of the coolant circuit / freshwater ............................................................ 95
6.10 The raw water circuit ...................................................................................................... 95
6.10.1 Clean raw water filter ......................................................................................................... 95
6.10.2 Causes with frequent impeller waste ................................................................................. 95
6.10.3 Replacement of the impeller .............................................................................................. 96
7 Generator Faults .......................................................................................................... 99
7.1 Personal requirements .................................................................................................. 99
7.2 Hazard notes for this chapter ........................................................................................ 99
7.3 Tools and measuring instruments .............................................................................. 101
7.4 Overloading the generator .......................................................................................... 101
7.5 Starting problems ......................................................................................................... 101
7.5.1 Fuel solenoid valve .......................................................................................................... 101
7.5.2 Dirty fuel filter .................................................................................................................. 102
7.6 Troubleshooting table .................................................................................................. 102
7.6.1 Generator output voltage too low .................................................................................... 102
7.6.2 Diesel motor fails to start ................................................................................................. 103
7.6.3 Starter is turning motor, but fails to start ......................................................................... 103
7.6.4 Motor does not achieve enough speed during starting process ...................................... 103
7.6.5 Motor runs unsteady ........................................................................................................ 103
7.6.6 Motor speed drops .......................................................................................................... 103
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7.6.7 Motor runs in off position ................................................................................................. 104
7.6.8 Motor stops by itself ......................................................................................................... 104
7.6.9 Sooty, black exhaust ....................................................................................................... 104
7.6.10 Generator must be shut off immediately if: ......................................................................104
8 Generator Tables........................................................................................................105
8.1 Cable cross section ...................................................................................................... 105
8.2 Diameter of conduits .................................................................................................... 105
8.3 Technical Data .............................................................................................................. 105
8.4 Types of coil .................................................................................................................. 106
8.5 Engine oil ...................................................................................................................... 106
8.5.1 Engine oil classification ................................................................................................... 106
8.5.1.1 Operating range:..................................................................................................................... 106
8.5.1.2 Quality of oil:........................................................................................................................... 106
8.6 Fuel ................................................................................................................................ 107
8.7 Coolant specifications ................................................................................................. 107
8.7.1 Coolant mixture ratio ....................................................................................................... 108
8.8 Diamensions ................................................................................................................. 109
9 Remote control panel Panda iControl......................................................................111
9.1 Safety instructions ....................................................................................................... 112
9.2 Connection of the iControl .......................................................................................... 112
9.3 Buttons and display of the iControl ............................................................................ 113
9.5 Operation manual ......................................................................................................... 115
9.5.1 Daily routine checks before starting ................................................................................ 115
9.5.2 General ............................................................................................................................ 116
9.5.3 Long time run of the generator ........................................................................................ 116
9.5.4 Start of the generator ....................................................................................................... 117
9.5.5 Stop of the generator ....................................................................................................... 117
9.5.6 Automatic start ................................................................................................................. 117
9.6 Error warnings .............................................................................................................. 118
9.8 Electronic board ........................................................................................................... 119
9.8.1 Location at the Panda i-series generator ......................................................................... 120
9.9.1 Intended use .................................................................................................................... 121
9.10 Bus adapter RS485 to FP bus - optional .................................................................... 121
10 Inverter Panda PMGi 5000 ........................................................................................123
10.1 Safety instruction ......................................................................................................... 124
10.2 Type plate ...................................................................................................................... 124
10.3 Front side/connection side .......................................................................................... 126
10.4 Back side - Top side ..................................................................................................... 128
10.5.1 Primary remarks / Winter operation ................................................................................. 129
10.5.2 Load at the PMGi ............................................................................................................. 129
10.5.3 Automatic start ................................................................................................................. 129
10.6 Status LED´s ................................................................................................................. 129
10.7 Cooling of the PMGi ..................................................................................................... 129
10.8.1 Electrical connection. ....................................................................................................... 130
10.9 Technical Data .............................................................................................................. 130
10.9.1 General Data ................................................................................................................... 130
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10.9.2 Generator Spezifikation ................................................................................................... 130
10.10PMGi protections .......................................................................................................... 131
10.10.1 Overload - switch point .................................................................................................... 131
10.10.2 Short circiut ..................................................................................................................... 131
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Page 9
General References and Regulations
9.12.10 General.R01.1 - Kapitel/Chapter 1: General References and Regulations Seite/Page 9
1. General References and Regulations
Fischer Panda
FISCHER GENERATORS have been manufactured since 1978 and are a well-known brand for first class diesel generators with especially effective sound-insulation. Fischer has been one of the leading manufacturers for marine generators in respect of quality and know-how during this period. FISCHER, as the worldwide manufacturer of modern marine diesel generators, developed the Sailor-Silent series for example and produced a GFK sound-insu­lated capsule as early as 1979 and the basis for new generator technology.
The companies Fischer and Icemaster amalgamated under the direction of Icemaster in 1988, in order to concen­trate on the development of new products. Production was moved to Paderborn.The amalgamation of the two quali­fied companies led to the development of a complete new programme within a short space of time. The generators developed at that time set new technological standards worldwide.
The generators became more efficient and powerful than other generators in the same nominal performance range, because of the improved cooling. Panda generator demonstrated its superiority in several tests by renowned institu­tes and magazines during the past years. The patented VCS (voltage Control System) means it can meet all demands including motor speed. The start-booster (ASB) means Panda generators meet the highest demands in respect of voltage stability and starting values.
A water-cooled Fischer Panda generator, with the same drive motor, produces 15 % more effective output than the majority of conventional generators. This superiority in efficiency also ensures a fuel saving to the same extent.
The Fischer Panda generators are currently manufactured in the performance range from 2 to 200 kW in various versions. Fast running motors are preferred for performances up to approx. 30 kW (nominal speed 3000 resp. 3600 rpm). The heavier slow runners are preferred for the higher range. The fast running generators have proved them­selves many times for many uses, that they meet the demands in quality of yachts and vehicles, and offer space and weight saving of 50 % compared to slow running generators.
In addition to the Panda series, Fischer Panda also supply the super compact high-tech sound-insulated battery charging generators from the DC/AC Panda AGT series, which is a very interesting solution for the production of mobile power.
The HTG-alternators ensure that a charging rate of 280 amps is achieved that was scarcely thought possible for this compact construction. This alternator replaces a separate shipboard generators (constant 230 volts AC with up to
3.500 W from the main machine)
Icemaster GmbH Fischer Marine
Generators
Conclusion Fischer -
Icemaster GmbH
100 % water cooled
Panda generators
Panda Vehicle
Generators
since
1977
since
1978
since
1988
since
1988
since
1988
Page 10
General References and Regulations
Seite/Page 10 General.R01.1 - Kapitel/Chapter 1: General References and Regulations 9.12.10
1.1 Safety first symbols
These symbols are used throughout this manual and on labels on the machine itself to warn of the possibility of per­sonal injury. Read these instructions carefully. It is essential that you read the instructions and safety regulations before you attempt to assemble or use unit.
Warning!: Toxic elements
This danger symbol refers to toxic danger and draws attention to special warnings, instructions or procedures which, if not strictly observed, may result in severe personal injury or loss of life.
Attention!: Important Advice
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!: Danger of fire
This warning symbol draws attention to special warnings, instructions or pro­cedures which, if not strictly observed, may result in damage or destruction of equipment
Prohibitation!: No Smoking
Do not smoke in that area / do not smoke during the describes works
Prohibitation: Fire and open flames prohibited
Fires and open light are ignition sources, which must be avoided.
Prohibitation: Turn on / start operation prohibited
Do not turn on or start operation. People are working at the generator and/or electrical system
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General References and Regulations
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Proscription!: Do not touch
Berühren der entsprechenden Teile und Anlagen verboten
Warning!: Automatic start.
Generator can be started by an external signal
Warning!: High voltage / danger by electricity ­Danger for life
These symbols refer to electrical danger and points to special warnings, instructions and advices, which must be noticed. Otherwise an electrical shock with personal injury or death can be the consequence.
Warning!: Danger for life and/or equipment
General Warning
Warning!: Harmful if accumulate
Substances can be harmful or lead to death, if accumulated or swallowed
Warning!: Electric shock
Warning of live parts, which can cause electrical impacts during contact. Special danger for persons with heart problems and/or pace makers.
Warning!: Rotating parts
Danger of injury by drawing into the machine. Injury by crushes and even­tually the separation of extremities. Danger of drawing during contact with extremities, loose clothes, scarf, ties etc.
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General References and Regulations
Seite/Page 12 General.R01.1 - Kapitel/Chapter 1: General References and Regulations 9.12.10
Warning!: Risk of explosion
Warning of materials, which can lead to explosions under certain conditions ­e.g. heat or ignition sources
Warning!: Hot surface
Surfaces and substances may be hot. Danger of burn / scalding
Warning!: Danger carrosive material - contermi­nation of persons possible
Warning of materials, which cause corrosive damage during contact. These materials can work contaminating when entering into the body.
Warning!: System can be under pressure!
When opening the system the pressure can suddenly escape and drag along liquids. Danger of injury by parts flying around, danger of burn by liquids and gases.
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General References and Regulations
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Warning!: Hearing damage
Warning!: Magnetic field
Warning!: High pressure
Instruction!: Wear personal protective equip­ment (PPE)
Protective clothing is close fitting, with low resistance to tearing, with narrow sleeves and without protruding parts. It mainly provides protection against being entangled by moving machine parts.
Instruction!: Wear personal protective equip­ment (PPE)
Wear ear defenders to protect the ears against hearing damage.
Instruction!: Wear personal protective equip­ment (PPE)
Wear safety glasses to protect the eyes against parts flying around or squirts of fluids. Optical eyeglasses are not replacement for appropriate eye protec­tors.
Instruction!: Wear personal protective equip­ment (PPE)
Wearing protective gloves protects the hands against friction, graze, punctures or deep cuts as well as contact with hot surfaces.
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General References and Regulations
Seite/Page 14 General.R01.1 - Kapitel/Chapter 1: General References and Regulations 9.12.10
Instruction!: Read the manual instructions
Read and consider the regulations, safety instructions and installation guide­lines of manual, in order to avoid dangers and accidents. You protect yours­elf and the generator.
Instruction!: Environmental protection
Environmental protection is the protection of our habitat. For you and your children
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General References and Regulations
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1.2 Tools
This symbols are used throughout this manual to show which tool must be used at maintenance or installation.
Spanners SW X = required size X mm
Hook wrench for oil filter
Screw driver, for slotted head screws and for recessed head screws
Multimeter, multimeter with capacitor measuring
Socket wrench set
Hexagon wrench keys
X
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General References and Regulations
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Current clamp (DC for synchron generators; AC for asynchron generators)
Torque wrench
Page 17
General References and Regulations
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1.3 Manufacturer declaration in accordance with the machine guideline 98/ 37/EG
Manufacturer declaration in accordance with the machine guideline 98/37/EG The generator has been developed in such a way, that all assembly groups correspond to the CE guidelines. If
machine guideline 98/37/EG is applied, then it is forbidden to start the generator, until it has been ascertained that the system into which the generator is to be integrated, also corresponds to the machine guideline regulation 98/37/ EG. This includes the exhaust system, cooling system and electrical installation.
The evaluation of "protection against contact" must be carried out when installed, in conjunction with the respective system. This includes correct electrical connections, a safe ground wire connection, foreign body and humidity pro­tection, protection against humidity due to excessive condensation, as well as overheating through appropriate and inappropriate use in its installed state. The responsibility lies with those who undertake installation of the generator in the final system.
1.4 Customer registration and guarantee
Use the advantages of the customer registration:
• Thus you receive to extended product informations, which are sometimes safety-relevant
• you receive, if necessarily free Upgrades
Far advantages: By your full information Fischer Panda technicians can give you fast assistance, since 90% of the disturbances
result from errors in the periphery. Problems due to errors in the installation can be recognized in the apron.
1.4.1 Technical Support
Technical Support per Internet: [email protected]
1.4.2 Attention, important directions regarding operation!
1. The installation certificate must be completed when taken into use, and certified by a signature.
2. The installation certificate must be despatched within two weeks of use to Fischer Panda.
3. The official guaranty confirmation will be completed by Fischer Panda after receipt and sent to the customer.
4. A guaranty must be shown to make any claims.
Claims against the guaranty will not be accepted of the above said instructions are not, or only partially, carried out.
Page 18
General References and Regulations
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1.5 Safety instructions - Safety first!
1.5.1 Safe operation
Careful operation is your best assurance against an accident. Read and understand this manual carefully before operating the engine. All operators, no matter how much experience they may have, should read this and other related manuals befor operating the generator or any equipment attached to it. It is the owner´s obnligation to provide all operators with this information and instruct them on safe operation.
1.5.2 Observe safety instructions
Read and understand carefully this manual and „Labels at the engine“ before attempting to start and operate the generator. Learn how to operate and work safely. Know how your equipment and its limitations. Always keep the generator in good condition.
1.5.3 Wear personal protective equipment (PPE)
Do not wear loose, torn or bulky clothing around the maschine that may catch on working controls and prejections or into fans, pulleys ond other moving parts causing personal injury.
Use additional safety items-PPE, e.g. safety protection, safety googles, gloves , etc. Do not operate the generator or any equipment attached to it while under the influence of alcohol,
medication, or other drugs, or while fatigued.
Do not wear radio or music headphones while operating the generator.
1.5.4 Cleanness protect
Keep the engine and the surrounding clean. Ensure that the generator is stopped before cleaning. Keep the generator clean and free of accu-
mulated dirt, grease and trash to avoid fire. Store flammable liquids in proper containers and cabi­nets away from sparks and heat. Check for leak immidiately and repair if necessary.
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General References and Regulations
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1.5.5 Safe handling of fuel and lubricants - Keep away from fire
Keep away open fire from fuels and lubricants. Always stop the generator before refueling and/or lubrivating and protect against unintentional
starting. Do not smoke or allow flames or sparks in your work area. Fuel is extremely flammable and explo-
sive under certain conditions.
Refuel at a well ventilated and open place. When fuel and/or lubrication are spilled, refuel after letting the generator cool down.
Do not mix gasoline or alkohol with diesel fuel. The mixture can couse a fire or severe generator damage.
Do not use unapproved containers e.g. buckets, bottles, jars. Use approved fuel starrage contai­ners and dispensers.
1.5.6 Exhaust gases and fire prevention
Generator exhaust fumes can be very harmful af allowed to accumulated. Be sure to run the engine in a well ventilated location and where there are no people or livestock near the engine.
Check the Generator and all pipes and hoses regularly of leaks and repair immediately if neces­sary.
The exhaust gas and the engine can be very hot during operation and afterwards. To prevent a fire, do not expose dry gras, moved gras, or any other combustible material to exhaust gas or the hot generator surface.
To prevent a fire, do not short electrical cables. Check regularly all electrical cables and wires. Uncoated wires and loose connections can cause electrical shock, electrical short circuit and fire.
The generator should be integrated in the local fire protecting system.
Exhaust gases of diesel engines and some components are carcinogen and can cause deformati­ons and other gene effects.
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.
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General References and Regulations
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1.5.7 Cautions against burns and battery explosion
To avoid burns, be cautious of hot components, e.g. muffler, muffler cover, radiator, hoses, engine body, coolants, engine oil, ect. during operation and after the engine has been shut down.
The Coolant system can be under pressure, Open the coolant system only, when the generator is colled down. Wear „Personal Protective Equipment„.
Be shure that the coolant system is closed and all hose clamps are tightend before operating the generator.
The battery (Starter battery and AGT battery bank) presents an explosive hazard. When the bat­tery is being charged, hydrogen and oxigen gasses are extremly explosive.
Do not use or charge a battery if its fluid level is below the lower mark. Otherwise, the component parts may deteriorate earlier than expected, which may shorten the the service life or cause an explosion. Immediatly, add distilled water until the fluid level is between the lower and the upper marks.
Keep sparks and open flames away from the battery, especially during charging. Do not strike a match near the battery.
Do not check the battery charge by placing a metal object across the terminals (danger of short circuit, battery damage and high danger of explosion). Use a Voltmeter or a hydrometer.
Do not charge a frozen battery. There is a riosk of explosion. When frozen, warm the battery up to at least 16°C.(61°F).
1.5.8 Keep hands away from rotating parts
Operate the generator with closed sound cover capsul only. Be shure to stop the generator befor checking or adjusting the belt tension. Keep your hands and body away from rotating parts, such as the cooing fan, V-Belt, fan drive
belt, ra´w water pump drive belt, pulley or Flywheel. Do not operate the generator without safety guards. Install safety guards securly before opera-
tion.
1.5.9 Anti-Freeze and disposal of fluids
Anti-freeze contains poison. Wear rubber gloves to avoid personal injury. In case of contact with skin, whash it off immideately. Do not mix different types of Anti-freeze. The mixture can produce chemical reactioncausing harmful substances. Use approved or genuine Fischer Panda Anti­freeze.
Protect the environment. When draining fluids from the generator, place a siutable container underneath the generator body. Consider the relevant enviromental protection regulations when disposing of oil, fuel, coolant, breakfluid, filters and batteries. Do not poor waste onto the ground, down a drain, or into any water source. Conducting safety checks and maintenance
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1.5.10 Implementation of security and maintenance
Disconnect the battery from the generator before conducting service. Put a „DO NOT OPERATE“ tag on the remote control panel to avoid accidental starting. Disconnect any automatic starter device, e.g. battery monitor to prevent automatic starting.
To avoid sparks from an accidental short circuit always disconnect the battery´s ground cable (-) first and connect it last. be shure that the generator is stopped and cooleed down when conducting daily and periodic maintaenance, service and cleaning.
Always use the apprppirate tools and fixtures. Verify that they are in good conditions before per­forming any service work. Make shure you understand how to use them before service.
Keep first aid kit and fire extinguisher handy at all times.
1.6 Warning and caution labels
Keep warning and caution labels clean and free from obstructing material. Clean warning and caution labels with soap and water, dry with a soft cloth. Replace damaged or missing warning and caution labels with new labels.
1.6.1 Safety instructions concerning operating the generator
The electrical installations may only be carried out by trained and qualified personnel!
The generator must not be taken into use with the cover removed.
If the generator is being installed without a sound insulation capsule, make sure 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 well-placed signs must show that the generator can only be switched on with a closed capsule.
All servicing-, maintenance or repair work may only carried out, when the motor is not running. 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.
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1.6.1.1 Protective grounding and potential equalisation
In the low voltage board for current supply of the consumers therefore a protective conductor is grounded and connected with electrically conductive objects. The connection with an outer conductor with these object then leads to the earth fault. This earth fault leads to the release of an over-current protection mecha­nism and thus to the disconnection of the voltage.
1.6.1.2 Ground wire
The generator, is "earthed" as series (centre and ground are connected together in the generator terminal box by a bridge). This is an initial ground fuse, which offers protection, as long as no other measures are installed. Above all, it is conceived for the delivery and possible test run.
This "neutralisation" (Protective Earthing Neutral - PEN) is only effective, if all parts of the electrical system are commonly "earthed" to a common potential. The bridges can be removed, if this is necessary for technical reasons and another protective system has been setup.
There is full current in the AC control box when the generator is running. It must therefore be ensured that the control box is closed and cannot be touched when the generator is running.
The battery must always be disconnected, if work on the generator or electrical system is to be carried out, so that the generator cannot be unintentionally started.
1.6.1.3 Switch off all load when working on the generator
All load must be disconnected, in order to avoid damages to the devices. In addition the semi conductors in the AC control box must be disconnected in order to avoid the boat capacitors being activated. The minus pole of the battery ought to be removed.
Capacitors are required to run the generator. These have two varying functions: A) The working capacitors B) The (Booster) capacitors Both Groups are located in a separate AC-Control box. Capacitors are electrical stores. There could be a residual of high electrical current at the contacts
for a period disconnection from the circuit. The contacts may not be touched for safety reasons, If the capacitors are to be exchanged or checked, and then a short circuit between the contacts should be made so that the stored energy is discharged.
If the generator is switched off in the normal manner, the working capacitors are automatically discharged by means of the windings. The booster capacitors are discharged by means of internal discharge resistors.
All capacitors must be short-circuited before work is carried out on the AC-Control box for safety reasons. Potential equalisation at Panda AGT DC generators. Further information for your generator see capture installation.
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1.6.1.4 Safety instructions concerning the cables
Cable Type
It is recommended is that the cable used be UL 1426 (BC-5W2) compliant, with Type 3 stranding (ABYC Section E-
11)
Cable Size
The cable size must be selected taking into account the amperage, voltage and conductor length (from the positive power source connection to the electrical device and back to the negative power source connection.
Cable Installation
It is recommended that a self draining wire loom classified as V-2 or better in accordance with UL 94 be installed in the section of the cable routed in the interior of the sound capsule. Care should be taken to avoid hot surfaces such as the exhaust manifold or engine oil drain bolt and routed clear of any possible sources of chafing.
1.6.2 Recommended starter battery size
Only use batteries which are certified as starter battery by the manufacturer. Only use batteries with capacity recommended by the engine manufacturer.
1.6.3 Important Advice for Batteries - Starting batteries and Traction batteries
ATTENTION!!! Initial operation:
Installation of battery lines. Consider the regulations and installation instructions of the battery manufacturer.
Consider ABYC regulation E11 AC and DC electrical systems on boats and/or EN ISO 10133:2000 small watercrafts, electrical systems, low voltage (DC) systems !
Ensure a professional battery installation.
The battery separation can be made mechanically or by an appropriate power relay. Consider the appropriate notes of the battery manufacturer concerning fire and explosion pre-
vention. Install a right sized fuse in the positive battery line as close as possible to the battery, but max.
12 inch, 300mm from the battery. The length of the cable to the fuse, the cable must be protected by a sheath or conduit against damage of the insu-
Attention !! Check before installation if the starter battery voltage correspond with the genera­tor start system.
f.e. 12V starter battery for 12V start system
f.e. 24V starter battery for 24V start system
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lation. Use only cable with self retardant and self extinguishing insulation suitable for high temperatures up to 195°F, 90°C. Install battery lines in a safe way that the cable insulation will not be shaved or damaged. Battery poles must be protected against short circuits by error. Inside the capsule of the Fischer Panda Generator the battery positive line must be protected
against heat and vibration by a suitable conduit or sheath and must be routed that way it is not touching any area that will get hot under normal operation like entire engine itself, exhaust elbow and exhaust manifold or exhaust lines or the V-belt and pulleys. The cable shall not be to tight otherwise damage will happen.
Run the generator carefully after installation and double check, if there is any possibility for damage of the battery cable. Correct if necessary.
Fig. 1.6-1: Sample scheme for starter battery installation
1.6.4 Safety Instructions for the Handling with Batteries
These instructions must be noticed additionally to the instructions of the battery manufac­turer:
• If the batteries are working, someone should be in your near area to help you in a case of emer­gency.
• Water and soap must be hold ready if battery acid corrode your skin.
• Wear eye protection and protective clothing. During working with the batteries don´t touch the eyes.
• If you got a acid splash on your skin or clothing grow it with much water and soap out.
• If you got acid in your eyes rinse them immediately with clear water until no cauterization is no­ticeable. Visit immediate a doctor.
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• Never smoke in the near of the batteries. Avoid naked flames or open fires. In the area of batte­ries exists danger of explosions.
• Pay attention that no tools fall on the battery poles, if necessary cover them.
• During the installation don´t wear a wrist watch or arm jewels, you can create under these cir­cumstances a battery short-circuit. Burning of the skin could be the result.
• Protect every battery contact against unintentional touch.
• For battery banks: Use only cyclical profoundly dischargeable batteries. Starter batteries are not appropriate. Lead-gel batteries are commended. They are maintenance-free, profoundly dischar­geable and not produce gas.
• Do not charge a frozen battery.
• Avoid a batterie short-curcuit.
• Take care of a good ventilation of the battery to drain off developing gas.
• The battery connection terminals must be checked of a tight contact at least before operating.
• The battery connection cable must be carefully mounted and checked about incorrect heating at operation with load. The vibrating devices must be regulary checked about scour points and flaw in the isolation.
Attention !! For battery charge generators (Fischer Panda AGT-DC)!
Check before installation if the battery bank voltage correspond with the generator output voltage
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In case of Emergency First Aid / Im Notfall ­Erste Hilfe
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2. In case of Emergency First Aid / Im Notfall - Erste Hilfe
First Aid in case of accidends 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.
Switch off the generator immediately.
if you cannot switch off the generator, pull, push, or lift the person to safety using a wooden pole, rope, or some nonconductive material.
Call an emergency doctor as soon as possible.
Immediately start necessary first aid procedures.
1 1
1
2
1
3
1
4
1
5
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2.7 WHEN AN ADULT STOPS BREATHING
Warning:DO NOT attempt to perform the rescue breathing techniques
provided on this page, unless certified. Performance of these techniques by uncertified personnel could result in further injury or death to the victim.
1
Does the Person Respond?
2
Shout, "Help!"
Tap or gently shake victim. Shout, "Are you OK?"
Call people who can phone for help.
3
Roll Person onto Back.
Roll victim toward you by pulling slowly.
4
Open Airway.
5
Check for Breathing.
Tilt head back, and lift chin. Shout, "Are you OK?"
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.
7
Check for Pulse at side of Neck.
8
Phone EMS for Help.
Feel for pulse for 5 to 10 seconds. Send someone to call an ambulance.
9
Begin Rescue Breathing.
10
Recheck Pulse Every Minute.
Keep head tilted back. Lift chin. Pinch nose shut. Give 1 full breath every 5 seconds. Look, listen, and feel for breathing
between breaths.
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.
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3. Basics
3.1 Intended use of the maschine
The Fischer Panda generator is used to produce electrical energy out of diesel fuel. The diesel fuel is converted to mechenical energy by the diesel engine. These mechanical energy drives the genera-
tor genset. In the genset, the mechanical energy is converted to electrical energy. These process is controled by the external components, like the remote control panel and the voltage control system (VCS).
For the process is a sufficent amount of fuel and combustion air necessary. Arising exhaust and heat must be lead away.
If the electrical power should be applyed to a local net, The regulation and installation instruktions of the Net owner and the regional authorities must be respected. This includes lightening conductor, personal protection switch etc.
Misaplication 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 circiut. 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.
3.1.1 Purpose of the manual und description of the definitions trained person/operator/
user
This manual is work instruction and operation instruction 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. The manual 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 may in accordance with
the law as required by the country and special situation.
3.1.1.1 Trained persons
Trained persons for the mechanical components are motor mechanics or persons with similar education and training.
Trained persons for the electrical components are electricions or persons with similar education and trai­ning.
After the Installation, the trained person must instruct the owner for operation and maintenance of the gene­rator. This must include the hazards of the generator use.
3.1.2 Operator
The operator is the for the operation of the generator responceble person.
After the installation, the operator must be instructed for the operation ad maintenance of the generator. This must include the hazards during operation of the generator and a instruction for the maintenance.
The operator must read and follow the manual and must respect the hazard notes and safety instructions.
3.1.2.1 User
Users are persons, established by the operator, to operate the generator.
The operator must assure that the user read and understand the manual and that all hazard notes and safety instructions are respected. The user must be instructed by the opertor regarding his activity at the generator.
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3.2 Panda Transport Box
3.2.1 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
3.2.2 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 accessories
4. Bend open the metal tab closures on the transport box bottom.
5. Remove the sidewalls
6. Open the generator attachment
3.2.3 Opening the MPL sound insulation capsule .
Fig. 3.2-1: Sound insulation capsule, side part
To open the sound insulation capsule, the closures must be rotated roughly 180° counter-clockwise. Use a fl at head screwdriver. Pull the sidewalls out by gripping into the slots.
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Fig. 3.2.3-2: Closure locked
Closure locked
Fig. 3.2-3: Closure open
Closure open
3.2.4 Opening the GFK sound insulation capsule
Fig. 3.2-1: Lash closures
GFK sound insulation capsule with lash closures
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Fig. 3.2-2: Lash closures
To open the lash closures pull the handle in arrow direc­tion and lift the lash of the closure pin. After lifting of the lashes, the sound isolation cover upper pars can be removed.
3.3 Transport and Loading/Unloading
3.3.1 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.
- 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.
3.3.2 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.
Fig. 3.3-1: Lifting yoke (example)
An adequate lifting yoke shall be used for transport/ loading
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3.4 Special Service Instructions and Measures for Extended Machine
Downtimes and Decommissioning
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)
3.4.1 Instructions for the starter battery for extended downtimes
Note:
Starter batteries
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.
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.
Note:
Fischer Panda recommends:
• 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.
3.4.2 Measures for short downtimes
Short downtime (1 to 3 months)
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• 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.
3.4.3 Measures for medium term downtimes / hibernation
Medium term downtimes (3 to 6 months)
3.4.3.1 Surface protection measures:
• 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. Refill 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.
• Drain diesel from tank and refill with a protective mixture (90 % diesel and 10 % preservative oil) (level to full).
Let engine warm up for 10 min.
• Dismount V-belt as specified, wrap and store in a dry location. Protect against UV radiation.
Attention!
Cover alternator apertures.
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).
Attention!
Before recommissioning, remove preservatives and protective measures.
3.4.3.2 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.
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• 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.
3.4.4 Measures for extended downtimes / decommissioning
Downtimes (more than 6 months)
3.4.4.1 Surface protection measures:
• 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. Refill 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.
• Drain diesel from tank and refill with a protective mixture (90 % diesel and 10 % preservative oil) (level to full).
Let engine warm up for 10 min.
• Dismount V-belt as specified, wrap and store in a dry location. Protect against UV radiation.
• Disconnect battery. Coat terminals with acid-free grease.
Attention!
Cover alternator apertures.
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. 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).
Note:
For storage for more than 12 months, the preservation measures shall be checked annually and supplemented as necessary.
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Attention!
Before recommissioning, remove preservatives and protective measures.
3.4.4.2 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
seconds. Repeat this procedure 2 times.
• Perform visual check of the generator similar to initial commissioning and start up generator.
Note:
Fischer Panda recommends:
After extended downtimes, a full 150 h inspection as per the inspection list should be performed.
3.5 Components
Fig. 3.5-1: Panda 5000i generator
1. Panda i-Generator Permanent-Magnet-Generator
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Fig. 3.5-2: iControl
2. Panel Panda iControl with electronic board at the genera­tor.
Fig. 3.5-3: PMGi 5000
3. Panda PMGi Inverter AC/AC
3.6 Range of operation
Reliable power supply on sailing boats
3.6.1 Main features of the Panda 5000i
• Extremely high starting capacity, perfect for a Bauer junior
2.2kW compressor!
• 230 V / 50 Hz (120V / 60Hz) system for all your domestic
appliances!
• Compact and light, takes up less space!
• Super silent sound insulation capsule!
• Graphical Display, easy to operate!
• Option for reduce speed at lower loads, saves fuel!
• Pure sinus wave, higher frequency and voltage stability!
• Optimized engine rpm (2800 rpm) for a long generator life!
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4. Panda 5000i PMS generator
4.1 Type plate at the generator
Fig. 4.1-1: Type plate
Fig. 4.1-2: Discription type plate
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4.2 Description of the Generator
4.2.1 Right Side View
Fig. 4.2.1-1: Right side view
01
03
04
06
10
05 09
11
08
07
02
01) Housing with iControl electronic board (DO NOT OPEN)
02) Coolant pipe, raw water pump - heat exchanger
03) Toothed belt
04) Raw water pump
05) Bus adapter RS485 to FP bus - optional
06) Sound cover base part
07) Passage for battery cable (+)
08) Passage for batterie cable (-)
09) Raw water inlet
10) Engine Kubota EA300
11) Generator housing with coil
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4.2.2 Left Side View
Fig. 4.2.2-1: Left side view
01
12
06
05
11
13
02
04
03
07
08 1009
01) Generator housing with coil
02) Water-cooled exhaust elbow
03) Raw water injection pipe
04) Coolant pipe, water tank - heat exchanger
05) Connection external ventilation valve
06) Sound cover base part
07) Engine Kubota EA300
08) Injection nozzle
09) Coolant pipe, water pump - engine
10) Coolant water pump
11) Suction port at air suction housing
12) Cooling water tank
13) Cooling water filler neck
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4.2.3 Front View
Fig. 4.2.3-1: Front side view
13
14
01
09
08
07
06
05
11
10
02
03
04
12
01) Solenoid switch for starter motor
02) Starter motor
03) Actuator
04) Housing with iControl electronic board „DO NOT OPEN“
05) Raw water pump
06) Pulley
07) Ground connection terminal
08) Oil dipstick
09) Engine oil filler neck
10) Oil drain hose
11) Fuel solenoid valve
12) Fuse 30A
13) Air suction housing with air filter inlet
14) Suction port
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4.2.4 Back View
Fig. 4.2.4-1: Back side view
19
16
15
14
10
13
12
07
06
05
04
03
02
01
11 091808
17
01) Housing with iControl electronic board „DO NOT OPEN“
02) Generator front cover
03) Generator housing with coil
04) Starter motor
05) Cooling water filler neck
06) Cooling water tank
07) Coolant pipe, water pump - engine
08) Connection external ventilation valve
09) Raw water injection nozzle
10) Exhaust outlet (through capsul bottem)
11) Exhaust elbow
12) Connection for fuel OUT
13) Connection for fuel IN
14) FP bus cable to PMGi
15) Cable for fuel pump
16) Cable for iControl
17) Cable for PMGi
18) Sound cover base part
19) Raw water inlet
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4.2.5 View from Above
Fig. 4.2.5-1: Top side view
01
13 07 06
04 05
02
11
09
08
10
03
12
01) Cooling water filler neck
02) Connection external ventilation valve
03) Cooling water tank
04) Exhaust out (through capsul bottem)
05) Generator housing with coil
06) iControl electronic board under cover „DO NOT OPEN“
07) Pulley
08) Starter motor
09) Fuel solenoid valve
10) Solenoid switch for starter motor
11) Air suction housing with air filter inlet
12) Coolant overflow hose
13) Suction port
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4.3 Details of function units
4.3.1 Remote control panel - see iControl manual
4.3.2 Components of the Cooling System (Raw Water)
Fig. 4.3.2-1: Cooling System (Raw Water)
Expansionstank with
fillercap
Heatexchanger
Freshwater side
elect. Waterpump
Engine Kubota EA 300
Watercooled
exhaustelbow
Overflow hose
Overpressure valve
in fillercap
Thermosensor
at Engine
Thermosensor
at exhaustelbow
iControl elektronic board
cooled
side
hot
side
coolant
Heatexchanger
Seewater side
Seewater
Impellerpump
Seewater
external
ventilation valve
Exhaust/Water
out
Water injec.
in exhaust hose
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4.3.3 Components of the Cooling System (Fresh Water)
Fig. 4.3.3-1: Cooling System (Fresh Water)
Expansionstank with
fillercap
Heatexchanger
Freshwater side
elect. Waterpump
Engine Kubota EA 300
Watercooled exhaustelbow
Overflow hose
Overpressure valve
in fillercap
Thermosensor
at Engine
Thermosensor
at exhaustelbow
iControl elektronic board
cooled
side
hot
side
coolant
Heatexchanger
Seewater side
Seewater
Impellerpump
Seewater
external
ventilation valve
Exhaust/Water
out
Water injec.
in exhaust hose
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4.3.4 Components of the Fuel System
Fig. 4.3.4-1: Components of the Fuel System
external Tank
external elec. fuelpump
fuel stop solonoid
fuel injection nozzle
fuel
in
fuel
out
air filter housing
engine
Kubota EA300
exhaust elbow
glow
plug
automatic venting
filler cap with strainer
injection pump
Fuel filter +
water seperator
fuel in
exhaust
out
combustion
air in
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4.3.5 Components of Combustion Air
Fig. 4.3.5-1: Components of Combustion Air
external Tank
external elec. fuelpump
fuel stop solonoid
fuel injection nozzle
fuel
in
fuel
out
air filter housing
engine
Kubota EA300
exhaust elbow
glow
plug
automatic venting
filler cap with strainer
injection pump
Fuel filter +
water seperator
fuel in
exhaust
out
combustion
air in
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4.3.6 Components of the Electrical System
Fig. 4.3.6-1: Components of the Electrical System
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4.3.7 Components of the Oil Circuit
Fig. 4.3.7-1: Components of the Oil Circuit
4.3.8 Sensors and switches for operating surveillance
Fig. 4.3.8-1: Thermo.switch at engine
Thermo-switch at engine
The thermo-switch at the engine is used for monitoring the engine temperature.
oil filler cap
engine
Kubota EA300
oil strainer
oil dipstick
oil
pressure
switch
oil drain hose
iControl electronic board
operator control
oil in
oil
out
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Fig. 4.3.8-2: TThermo-switch at exhaust connection
Thermo-switch at exhaust connection
If the impeller pump drops out and deliveres no more seawa­ter, the exhaust connection becomes extremely hot.
Fig. 4.3.8-3: Thermo-switch coil
Thermo-switch coil
One thermo sensor is located in the stator winding
Fig. 4.3.8-4: Oil pressure switch
Oil pressure switch
In order to be able to monitore the lubricating oil system, an oil pressure switch is built into the system.
1
2
3
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4.4 Operation Instructions - see separate control panel manual
4.4.1 Daily routine checks before starting - See iControl manual.
4.4.2 Starting Generator - See iControl manual.
4.4.3 Stopping the Generator - See iControl manual.
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5. Installation Instructions
All connections (hoses, wires etc) and installation instructions are designed and suited for “standard” installation situations.
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 may 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.
5.1 Personal requirements
The described instrallation must be done by a technical trained person or a Fischer Panda service point.
5.1.1 Hazard notes for the installation
Notice!:see “Safety instructions - Safety first!” on Page 18.
Follow the general safety instruction at the front of this manual.
Warning!: Risk of injuryrWorking at a running generator can result in severe per­sonal injury. Therfore befor starting work at the genera­tor:
Make shure that the generator ist stopped and the starter battery is diconnected to guarantee that the generator cannot be inadvertently started.
Do not run the generator with removed sound isolation cover-
Warning!: Risk of injuryr
Impropper installation can result in servere personal injuries or material damage.
- 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 avalilable tools and special tools. incorrect or damaged tools can result injuries.
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-Warning!: Danger of fire
Oil and fuel vapours can ignite on contact with ignition sources. Therfore:
- No open flames during work on the generator.
- Do not smoke.
- Remove oil and fuel residues from the generator and floor.
Danger!: Danger of poisoning
Contact with engine oil, antifreeze and fuel can result in damage to health
. Therefor :
- Avoid skin contact with engine oil, fuel and antifreeze.
- Remove oil and fuel splashes and antifreeze from the skin immediatlly.
- Do not inhale oil and fuel vapours.
ATTENTION!: Danger to Life - High voltageDanger for Life. Improper handling, operation, installa­tion and maintenance can result in sévere persoanl injury and/or material damage.
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.
Warning!: Hot surface/materialGenerator, oil and antifreeze can be hot during/after ope­ration. Risk of severe burns.
Instructiont!: Personal protective equipment
necessary.
During Installation/mainenance personal protective equipment is required to minimize the helth hazards.
- Protective clothing
- safety boots
- protective gloves
- Ear defender
- safety glasses
Attention!: disconnect all load
Disconnet all load during the work atthe generator to avoid damages at the load.
5.2 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.
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The generator should not be placed in the proximity of light walls or floors, which can have resonance vibrations because of airborne sounds. If this should be unavoidable, then it is recommended that this surface is lined with 1 mm lead foil, which will change the mass and the vibration behaviour.
You should avoid fixing the generator on a slippery surface with little mass (i.e.). This acts as an amplifier of airborne sounds in the most unreasonable case. An improvement can be achieved by reinforcing these surfaces with ribs. In addition, the breakthroughs, which interrupt these surfaces, should be sawed off. The lining of the surrounding walls with a heavy layer (i.e lead) and foam additionally improve the conditions.
The generator sucks its air from the surrounding engine room. Therefore it must be ensured that sufficient ventilation openings are present, so that the generator cannot overheat.
High temperature of the intake air decline the power of the generator and increases the coolant temperature. Air temperatures of more than 40 °C reduce the power by 2 % per temperature rise of 5 °C. In order to keep th ese effects as small as possible, the temperature in the engine room should not be higher than 15 °C in relation to the outside temperature.
5.2.1 Advice for optimal sound insulation
Fig. 5.2.1-1: Generator Base
The convenient base consists of a stable framework, on which the generator is fastened by means of shock-mounts.
Since the aggregate is "free" downward, the combustion air can be sucked in unhindered.
In addition are void the vibrations, which would arise with a closed soil.
5.3 Generator Connections
Connect all electrical wires within the capsule tightly to the motor and the generator. This is also the case for fuel lines and cooling water lines.
The electrical connections MUST be carried out according to the respective valid regulations. This also concerns used cable materials. The cable supplied is meant for laying "protected" (i.e. in pipe) at a temperature up to a max of. 70 °C (160 °F). The on-board circuit must also be fitted with all essential fuses.
ATTENTION! Before working (installation) on the System read the sec-
tion „Safety Instructions“ in this Manual.
5.4 Cooling System Installation - Raw water
5.4.1 General References
The generator 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:
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5.4.2 Installation of the thru-vessel fitting in Yachts
Fig. 5.4.2-1: Thru-vessel fitting
It is good practice for yachts to use a hull inlet fitting with an integrated strainer. The thru-vessel fitting (raw water intake) is often mounted against the sailing direction to induce more water intake for cooling.
For Panda generators, the thru-vessel inlet should NOT point in the sailing direction! When sailing at higher speeds more water will be forced into the inlet than what the pump can handle and your generator will overflood!
5.4.3 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 (i.e. sea cock, thru-hull fitting, inlet filter, etc.) must have an inner diameter of at least 1" (25mm).
This applies also to installation components such as thru-hull fitting, sea cock, raw water filter etc. The intake suction line should be kept as short as possible. Install the raw water inlet in close proximity to the genset.
NoticeAfter start-up the cooling water quantity must be measu­red (e.g. by catching at the exhaust). The flow rate, as well as the necessary cross section of the cooling water pipe take from Table 8.2-1, “Diameter of conduits,” on page 105.
5.4.4 Installation above waterline
The Panda is equipped with a direct drive water intake pump mounted directly on the motor. Since the intake pump is an impeller pump there are wearing parts which are likely to require replacement after a period of time. Ensure that the genset is installed so that the intake pump can be easily accessed. If this is not possible, an external intake pump could be installed in an easily accessible location.
If the generator is installed above the waterline, it is possible that the impeller will wear out faster, because after star­ting, the pump runs dry for some seconds.
The seawater hose should form a loop as near as possible to the seawater 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 seawater and the impeller life span will be increased.
By the installation of a check valve in the sea water inlet line, which is under the waterline, this problem can be restricted.
The impeller pump will remain intact longer, if an electrical booster pump is installed, and is strongly recommended in order to preserve the impeller pump.
NoticeNever change the impeller for many years, without exchanging the old pump sealing ring. If the sealing ring is defective within the pump, seawater runs into the sound insu­lated capsule of the generator. A repair is then very expen-
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sive. Replacement impeller and also a spare pump should always
be on board. The old pump can be sent back to Fischer Panda, where it is then economically overhauled completely.
Fig. 5.4.4-1: Installation example
5.4.5 Installation below waterline
Fig. 5.4.5-1: Ventilation valve
If the generator can not be attached at least 600 mm over the waterline, a vent valve must be installed into the seawater line. With location beside the "midship line" a possible hee­ling must be considered! The water hose for the external vent valve at the back of the sound insulated capsule splits on the pressure side of the pump and at both ends in each case extended with a connecting nipple by a hose end. Both hose ends must be led out outside of the sound insulated capsule to one point, if possible 600 mm over the waterline in the midship line. The valve is connected at the highest place with the two hose ends. If the valve is blocked, the cooling water pipe cannot be ventilated after the stop of the generator, the water column is not interrupted and the water can penetrate into the combustion chamber of the engine. This leads to the destruction of the engine!
1) Hull inlet
2) Reducer
3) Water cock
4) Raw water filter
5) Raw water pump
6) Heat exchanger
7) Electric water pump
8) Raw water injection into exhaust
9) Engine
10) Water tank
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Fig. 5.4.5-2: Installation example
Fig. 5.4.5-3: Tube bend for ventilation valve
The tube bend must be removed. Now the two ends are extended in each case with a hose and attached at a value of approx. 600 mm over the waterline with a ventilation valve.
5.5 The Freshwater - Coolant Circuit
5.5.1 De-aerating at the first filling of the internal cooling water circuit
1. For the preparation of filling the following steps are to be undertaken:
a. Open the cooling water cap on the cooling water tank.
1) Hull inlet
2) Reducer
3) Water cock
4) Raw water filter
5) Raw water pump
6) Heat exchanger
7) Electric water pump
8) Raw water injection into exhaust
9) External ventilation valve
10) Water tank
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Fig. 5.5.1-1: Cooling water filler neck
2. Filling the cooling water circle
Fig. 5.5.1-2: Cooling water filler neck
a. Fill in the prepared mixture (cooling water with anti­freeze protection according to the intended mixture) at the filler neck at the cooling water tank slowly so long, until cooling water reach the max. level at the neck.
Anti-freeze
In the interest of safety, the freezing point of the closed circuit coolant should be checked on a regular basis. Be sure that the coolant/antifreeze mixture is good for at least -15°C (5°F) and if it is possible that y our genset experi­ences lower temperatures, for example during storage or transportation, then the entire cooling system should be drained and purged. To purge the cooling system, compressed air at about 0.5 bar (7.5 psi) is sufficient.
Electric cooling water pump
Connect the cooling water pump to an external DC power supply and start the pump. Refill the the cooling water at the filler neck while the pump runs.
3. De-aerating
The cooling water circuit of the generator is self de-aerating.
ATTENTION! During the de-aerating process it must be checked again and again if the cooling water is indeed circulating. If air bubbles established in the internal cooling water pump, it could be, that the cooling water circuit is not circulate. Then the generator would be warming very fast and swit­ched off by overheating.
5.6 Watercooled Exhaust System
By injecting the outlet raw water into the exhaust manifold, the exhaust gases are cooled and the noise emissions from the exhaust system are reduced.
5.6.1 Installation of the standard exhaust system
The generator exhaust system must remain completely independent and separate from the exhaust system of any other unit(s) on board. The exhaust hose has an inner diameter of 40 mm (1.6") (Panda 15000 and above approx.
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50 mm). The water lock must be installed at the lowest point of the exhaust system. An optional noise insulated water lock can also be installed. The exhaust hose descends from the capsule to the water lock. Then the hose rises via the "goose neck" to the silencer (see drawing). The goose neck must be vertical and sit preferably along the ship's keel centre line. The exhaust system must be installed so that the back pressure inside the exhaust does not exceed 0.4 bar (6 psi) and total length does not exceed 6 m (20 ft.).
Exhaust diameter see “Diameter of conduits” on Page 105.
Fig. 5.6.1-1: Installation example
5.6.2 Installation of the water collector
Unfortunately, it can occasionally occur that, because of an disadvantageous mounting position of the water collec­tor, 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 duct and thus get into the engine.
Thereby, the position of the generator and the water collector, as well as the arrangement of the coolant and exhaust ducts plays the decisive role.
If the water collector is arranged in an unfavourable position, the coolant flowing back in the exhaust duct 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 coolant that got into the oil pan. If the engine isstarted under these con­ditions, the water and the oil are mixed into an emulsion. The the oil will quickly become so viscous that one will have to call it a paste. In this phase the fine oil ducts are blocked and a few moments later the machine gets destroyed because of insufficient lubrication. Before this happens, an immediate oil 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
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the engine with the starter motor.)
The coolant can reach the exhaust area via the exhaust duct as well as via the coolant feed.
5.6.3 Possible cause: Exhaust duct
If the cause is the exhaust duct itself, the following points are to be checked at the duct: a) Position of the water collector is too high. The water reaches the exhaust duct. b) Position of the water collector is too far away from the middle of the generator. The water reaches the exhaust
duct in tilted position. c) The water collector is too small relating to the length of the exhaust duct.
5.6.4 Possible cause: Coolant duct
If the generator is not clearly installed 600 mm over the water line, the coolant feed must be equipped with a ’venting valve’, which is at least lead 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 can not 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 valves’ function needs to be chek­ked regularly.)
As it consistently happens that funtioning risks are not realised during the laying of the exhaust duct, the following explanations refer explicitly to the exhaust duct. Here, the location, the size and the position of the ’exhaust water collector’ play a very decisive part:
5.6.5 Installation area of exhaust water collector
Concerning a water-cooled exhaust system, it must be regarded that - under no circumstances - coolant from the exhaust duct can get into the exhaust elbow area at the engine. If this happens, the coolant can get into the combu­stions 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 water collector even more important. In general one could say that:
The deeper the water collector is located underneath the generator, the better the protection from entering water into the combustion chamber.
The pictures below, the distance between the critical point at the exhaust elbow and the maximum permissible water level in the exhaust duct is stated with 600 mm. This distance should be understood as a minimum distance.
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Fig. 5.6.5-1: Installation area of the exhaust water collector
5.6.5.1 The volume of the exhaust water collector
The exhaust water collector must be measured so large, that it can take the entire amount of water flowing back from the exhaust duct. The amount of water depends on the ducts’ length (L) and its cross section. While the diesel engine is running, coolant 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 coolant out. All coolant remaining in the duct at that point flows back into the water collector. At the same time, the diesel engine itself conti­nues to cart coolant through the coolant pump, as long as it keeps on rotating.
The water collector must necessarily be measured so large, that it can take the entire amount of coolant and, and the same time, does not exceed the prescribed vertical height of 600 mm up to the critical point at the exhaust elbow.
Fig. 5.6.5.1-1: Volume of the exhaust water collector
If there are any doubts, a verifiction can easily be made by temporarily using a clear-sighted hose as exhaust hose. In that way, the coolant level can be checked very easily.
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Fig. 5.6.5.1-2: Testing the coolant level
1
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5.6.5.2 Position of the water collector
Important Note! The ideal position of the water collector would be in center underneath the generator. Only in this position it
is assured that the water level can not change drastically in tilted position by the water collector moving out of the center line. See the following pictures:
Fig. 5.6.5.2-1: Ideal position of the water collector
In this picture, the water collector is mounted in center under­neath the generator. When the ship tilts, the position of the water collector related to the critical point at the exhaust duct changes only slightly.
Fig. 5.6.5.2-2: Tilted position 15 degrees
Tilted position 15 degrees
The distance from the exhaust elbow to the hydrostatic head derated to 540 mm.
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Fig. 5.6.5.2-3: Tilted position 30 degrees
Tilted position 30 degrees
The distance of the water level, even in ideal position, chan­ges in a way that only 458 mm distance remain. So the criti­cal distance is under-run already.
Fig. 5.6.5.2-4: Tilted position 45 degrees
Tilted position 45 degrees
In this case the water level rose so high, that the distance constitutes only 325 mm.
Even when the collector 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 motion (’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.
Summary:
The preset minimum height of 600 mm must be regarded unconditionally and is only valid, if the water collector 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.
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5.6.5.3 Example of the installation of the water collector off-center and possible effects:
The following pictures are primarily relevant for an installation of the generator with the water collector 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 water collector is measured so large, that it can take the entire amount of water flowing backand at the same time maintains the minimum distance of 600 mm.
A) Installation of the water collector 500 mm next to the generators center line:
Fig. 5.6.5.3-1: Water collector, 500 mm next to the center line
Fig. 5.6.5.3-2: Tilted position, 15 degrees
Tilted position 15 degrees
The distance is only 404 mm instead of the original 600 mm. So this is very close to the critical point.
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Fig. 5.6.5.3-3: Tilted position 30 degreed
Tilted position 30 degreed
The distance between the hydrostatic head and the critical point at the exhaust elbow is only 216 mm. This means that in a tilted position of 30 degrees you already face the highest risk of sea water sloshing into the combustion chamber.
Fig. 5.6.5.3-4: Tilted position 45 degrees
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 infiltration of coo­lant into the combustion chamber is inevitable. Irreparable damages are preprogrammed.
B) Installation distance between exhaust water collector and generators’ center line 1000 mm
Fig. 5.6-5: Exhaust water collector, 1000 mm next to center line
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Fig. 5.6.5.3-6: Tilted position 15 degrees
Tilted position 15 degrees
The distance is, contrary to the original 600 mm, only 327 mm. This is very close to the critical point already.
Fig. 5.6.5.3-7: Tilted position 30 degrees
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 coolant into the combustion chamber is inevitable. Irrepara­ble damages are preprogrammed.
Summary:
Concerning sailing yachts it must be regarded, that the water collector is mounted in center underneath the genera­tor, at least in reference to the ships’ center line. Thus the water collector is prevented from ’leaking’ very strongly when the ship is tilted.
The ’leaking’ of the water collector leads to a rise of the water level which then gets too close to the exhaust elbows’ critical point.
5.6.6 Exhaust / water separator
The exhaust/water separator
In order to reduce the noise level of the generator unit to a minimum, an optional exhaust outlet muffler can be mounted next to the thru-hull fitting. Additionally there is a component at Fischer Panda, which acts as both an "exhaust goose neck", and water separator. With this "exhaust/water separator" the cooling water is derived over a separate pipe. The exhaust noises emanating from the exterior of the yacht are strongly decreased. Particularly the "water splash".
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Fig. 5.6.6-1: Exhaust/water separator
The water flow on the exhaust/water separator unit has an inner diameter (ID) of 30 mm. If the path from the water sepa­rator to the sea water outlet is very short, the hose can be fur­ther reduced to 1" (25 mm) ID.
Fig. 5.6.6-2: Exhaust/water separator
1. Raw water outlet ø 30 mm
2. Hose connection ø 30 mm
3. Reducer 30/20 mm (if required)
4. Hose for hull inlet
5. Hose connector
6. Sea cock
7. Hull outlet Hose clamps
5.6.7 Installation exhaust/water separator
If the exhaust/water separator was sufficiently highly installed, a goose neck is no longer necessary. The exhaust/ water separator fulfills the same function. If the "Supersilent" 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.
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Fig. 5.6.7-1: Installation example
If the thru-hull exhaust outlet has to be mounted far from the generator, an exhaust-water separator must definitely be installed. The sea water from the separator must then run along the shortest possible path is the thru-hull outlet. For such long exhaust routes, the exhaust hose diameter should also be increased from NW 40 mm to NW 50 mm 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 to 50 mm. An additional outlet exhaust muffler close to the hull outlet will help further to reduce noise emissions.
5.7 Installation of the fuel system
5.7.1 General references
Inside the generator capsule itself, there is the fuel filter installed (exception: Panda 4200 and 4500). Additional fuel filters (with water separator) must be mounted outside the capsule in easily accessible places in the fuel lines bet­ween the tank intake fuel pump and the diesel motor's fuel pump.
Generally forward and return fuel flow pipes must be mounted to the diesel tanks. Do not connect the generator fuel supply lines with any other fuel lines of other diesel systems.
• The following items need to be installed:
• Fuel supply pump (DC)
• Pre-filter with water separator (not part of the delivery)
• Fine particle fuel filter
• Return fuel line to fuel tank (unpressurized) The fuel supply pump should be mounted as close to the fuel tank as possible. The electric cable for the fuel pump
is already installed on the generator (length 5 m).
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Fig. 5.7.1-1: Installation Scheme Fuel System
5.7.2 The Electrical Fuel Pump
Fig. 5.7.2-1: Electrical Fuel Pump
Electrical fuel pump
With the 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 are pre­loaded at the generator with the lead planned.
Suction hight of the pump: max. 1,2 m at 02, bar
Diameter of fuel lines: section 8.2, “Diameter of conduits,” on page 105.
5.7.3 Connection of the fuel lines at the tank
Lead the return fuel pipe connected to the day tank to the floor
The return pipe connected to the tank must be dropped to the same depth as the suction pipe, if the generator is mounted higher than the tank, in order to prevent fuel running back into the tank after the motor has been switched off, which can lead to enormous problems, if the generator is switched off for a long period.
Non-return valve in the suction pipe
A non-return valve must be fitted to the suction pipe, which prevents the fuel flowing back after the generator has been switched off, if it is not possible to use the return flow pipe as a submerge pipe placed in the tank. The instruc-
1
2
3
4
5
8
7
6
1. Generator
2. Fuel stopcock
3. Fuel filter
4. Fuel return
5. Condensation water suction pump (optional)
6. Fuel tank
7. Fuel supply
8. Electrical fuel pump (DC)
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tions "Bleeding Air from the Fuel System" must be read after initial operation or after it has stood still for a long period, in order to preserve the starter battery.
ATTENTION!
Non-return valve for the fuel return pipe
If the fuel tank should be installed over the level of the genera­tor (e.g. daily tank), then a non-return valve must be installed into the fuel return pipe to guarantee that through the return pipe no fuel is led into the injection pump.
5.7.4 Position of the pre-filter with water separator
Fig. 5.7.4-1: Pre-filter with water separator
Additionally to the standard fine filter a pre-filter with water separator must be installed outside of the sound insulation capsule in the fuel system line (not included in the delivery).
5.7.5 Ventilating air from the fuel system
Normally, the fuel system is designed to vent air itself i.e. as soon as the electric starter motor starts; the fuel pump starts working and the fuel system will be air-vent automatically after some time. It is, nevertheless essential, to vent the system as follows prior to the first operation (as all hoses are empty):
1. Switch main power switch on control panel "ON".
2. Push failure bypass switch and hold tight. The electric fuel pump has to be run audibly. By moving the failure bypass switch you can hear the solenoid valve of
the generator starting and stopping (when the sound insulation cover is taken off).
3. After the fuel pump has been running 3 to 4 minutes, because the failure bypass switch has been pressed down, the bleeding screw of the solenoid valve has to be unscrewed. The switch has to be continuously depressed, when opening the screw. A piece of cloth or absorbent paper should be put under the connection to avoid fuel entering the sound insulation cover.
4. The air vent screw can be screwed in again, as soon as fuel runs out without bubbles. Then release the depres­sing the failure bypass switch.
5. Starting the generator Now the generator can be started by pushing the "START"-button. The generator should start after a short while.
One of the pipe union nuts of an injection hose has to be unscrewed, should the unit not start; then try to restart the generator. After the generator has started, the pipe union nut has to be tightened again.
Main power switch "OFF"
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Fig. 5.7.5-1: Vent Screw at the Fuel Stop Solenoid Valve
Vent Screw at the fuel stop solenoid valve
Not installed at all models!
5.8 Generator DC system installation
NoticeThe Panda 5000i has no DC alternator to charge the Star­ter battery. The Starterbattery must be charged by an external device.
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.
5.8.1 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).
NOTE:
Panda Generators Panda 6000 and higher normaly provided with an alternator/dynamo to charge the starter battery. At generators without alternator/dynamo it is needed to charge the starter battery with an external battery charger.
ATTENTION!
Make shure that the voltage of the starter battery fits to the start system voltage
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 batte-
rys in a row)
NOTE:
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.
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Attention!: Consider correct connection sequence
It must be guaranteed that first the cables are attached at the generator and then at the battery.
Attention!: Right connection of the battery.
Battery connection
Wrong connection of the battery bank can cause a short-cir­cuit and fire.
Install an appropriate fuse and a battery circuit breaker in the plus pole cable of the batterie, 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 layed 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 layings and the electrical connections.
5.8.2 Connection of the DC starter battery
Fig. 5.8.2-1: Connection starter battery
The positive (+) battery cable is connected direcly to the solenoid switch of the starter motor.
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Fig. 5.8.2-2: Connection starter battery
The negative (-) battery cable is connected to the engine.
Fig. 5.8.2-3: Battery installation - Scheme
1
2
4
3
1. Generator
2. Battery block
3. Fuse
4. Battery main switch
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5.8.3 Fuse
Fig. 5.8.3-1: Terminal block AGT 5000 12V
F1: Fuse 30 A for DC system
5.8.4 Installation of the iControl panel - See iControl Manual
5.9 Generator AC System Installation
ATTENTION! Before the electrical system is installed, READ the
SAFETY INSTRUCTIONS of this manual FIRST! Be sure that all electrical installations (including all safety systems) comply with all required regulations of the regional authorities. This includes lightening conductor, personal protection switch etc.
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 “Cable cross section” on
Page 105).
F1
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Fig. 5.9-1: Electrical installation - example
5.9.1 Installation PMGi inverter - See separat PMGi 5000 inverter manual
All electrical safety installations have to be made on board.
5.9.2 Power source selector
A power source selector switch must be installed between the generator (or if applicable, AC-Control box) and the ship's electrical supply system. This switch must used to ensure that all AC consumers can be swit­ched off at once. This switch should also be installed to keep the generator and shore (grid) power systems
1
2
3
4
5
1. Generator
2. Electrical fuel pump DC
3. PMGi 5000 inverter
4. iControl panel
5. Starter battery DC
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separate.
Fig. 5.9.2-1: 3-Way Cam Switch
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 8.1, “Cable cross section,” auf Seite 105
Required cable cross-sections
The following recommended electrical cable dimensions (cross sections) are the minimum required sizes for a safe installation. (siehe Tabelle 8.1, “Cable cross section,” auf Seite 105)
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5.9.3 Insulation test
ATTENTION: Once the electrical system installation is complete, a ground insulation test must be performed as follows:
1.) Switch off all on-board electrical devices.
2.) Start the generator.
3.) Measure the AC-voltage with a voltmeter (adjust to Volt/AC) between
a) generator housing and AC-Control box b) generator housing and ground. The measured voltage must not exceed 50mV (millivolts).
8. Once the safety systems have been installed, they must be checked. If a RCD (Leakage Current Relay) has been
installed, it also has to be tested, in order to ensure that it functions properly. The individual phrases must be checked against each other, and between phase and ground, (the single phase or 4th phase also needs to be checked in this fashion).
9. If the generator is protected by a ground connection, then ALL electrical devices must also be connected to this
"common" ground (usually ground contacts are attached to the devices' metallic housings).
The electrical system installation must also comply with the hook-up requirements of the shore current grid. Gene­rally a leakage current relay is sufficient for safe electrical operation; however, this must be confirmed by the electri­cal safety standard in the region where the system is attached to a main land power grid. The relay has to meet the required safety standard regulations.
Checking the electrical connections
There is always the possibility that circuits have been rerouted/changed or individual components have not been not been correctly laid out on the circuit diagrams.
The installation electrician should therefore check and label all electrical connections to ensure that they correspond to the main circuit diagram. The inspection and correct labelling is especially critical for terminals L1/ L2/L3/L1'/N (for the 230 V - 50 Hz model) and for terminals L1/L2/L3/N &1/ 2/ 4 for the 60 Hz (120 V) models. The electrician is the­refore obliged, before installation to check whether the generator is earth-free. As long as this test has not been car­ried out all other components for electrical installation must be removed. Once the system has been installed and inspected, this test should also be performed with all electrical devices (i.e. voltage check between common and metallic housings) while the generator is running.
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6. Maintenance Instructions
6.1 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.
6.2 Hazard notes for this chapter
Notice!:see “Safety instructions - Safety first!” on Page 18.
Follow the general safety instruction at the front of this manual.
Warning!: Automatic start
Danger for life! - The generator can be equipped with a automa­tik 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 disconected before start wor­king at the generator.
Warning!: Risk of injury
Working at a running generator can result in severe personal injury. Therfore before starting work at the generator:
Make shure that the generator ist stopped and the starter battery is diconnected to guarantee that the generator cannot be inadvertently started.
Do not run the generator with removed sound isolation cover.
Warning!: Risk of injury
Improper installation/maintenance can result in servere perso­nal injuries or material damage.
- Always make installation/maintenance work only when the generator is switched off.
- Ensure that there is sufficient space for maintenance work before starting.
- Ensure tidiness and cleanliness at the workplace. Loose components and tools laying around or on top of each other are sources of accidents.
- Only use commercially avalilable tools and special tools for maintenance work. Incorrect or damaged tools can lead to injuries.
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Warning!: Danger of fire
Oil and fuel vapours can ignite on contact with ignition sources. Therfore:
- No open flames during work on the generator.
- Do not smoke.
- Remove oil and fuel residues from the generator and floor.
Danger!: Danger of poisoning
Contact with engine oil, antifreeze and fuel can result in damage to health. Therefor :
- Avoid skin contact with engine oil, fuel and antifreeze.
- Remove oil and fuel splashes and antifreeze from the skin immediatlly.
- Do not inhale oil and fuel vapours.
ATTENTION!: Danger to Life - High voltage
Danger for Life. Improper handling, operation, installation and maintenance can result in sévere personal injury and/or mate­rial damage.
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.
Warning!: Hot surface/material
Generator, oil and antifreeze can be hot during/after operation. Risk of severe burns.
Instruction!: Personal protective equipment necessary.
During Installation/mainenance personal protective equipment is required to minimize the helth hazards.
- Protective clothing
- safety boots
- protective gloves
- Ear defender
- safety glasses
Attention!: Disconnect all load
Disconnet all load during the work atthe generator to avoid damages at the load.
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Warning!:Batteries contains acid or alkalis. Improper handling can result in battery explosion and lea-
kage. Acid or alkalis can run out. An explosion of the battery is possible.
See the operation and safety instruction from your battery manufacturer.
6.3 Environmental protection
Environmental protection.
Danger to the environment due to mishandling!
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 mate-
rials 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.
6.4 General maintenance instructions
6.4.1 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
Once a month
• Grease/oil the servo motor - Trapezoid thread-spindle
Maintenance intervals - see seperate datasheet
6.4.2 Check of Hoses and Rubber Parts in the sound insulated capsule
Check all hoses and hose connections for good condition. The rubber hoses are very sensitive to environmental influences. They wear 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 control of the sacrificial anode (cooling water connection block) and the front seal cover at the generator.
6.5 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
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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 prescri bed.
For filling quantity, see „Technical Data“ at page 107.
6.5.1 Checking oil-level
You require:
paper towels / cloth for the oildipstick
The generator must be placed at level.
- with vehicular generators: Place the vehicle on a leveled surface.
- with PSC generators: Place the generator on a leveled surface.
- with marine generators: Measure the oil-level when the ship is not lop-sided. Run the generator for about 10 minutes to ensure that the engine is warm.
Wait for 3 minutes, so the oil can flow back into the oil pan.
Caution: Burn hazard!Generator and coolant can be hot during and after opera-
ting.
Wear personal protective equipment. (Gloves, protective goggles, protective clothing and safety shoes)
- Assure generator against accidental start.
- Open the generator casing.
- Pull the oildipstick out of the check rail.
- Clean oildipstick.
- Put the oildipstick back into the check rail and wait for 10 seconds.
- Pull the oildipstick out of the check rail and read off the oil-level at the lower end of the stick.
Fig. 6.5-1: Oildipstick - Sample
Oildipstick
The oil-level is to be checked by means of the oildipstick. The prescribed filling level must not cross the „Max“-mark.
We recommend an oil-level of 2/3.
Sample picture
2/3 Suggestion
Oil Max.
Oil Min.
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Fig. 6.5-2: Samplepicture Oildipstick
Oildipstick EA 300 Engine
The oil-level is to be checked by means of the oildipstick. The prescribed filling level must not cross the „Max“-mark.
We recommend an oil-level of 2/3.
Sample picture
Oil should be refilled, if the oil-level is under 1/3 between the minimum and the maximum mark. Fischer Panda recommends an oil-level of 2/3 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 servicepoint.
- if the oil is cloudy or even „creamy“, coolant might have mixed with the oil. See a garage or a Fischer Panda ser­vicepint immediately.
6.5.2 Refilling Oil
You require:
Engine oil
1. Check oil-level as described under „Checking oil-level“ on page 1.
2. Oildipstick is pulled out of the check rail.
3. Open the oil filler cap.
4. Fill in oil (approx. 1/2 liter) and wait for about 2 min. so this it can flow into the oil pan.
5. Wipe off the oildipstick and put it into the check rail.
6. Pull the oildipstick out of the checkrail and check the oil-level. See „Checking oil-level“ on page 1. If oil-level is still too low (under 2/3): repeat steps 4-6.
6.5.3 After the oil level check and refilling the oil
- Put the oildipstick back into the check rail.
- Close the oil filling cap.
- Remove potential oil stains and splashs from the generator and surroundings.
- Close the generator casing.
- Remove lock against accidental generator start.
Oil Max.
Oil Min.
2/3 Suggestion
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6.6 Exchanging engine oil and engine oil filter
You require:
- Engine oil. See attachment.
- New oil filter (not with generators with EA300 engines)
- Sealings 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 vehicular generators: Place the vehicle on a leveled surface.
- with PSC generators: Place the generator on a leveled surface.
- with marine generators: Change the oil when the ship is not lop-sided. Run the generator for about 10 minutes to ensure that the engine is warm.
Wait for 3 minutes, so the oil can flow back into the oil pan.
Caution: Burn hazard!Generator and coolant can be hot during and after opera-
ting.
Wear personal protective equipment. (Gloves, protective goggles, protective clothing and safety shoes)
1. Prepare generator.
- Assure generator against accidental start.
- Open the generator casing.
- with generators that have an external oil drain hose: Release the oil drain hose from the mounting.
- with generators that have an internal oil drain hose: Open the lead-through for the oil drain hose (left turn of the sealing). Pull out the sealing with the oild drain hose.
Place an oil resistant mat under the oil drain hose area and prepare the container.
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Fig. 6.6-1: Oil filling cap
2. Loosen 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.
Sample picture
Fig. 6.6-2: Oil drain hose
3. Open oil drain screw.
Unsrew 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 17mm.
4. Discharge used oil.
Let the entire amount of oil drain out of the engine. This can take several minutes.
Fig. 6.6-3: Oil filter
5. Remove used oil filter / clean oil screen
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
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Fig. 6.6-4: Oil screen
Oil screen with generators with EA300 engines
The oil screen should be cleaned every 500 operating hours: to do so follow the instructions in the engine manual.
Use spanner size 17mm.
Sample picture
Fig. 6.6-5: Oil screen sealing ring
6. Preparing a new filte 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) Fill the engine oil into the engine via feed hopper. Check oil-level after every 2 liters with the oildipstick.
9. Check proper filling level. See „Checking oil-level“ on page 1. 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 oildipstick. If it is too low, refill some oil.
10. Clean up Wipe off all oil splashs from the generator and make sure that the drain screw has no leak.
6.6.1 After the oil change
- Put the oildipstick back into the check rail.
- Close the oil filling cap.
- Remove potential oil stains and splashs from the generator and surroundings.
- Close the generator casing.
- Remove lock against accidental generator start.
11. Duly disposure 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).
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6.7 Verifying the starter batterie and (if necessary) the battery bank
Check the condition of the battery. Proceed here as prescribed by the battery manufacturer. If from the battery manufakturer not otherwise mentioned
6.7.1 Battery
6.7.1.1 Check battery and cable connections
Fig. 6.7.1-1: Battery
• Keep battery clean and dry.
• 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.
6.7.1.2 Check electrolyt level
Fig. 6.7.1-1: Battery
• Remove sealing caps 1.
• If testers 2 are present:
• Electrolyte level should reach the base of these.
• Without testers:
The electrolyte level should be 10-15 mm above the top of the plates.
• If necessary, top up with distilled water.
• Screw sealing caps back in.
6.7.1.3 Check electrolyt density
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Fig. 6.7.1-1: Battery
• Measure the electrolyte density of individual cells with a commercial hydrometer. The hydrometer reading (see table on following page) indicates the battery’s state of charge. During measurement, the temperature of the electrolyte should preferably be 20 °C.
AttentionThe gases emitted by the battery are explosive! Keep
sparks and naked flames away from the battery!
Do not allow battery acid to come into contact with skin or clothing!
Wear protective goggles!
Do not rest tools on the battery!
Electrolyte density in [kg/ l] Charge status Normal Tropical
1.28 1.23 well charged
1.20 1.12 semi-charged, re-charge
1.12 1.08 discharged, immediately charge
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6.8 Checking the water separator in the fuel supply
Fig. 6.8-1: Pre-filter with water separator
The pre-filter with water separator has a cock underneath, by which means the water can be drained.
This water sinks to the bottom, due to the difference in the densities of water and fuel. Water is heavier than the diesel
Sample picture
6.8.1 Exchange of the Fuel Filter
Fig. 6.8.1-1: Fuel Filter
Exchanging the filter, depending upon fuel contamination, should take place after 300 operational hours at the very least. T
he 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.
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6.8.1.1 Optional fuel filter with sight glass
Fig. 6.8.1-1: Fuel filter
The filter change depends on the fuels’ degree of pollution, but should be executed every 300 operating hours at the latest.
01. Fuel filter housing
02. Fuel filter element
03. Sight glass
Fig. 6.8.1-2: Fuel filter
Unscrew the housing from its mount (left hand rotation).
Fig. 6.8.1-3: Fuel filter
Unscrew the filter element from the mount (left hand rotation).
01
02
03
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Fig. 6.8.1-4: Fuel filter
Screw the new filter element into the mount.
Lubricate the sight glasses o-ring with a heat resistant grease (Specification: Antiseize) and screw the sight glass back into its mount (right hand rotation).
6.8.2 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):
Fig. 6.8.2-1: Fuel return pippe
1. Put a container under the fuel return pipe to catch running out fuel to catch.
Fig. 6.8.2-2: Starter motor
2. Take off the plug at the solenoid of the starter motor.
3. Switch the panel „ON“.
4. Press „START“-button. The fuel pump runs audible.
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Fig. 6.8.2-3: iControl
5. Switch the panel „OFF“.
6. Switch the panel „ON“.
7. Press again the „START“-button.
This procedure must be repeated several times, until fuel (nonporously) withdraws perfectly at the fuel return pipe.
8. Switch the panel „OFF“.
9. Attach the plug at the solenoid of the starter motor.
6.8.3 Replacement of the air filter
Fig. 6.8.3-1: Air filter
Open the air suctin housing by loosen the six hexagon head screws on the frame cover.
Fig. 6.8.3-2: Air filter mat
Change the air filter mat and close the cover again.
8
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6.9 De-aerating of the coolant circuit / freshwater
The Panda 5000i PMS is self de-aerating.
6.10 The raw water circuit
6.10.1 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. 6.10.1-1: Raw water filter
6.10.2 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 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").
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6.10.3 Replacement of the impeller
Fig. 6.10.3-1: Raw water stop cock
Close the raw water stop cock.
Fig. 6.10.3-2: Raw water pump
Raw water pump on the front side of the genset.
Fig. 6.10.3-3: Raw water pump
Remove the cover of the raw water pump by loosen the wing screws from the housing.
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Fig. 6.10.3-4: Impeller
Pull to the impeller with a multigrip pliers of the wave.
Mark the impeller, to make sure that these is used in the correct position at re-installation.
Fig. 6.10.3-5: Impeller
Check to the impeller for damage and replace it if neces­sary.
Before the reinsertion into the housing the impeller should have been lubricated with glycerin or with a non-mineral oil based lubricant e.g. silicone spray.
Fig. 6.10.3-6: TImpeller seal
he impeller is attached to the pump wave (if the old impeller is used, pay attention to the before attached marking).
Fastening the cover and use a new seal.
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7. Generator Faults
7.1 Personal requirements
The work described here, unless otherwise indicated, are performed by the operator. Any further repair work may be performed only by specially trained personnel or by authorized repair shops (Fischer
Panda service points). This is especially for working on the valve timing, fuel injection system and the engine repair.
7.2 Hazard notes for this chapter
Note!:see “Safety instructions - Safety first!” on Page 18.
Also consider the general safety instructions at the first pages of this manual.
Warning!: Automatic start
Danger for life! - The generator can be equipped with a automa­tik 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 disconected before start wor­king at the generator.
Warning!: Risk of injury
Working at a running generator can result in severe personal injury. Therefore before starting work at the generator:
Make sure that the generator ist stopped and the starter bat­tery is diconnected to guarantee that the generator cannot be inadvertently started.
Do not run the generator with removed sound isolation cover.
Warning!: Risk of injury
Improper installation/maintenance can result in servere perso­nal injuries or material damage.
- 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 avalilable
tools and special tools. incorrect or damaged tools can result injuries.
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Warning!: Danger of fire
Oil and fuel vapours vcan ignite on contact with ignition sources. Therfore:
- No open flames during work on the generator.
- Do not smoke.
- Remove oil and fuel residues from the generator and floor.
Danger!: Danger of poisoning
Contact with engine oil, antifreeze and fuel can result in damage to health. Therefor :
- Avoid skin contact with engine oil, fuel and antifreeze.
- Remove oil and fuel splashes and antifreeze from the skin immediatlly.
- Do not inhale oil and fuel vapours.
ATTENTION!: Danger to Life - High voltage
Danger for Life. Improper handling, operation, installation and maintenance can result in severe persoanl injury and/or mate­rial damage.
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.
Warning!: Hot surface/material
Generator, oil and antifreeze can be hot during/after operation. Risk of severe burns.
Instruction!: Personal protective equipment necessary.
During Installation/mainenance personal protective equipment is required to minimize the helth hazards.
- Protective clothing
- safety boots
- protective gloves
- Ear defender
- safety glasses
Attention!: Disconnect all load
Disconnet all load during the work atthe generator to avoid damages at the load.
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