Generator manual Panda 5000i PVMV-N Panda 5000i PVM 230V 50Hz 4kW Super silent technology Fischer Panda GmbH Panda_5000i_PVMV-N_Book_eng.R04 29.11.
Current revision status Document Actual: Panda_5000i_PVMV-N_Book_eng.R04_29.11.13 Replace: Panda_5000i_PVMV-N_Book_eng.R05 Revision Page iControl 2 eingepflegt (R03) PMGi mit Lade/Wechselrichtern (R04) Update auf neue Normbausteine (R06) Erstellt durch / created by Fischer Panda GmbH - Leiter Technische Dokumentation Otto-Hahn-Str. 32-34 33104 Paderborn - Germany Tel.: +49 (0) 5254-9202-0 email: info@fischerpanda.de web: www.fischerpanda.
Inhalt / Contens Current revision status.............................................................................................................................. 2 1 General Instructions and Regulations ................................................................................................ 12 1.1 Safety first! ................................................................................................................................. 12 1.2 Tools ........................................
Inhalt / Contens 3.8 3.9 Special Service Instructions and Measures for Extended Machine Downtimes and Decommissioning 34 3.8.1 Instructions for the starter battery for extended downtimes ........................................ 35 3.8.2 Measures for short downtimes .................................................................................... 35 3.8.3 Measures for medium term downtimes / hibernation .................................................. 35 3.8.3.1 Courses for preservation: .............
Inhalt / Contens 5.8 ................................................................................................................................................... 54 6 Installation ............................................................................................................................................. 55 6.1 Personal requirements ............................................................................................................... 55 6.2 Environmental protection .....
Inhalt / Contens 6.12 Custom installations ................................................................................................................... 88 6.12.1 External heat exchangers ........................................................................................... 88 6.12.2 External engine pre-heater ......................................................................................... 88 6.12.3 Keel cooling ............................................................................
Inhalt / Contens 7.9 Replacement of the air filter matt ............................................................................................. 115 8 Tables.................................................................................................................................................... 117 9 8.1 Troubleshooting ....................................................................................................................... 117 8.2 Technical Data .........................
Inhalt / Contens 10.2 Safety instructions .................................................................................................................... 147 11 General operation ................................................................................................................................ 149 11.1 The Panda iControl2 panel ...................................................................................................... 149 11.2 Starting preparation / Checks (daily) ..............
14.1.2 Warning messages ................................................................................................. . 176 14.2 Faults ....................................................................................................................................... 176 14.2.1 Error messages ...................................................................................................... . 177 14.2.2 Warning and fault thresholds ...............................................................
Seite/Page 10 - Kaptitel/Chapter 1: 29.11.
Dear Customer, Thank you for purchasing a Fischer Panda Generator and choosing Fischer Panda as your partner for mobile power on board. With your generator, you now have the means to produce your own power – wherever you are - and experience even greater independence. Not only do you have a Fischer Panda generator on board, you also have worldwide support from the Fischer Panda Team. Please take the time to read this and find how we can support you further.
General Instructions and Regulations 1. General Instructions and Regulations 1.1 Safety first! These symbols are used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury of lethal danger during certain maintenance work or operations. Read these instructions carefully. Can cause acute or chronic health impairments or death even in very small quantities if inhaled, swallowed, or absorbed through the skin.
General Instructions and Regulations Touching of the corresponding parts and systems is prohibited. PROHIBITED: Do not touch Danger for life! Working at a running generator can result in severe personal injury. DANGER: Automatic start-up The generator can be equipped with a automatic start device. This means, an external signal may trigger an automatic start-up. To avoid an unexpected starting of the generator, the starter battery must be disconnected before working at the generator.
General Instructions and Regulations Warning of substances that may cause an explosion under certain conditions, e.g. presence of heat or ignition sources. WARNING: Explosion hazard Warning of hot surfaces and liquids. Burn/scalding hazard. WARNING: Hot surface Warning of substances that cause chemical burns upon contact. These substances can act as contaminants if introduced into the body.
General Instructions and Regulations Wearing the applicable snugly fitting protective clothing provides protection from hazards and can prevent damage to your health. MANDATORY INSTRUCTION: Wear snugly fitting protective clothing (PPE). Wearing hearing protection provides protection from acute and gradual hearing loss. MANDATORY INSTRUCTION: Wear hearing protection (PPE). Wearing safety goggles protects the eyes from damage. Optical spectacles are not a replacement for the corresponding safety goggles.
General Instructions and Regulations 1.2 Tools These symbols are used throughout this manual to show which tool must be used for maintenance or installation. Spanners W.A.F X = width across flats of X mm Hook wrench for oil filter Screw driver, for slotted head screws and for Phillips head screws Multimeter, multimeter with capacitor measuring unit Socket wrench set Hexagon socket wrench set Seite/Page 16 - Kaptitel/Chapter 1: General Instructions and Regulations 29.11.
General Instructions and Regulations Clamp-on ammeter (DC for synchronous generators; AC for asynchronous generators) Torque wrench 29.11.
General Instructions and Regulations 1.3 Manufacturer declaration in accordance with the Machinery Directive 2006/42/EC Manufacturer declaration in accordance with the Machinery Directive 2006/42/EC The generator was designed in such a way that all assemblies correspond with the CE guidelines.
General Instructions and Regulations 1.5 Safety Instructions - Safety First! 1.5.1 Safe operation Careful handling of the equipment is the best insurance against an accident. Read the manual diligently, and make sure you understand it before starting up the equipment. All operators, regardless of their experience level, shall read this manual and additional pertinent manuals before commissioning the equipment or installing an attachment.
General Instructions and Regulations 1.5.5 Safe handling of fuels and lubricants Keep fuels and lubricants away from naked fire. Before filling up the tank and/or applying lubricant, always shut down the generator and secure it against accidental start-up. Do not smoke and avoid naked flame and sparking near fuels and the generator. Fuel is highly flammable and may explode under certain conditions. Refuel in well-ventilated open spaces only. If fuel/lubricant was spilled, eliminate fluids immediately.
General Instructions and Regulations 1.5.7 Safety precautions against burns and battery explosions The generator and its cooling agents and lubricants as well as the fuel can get hot while the generator is operated. Use caution around hot components such as parts containing exhaust fumes, radiator, hoses, and engine block during operation and after the generator was shut down. The cooling system may be pressurised. Open the cooling system only after letting the engine and the coolant cool down.
General Instructions and Regulations 1.5.10 Implementation of safety inspections and maintenance Disconnect the battery from the engine before performing service work. Affix a sign to the control panel - both the main and the corresponding slave panel - with the instruction “DO NOT START UP - MAINTENANCE IN PROGRESS“ to prevent unintentional start-up. To prevent sparking due to accidental short-circuiting, always remove the earthing cable (-) first and reconnect it last.
General Instructions and Regulations 1.6.1.1 Protective conductor and potential equalisation: Electric current below 48 V may be life-threatening. Fort this reason systems are grounded with a protective conductor. In connection with a RCD the current supply will be disconnected in case of a failure. Appropriate safety precautions like the RCD and corresponding fuses have to be provided by the customer to guarantee a save operation of the generator. 1.6.1.
General Instructions and Regulations 1.6.1.5 Safety instructions concerning cables Cable types It is recommended to use cables that are in compliance with the standard UL 1426 (BC-5W2) with type 3 (ABYC section E-11). Cable cross-section The cable shall be selected taking into account the amperage, cable type, and conductor length (from the positive power source connection to the electrical device and back to the negative power source connection).
General Instructions and Regulations Observe the applicable instructions concerning fire and explosion protection of the battery manufacturer. Install a fuse of appropriate size in the positive connection of the starter battery. Install as close to the battery as possible but with a max. distance of 300 mm (12 in) from the battery. The cable from the battery to the fuse shall be protected with a conduit/protective sleeve against fraying.
General Instructions and Regulations • If you have acid splashes on the skin or clothing, wash them out with lots of water and soap. • If acid sprays into your eyes, immediately flush them with clean water until no more burning is felt. Immediately seek medical assistance. • Do not smoke near the batteries. Avoid naked fire. The area around batteries is a potentially explosive atmosphere. • Ensure that no tools are dropped on the battery terminals; cover them as necessary.
In case of Emergency First Aid / Im Notfall Erste Hilfe 2. In case of Emergency First Aid / Im Notfall - Erste Hilfe First Aid in case of accidents by electrical shocks 5 Safety steps to follow if someone is the victim of electrical shock Do not touch the injured person while the generator is running. 1 Switch off the generator immediately. 12 13 If you cannot switch off the generator, pull, push, or lift the person to safety using a wooden pole, rope or some nonconducting material.
In case of Emergency First Aid / Im Notfall Erste Hilfe 2.7 WHEN AN ADULT STOPS BREATHING DO NOT attempt to perform the rescue breathing techniques provided on this page, unless certified. Performance of these techniques by uncertified personnel could result in further injury or death to the victim. Warning: 1 Does the Person Respond? Tap or gently shake victim. Shout, “Are you OK?“ 2 Shout, “Help!“ Call people who can phone for help. 3 Roll Person onto Back.
Basics 3. Basics 3.1 Intended use of the machine The Fischer Panda generator is made to produce electrical energy out of diesel fuel. The diesel fuel is converted to mechanical energy by the diesel engine. This mechanical energy drives the generator. In the genset, the mechanical energy is converted to electrical energy. This process is controlled by (sometimes external) components, the remote control panel and the VCS (voltage control system).
Basics 3.2.3 User Users are persons, established by the operator, to operate the generator. The operator has to ensure that the user has read and understood the manual and that all hazard notes and safety instructions are respected. The user must be instructed by the operator regarding his activity at the generator, especially concerning the maintenance. 3.3 Components of the i system 1. Panda i PMS Generator Fig. 3.3-1: Panda i generator Permanent-Magnet-Generator representative picture 2.
Basics 3. Panda PMGi Inverter AC/AC Fig. 3.3-3: PMGi inverter representative picture 4. Fischer Panda manual Fig. 3.3-4: Manual The Fischer Panda manual comprises the following components: a.- Transparent envelope with general information, warranty terms, installation certificates, and service list. b.- Generator manual c.- Spare parts catalogue „Installation & Service Guide“ d.- Engine manual from the engine manufacturer e.- Generator circuit diagram representative picture 3.
Basics 2. Remove the cover 3. Remove the loose 4. Bend open the metal tab closures at the bottom of the transport box 5. Remove the sidewalls 6. Open the generator attachment 3.6 Opening the MPL sound insulation capsule To open the sound insulation capsule, the closures must be rotated roughly 180° counter-clockwise. Use a flat head screwdriver. Pull the sidewalls out by gripping into the slots. Closure locked Seite/Page 32 - Kaptitel/Chapter 3: Basics Fig. 3.
Basics Closure open Fig. 3.6-3: Closure open 3.6.1 Opening the GFK sound insulation capsule GFK sound insulation capsule with lash closures Fig. 3.6-1: Lash closures To open the lash closures pull the handle in arrow direction and lift the lash of the closure pin. After lifting off the lashes, the sound isolation cover upper part can be removed. Fig. 3.6-2: Lash closures 29.11.
Basics 3.7 Transport and Loading/Unloading 3.7.1 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.
Basics 3.8.1 Instructions for the starter battery for extended downtimes Starter batteries Note: Information starter battery Self-discharge of batteries is a physical and chemical process and cannot be avoided even if the battery is disconnected • For extended downtimes, the battery shall be disconnected from the genset. • Charge battery regularly. Observe instructions of the battery manufacturer.
Basics 3.8.3.1 Courses for preservation: • Check battery charge status and recharge regularly, roughly every 2 months, as necessary. Observe instructions of the battery manufacturer. • Check cooling water anti-freeze level and refill as necessary. The anti-freeze agent must not be older than 2 years. The anti-freeze content shall be between 40 % and 60 % to ensure corrosion protection of the cooling water circuit. Top off coolant if necessary. If the cooling water is drained, e.g.
Basics 3.8.4 Measures for extended downtimes / decommissioning Downtimes (more than 6 months) 3.8.4.1 Courses for preservation: • Check battery charge status and recharge regularly, roughly every 3 months, as necessary. Observe instructions of the battery manufacturer. • Check cooling water anti-freeze level and refill as necessary. The anti-freeze agent must not be older than 2 years. The anti-freeze content shall be between 40 % and 60 % to ensure corrosion protection of the cooling water circuit.
Basics • 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.
The Panda Generator 4. The Panda Generator 4.1 Type plate at the generator Fig. 4.1-1: Type plate at the generator Fig. 4.1-2: Typeplateg 29.11.13 Panda_5000i_PVMV-N_Book_eng.
The Panda Generator 4.2 Description of the Generator 4.2.1 Front view - Panda 5000i PVMV-N Fig. 4.2.1-1: Front view - Panda 5000i PVMV-N 01 02 03 04 05 09 10 01. Watercooled pre silencer 02. Venting screw at the pre silencer 03. Combustion air intake 04. Air filter housing with filter 05. Protective resistor for thermoswitch 75°C/70°C 06. Starter 07. Oil pressure switch 08. iControl electronic board „DO NOT OPEN - Danger to life“ 09.
The Panda Generator 4.2.2 Rear View - Panda 5000i PVMV-N Fig. 4.2.2-1: Rear View - Panda 5000i PVMV-N 01 02 03 08 10 11 12 04 05 07 09 13 14 15 16 01. Cooling water pump 02. iControl electronic board „DO NOT OPEN - Danger to life“ 03. Generator housing with stator winding 04. Generator housing front cover 05. Venting screw engine 06. Cooling water hose 07. Water cooled pre silencer 08. Starter battery connection (-) 09. Starter battery connection (+) 10. Sound cover base part 11.
The Panda Generator 4.2.3 Top view - Panda 5000i PVMV-N Fig. 4.2.3-1: Top view - Panda 5000i PVMV-N 01 02 03 04 05 06 07 08 09 10 12 11 13 14 16 15 19 20 01. Watercooled pre silencer 02. Exhaust out 03. Cooling water out 04. Compensator under heat isolation 05. Cooling water hose 06. Watercooled exhaust elbow 07. Venting screw exhaust elbow 08: Fuel connection 09. Generator housing front cover 10. Generator housing with stator winding 11.
The Panda Generator 4.2.4 Side view right - Panda 5000i PVMV-N Fig. 4.2.4-1: Side view right - Panda 5000i PVMV-N 01 01. Water cooled pre silencer 29.11.13 Panda_5000i_PVMV-N_Book_eng.
The Panda Generator 4.2.5 Side view left - Panda 5000i PVMV-N Fig. 4.2.5-1: Side view left - Panda 5000i PVMV-N 02 05 03 06 01. Cooling water pipe, pump to engine 02. iControl electronic board „DO NOT OPEN - Danger to life“ 03. Type plate at engine EA 300 Seite/Page 44 04 03 04. Cooling water pump 05. Lead-through for oil drain hose 06. Sound cover base part Panda_5000i_PVMV-N_Book_eng.R02 - Kapitel/Chapter 4: The Panda Generator 29.11.
The Panda Generator 4.3 Details of function units 4.3.1 Remote control panel - see iControl data sheet 4.3.2 The cooling system - schema Fig. 4.3.2-1: The cooling system - schema 29.11.13 Panda_5000i_PVMV-N_Book_eng.
The Panda Generator 4.3.3 The fuel and combustion air system - schema Fig. 4.3.3-1: Fuel and combustion air system - schema Seite/Page 46 Panda_5000i_PVMV-N_Book_eng.R02 - Kapitel/Chapter 4: The Panda Generator 29.11.
The Panda Generator 4.3.4 Components of the electrical system Fig. 4.3.4-1: Electrical system 29.11.13 Panda_5000i_PVMV-N_Book_eng.
The Panda Generator 4.3.5 The oil circuit - schema Fig. 4.3.5-1: Oil circuit 4.3.6 Thermosensor/switches Thermosensor cylinderhead Seite/Page 48 Panda_5000i_PVMV-N_Book_eng.R02 - Kapitel/Chapter 4: The Panda Generator Fig. 4.3.6-1: Thermosensor cylinderhead 29.11.
The Panda Generator Thermoswitch/Thermosensor pre silencer Panda 5000i PVMV-N Fig. 4.3.6-2: Thermoswitch/sensor At this point the cooling water has normal the highest temp. 1 1. Thermosensor 2 2. 82°C/77°C (Fan fast) 3. 75°C/70°C (Fan slow) 3 Thermoswitches watercooled exhaust elbow Panda 5000i PVM At this point the cooling water has normal the highest temp. Fig. 4.3.6-3: Thermoswitches 1 1. 82°C/77°C (Fan fast) 2. 75°C/70°C (Fan slow) 2 Resistor Fig. 4.3.6-4: Resistor 01.
The Panda Generator Winding- Thermosensor Fig. 4.3.6-5: Thermosensor winding Another Thermosensor is build into the winding Oil pressure switch at the engine Fig. 4.3.6-6: Oil pressure switch PMGi 5000 The „inverter“ of the Panda 5000i 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.
5. Generator operation instruction 5.1 Personal requirements Only instructed persons are allowed to run the generator. Instructed Persons has read the manual of the generator and all ancillary components and external equipment. He must be acquaint with the specific risks and safety instructions. Only persons who are expected to perform their tasks reliably are permitted as personnel. Persons whose reaction capability is impaired, e.g. through drugs, alcohol or medication are not permitted.
lubricant oil ect. must be suitable for this temperatures. These should be checked before start. Cold start spray ect. are not allowed to use, or the warranty will be lost. 5.3.1.1 Pre-heating the diesel motor Pre.champer diesel engines are equipped with a quick glow plug. The maximum pre glow time should not exceed 20 sec. At 20 °C or more the pre glow time should be about 5-6 sec.
5.3.4 Protection conductor: The standard Panda generator is grounded. The 3-phase connection (delta) centre point is bridged to earth in the AC output terminal box (mounted on the generator). This is the initial earth safety point and is sufficient to ensure safe operation however only as long as no other system is installed. This system is adapted to enable test running of the generator before delivery.
5.6 Starting the generator - see remote control panel data sheet The instructions and regulations of the remote control panel data sheet must be respected. Note: Respect the safety instruction in front of this manual. 5.7 Stopping the generator - see remote control panel data sheet The instructions and regulations of the remote control panel data sheet must be respected. Note: Respect the safety instruction in front of this manual. 5.8 Seite/Page 54 - Kaptitel/Chapter 5: 29.11.
Installation 6. Installation All connections (hoses, wires etc) and installation instructions are designed and suited for “standard” installation situations. Attention! 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.
Installation Oil and fuel vapours can ignite on contact with ignition sources. Therefore: -Warning!: Danger of fire • No open flames during work on the generator. • Do not smoke. • Remove oil and fuel residues from the generator and floor. Contact with engine oil, antifreeze and fuel can result in damage to health.Therefor: Danger!: Danger of poisoning • Avoid skin contact with engine oil, fuel and antifreeze. • Remove oil and fuel splashes and antifreeze from the skin immediately.
Installation 6.2 Environmental protection Engine liquids/batteries are harmful for the environment. Environmental protection. Collect discharged engine liquids and dispose it properly. Batteries should be disposed properly. 29.11.13 Panda_5000i_PVMV-N_Book_eng.
Installation 6.3 Placement 6.3.1 General instructions • It is important to pay attention to the fresh air intake. • Sufficient space must be available below/next to the generator, in order to allow flow of cooling air. (Underside and side: Underneath is not sufficient!) • The radiator may not be covered. • Untrained personnel should never open the generator. 6.3.2 Preparing the base - Placement Since Panda generators have extremely compact dimensions, they can be installed in tight locations.
Installation Shock mount Fig. 6.3.3-1: Shock mount representative picture Captive shock mount Fig. 6.3.3-2: Captive shock mount representative picture 29.11.13 Panda_5000i_PVMV-N_Book_eng.
Installation 6.4 Air suction filter as a source of noise The external suction filter (not included on delivery) must always be used if the generator is to be used in a dust-free environment. This filter is connected by means of a hose with a connecting piece to the generator housing. The filter can be the source of considerable noise. If this is the case, an air intake muffler with the appropriate nominal width should be ordered from Fischer Panda.
Installation 6.5.2 Connections Panda 5000i PVMV-N Fig. 6.5.2-1: Connections 1 2 3 4 1. Cooling water in 2. Cable to the PGMi 3. Cable to the radiator fan 4. Cable to the fuel pump 5. Cable to the iControl panel 6. Fuel out 7. Fuel in 6.6 5 6 7 8 9 8. Cooling water out (hot side) 9. Exhaust out 10. Starterbatteye (-) 11. Starterbattery (+) For the iControl system with FP-Bus an aditional cable is installed to connect the generator with the PMGi Fuel system installation 6.6.
Installation Fuel hose Fig. 6.6.1-1: Fuel hose representative picture No return valve Fig. 6.6.1-2: No return valve representative picture Pre filter with water separator Fig. 6.6.1-3: Pre filter with water separator representative picture Seite/Page 62 Panda_5000i_PVMV-N_Book_eng.R02 - Kapitel/Chapter 6: Installation 29.11.
Installation Pre filter with water separator Fig. 6.6.1-4: Pre filter with water separator Alternative Article representative picture Quick connector for fuel lines Fig. 6.6.1-5: Quick connector for fuel lines representative picture Hose clamps Fig. 6.6.1-6: Hose clamps representative picture 6.6.1.
Installation Electrical fuel pump With the Fischer Panda generator is usually supplied an external, electrical fuel pump (DC). The fuel pump must be installed close at the fuel tank. The electrical connections is prepared at the generator. Fig. 6.6.1-1: electrical fuel pump Some generators (f.e. with Deutz diesel engine) has an engine driven internal fuel pump. At these generators the electrical fuel pump is optional,. Seite/Page 64 Panda_5000i_PVMV-N_Book_eng.R02 - Kapitel/Chapter 6: Installation 29.
Installation Fig. 6.6.1-2: Fuel system - schema 2 3 1 4 6 5 1. Fuel tank 2. external fuel pump 3. external fuel prefilter with water separator 29.11.13 4. Non return valve 5. Fuel fine filter 6. Generator Panda_5000i_PVMV-N_Book_eng.
Installation External fine filter Fig. 6.6.1-3: externer Feinfilter At generators with Kubota EA 300 or Farymann engines, the fine filter is delivered with the generator. This fine filter should be installed in the fuel feed line next to the generator. representative picture 6.6.2 Connection of the fuel lines at the tank General fuel feed and return line must be connected to the tank at separate connection points.
Installation 6.6.3 Position of the pre-filter with water separator Inside the generator capsule itself, there is the fuel filter installed (exception: Panda 4500). Additional fuel filters (with water separator) must be mounted outside the capsule in easily accessible places in the fuel lines between the tank intake fuel pump and the diesel motor's fuel pump.
Installation To avoid large voltage drops the battery should be installed as near as possible to the generator. The positive terminal of the battery is attached at the red cable, the negative pole at the blue cable. NOTE: It must be guaranteed that first the cables are attached at the generator and then at the battery. ATTENTION!: Consider correct connection sequence Battery connection ATTENTION!: Right connection of the battery.
Installation Positive battery cable Fig. 6.7.1-1: Positive battery cable The positive (+) battery cable is connected directly to the solenoid switch of the starter. Negative battery cable Fig. 6.7.1-2: Negative battery cable The negative (-) battery cable is connected to the engine foot. Note! The battery negative pole may not be connected with the boat ground or with the protective grounding of the 12 V installation! DC starter motor Fig. 6.7.
Installation Fig. 6.7.1-4: Connection starter battery 12 V - schema 1. Generator 2. Battery block 3. Fuse 4. Battery main switch Fig. 6.7.1-5: Connection starter battery 24 V - schema 1. Generator 2. Battery block Seite/Page 70 3. Fuse 4. Battery main switch Panda_5000i_PVMV-N_Book_eng.R02 - Kapitel/Chapter 6: Installation 29.11.
Installation 6.7.2 How to connect two 12 V batteries to a 24 V battery bank The starter batteries have to be connected in this order: Fig. 6.7.2-1: Installation starter battery 1. (+) cable of first battery 2. (-) cable of second battery Fig. 6.7.2-2: Installation starter battery 3. (+) cable of second battery Fig. 6.7.2-3: Installation starter battery 29.11.13 Panda_5000i_PVMV-N_Book_eng.
Installation 4. (-) cable of first battery Fig. 6.7.2-4: Installation starter battery 5. Disconnect the batteries in reverse procedure. 6.7.3 Connection of the remote control panel - see separate control panel manual 6.8 Generator Electric-System-Installation 6.8.1 Connection of electrical components Required cable cross-sections The following recommended electrical cable dimensions (cross sections) are the minimum required sizes for a safe installation.
Installation Fig. 6.8.1-1: Installation sample 1 4 5 2 3 1. Generator 2. PMGi 5000 3. Radiator with fan 29.11.13 4. iControl panel 5. External fuel pump Panda_5000i_PVMV-N_Book_eng.
Installation 6.9 Connection of the external radiator - schema Fig. 6.9.0-1: Connection of the external radiator - schema 1 1 1. Generator Seite/Page 74 2. Radiator Panda_5000i_PVMV-N_Book_eng.R02 - Kapitel/Chapter 6: Installation 29.11.
Installation 6.10 Installation of the cooling system 6.10.1 The cooling system / general instructions The Fischer Panda vehicle generator is delivered without a radiator, with the exception of generators with permanently installed radiators such as the PVK-UK or the PSC series. Depending on the purpose and installation situation, a wide variety of Fischer Panda radiators are available for the optimum customization of the system. Operation with a commercially available vehicle radiator is possible.
Installation T-fittings Fig. 6.10.2-3: T-fittings e.g. for connecting the external expansion tank. Example Connection piece sensor Fig. 6.10.2-4: Connection piece sensor for temperature sensors/ switches for fan open-loop/closedloop control Example Roof feed-throughs Fig. 6.10.2-5: Roof feed-throughs in single or double design Example Seite/Page 76 Panda_5000i_PVMV-N_Book_eng.R02 - Kapitel/Chapter 6: Installation 29.11.
Installation External expansion tanks Fig. 6.10.2-6: External expansion tanks Example Hose clips Fig. 6.10.2-7: Hose clips Example Radiator Fig. 6.10.2-8: Radiator Various radiator models are available for roof mounting, side mounting, or underfloor installation. The output levels are adapted to the generators and the application (e.g. radiators with increased output for use in hot regions). Example 6.11 Radiator baseplate The radiator baseplate shall be dimensioned in accordance with the purpose.
Installation In principle, the thermal load of the generator equals 1.8 times the electrical rated power (1.8 times with a watercooled silencer, 1.2 times with a dry silencer) in kW. This means that e.g. a Panda 12000 PVMV-N generator with a rated power of 10 kW has a thermal load of 18 kW. Note: The radiator must always be dimensioned taking into account a safety margin adjusted for the operating conditions. Undersized radiators will result in an emergency shut-down.
Installation 6.11.3.1 Installation location for radiators for roof, side, or underfloor mounting on the vehicle Fig. 6.11.3-1: Radiator installation - example 1 2 3 1. Radiator mounted on the roof 2. Radiator mounted in vertical position 3. Radiator mounted under the vehicle Fig. 6.11.3.1-2: Radiator dimensions 29.11.13 Panda_5000i_PVMV-N_Book_eng.
Installation 6.11.3.2 Roof installation Please note: • Minimum distance to vehicle roof: 100 mm. • Minimum distance to next vertical wall: 1/2 radiator width. • Min. distance to gas exhaust (heat and dirt source): 500 mm. • The max. permissible vehicle height must not be exceeded. • Install warnings stating new vehicle height inside driver's cab. • During operation, the exhaust flow must be uninhibited for at least 3 meters. Fig. 6.11.3.2-1: Schematic: radiator, roof installation Fig. 6.11.3.
Installation 6.11.3.3 Installation on the vehicle wall Please note: • Minimum distance to vehicle wall: 100 mm. • Min. distance to gas exhaust (heat and dirt source): 500 mm. • The max. permissible vehicle length or width must not be exceeded. • During operation, the exhaust flow must be uninhibited for at least 3 meters. Fig. 6.11.3.3-1: Schematic: radiator, vehicle wall installation Fig. 6.11.3.3-2: Schematic: radiator, vehicle wall installation 29.11.13 Panda_5000i_PVMV-N_Book_eng.
Installation 6.11.3.4 Underfloor installation of radiator Please note: • Minimum distance to vehicle floor: 100 mm. • Minimum distance to ground: 1/2 radiator width • Min. distance to gas exhaust (heat and dirt source): 500 mm. • The max. permissible vehicle height must not be exceeded. Fischer Panda does not recommend underfloor installation. The radiator can quickly become dirty. Rock impacts can result in damage to the radiator. The efficiency of the radiator will drop due to thermal short-circuiting.
Installation 6.11.3.5 Installation location for radiator in the vehicle wall or cabin wall A cabin installation is achieved if the set-up location is freely accessible during operation and serves as a working space, if applicable. Please note: • If persons are present in the set-up space during operation, a safety circuit must ensure that the air intake is opened. Incorrect installation in the cabin Fig. 6.11.3.
Installation 6.11.3.6 Installation location for radiator in a tunnel A tunnel installation is implemented if the set-up location is separated from the vehicle cab by constructive measures. Please note: • The total of the air intakes must be at least equal to the radiator width ( • The total of the cross-sections of the air ducts incl.
Installation 6.11.3.7 Installation location for generators of the PVK-UK series Generators of the PVK-UK series are designed for lateral installation on the vehicle chassis Please note: • Min. distance between radiator and vehicle chassis must be 1/2 B. • Min. distance to gas exhaust (heat and dirt source): 500 mm. • The exhaust flow area must be unobstructed. No impairment to the vehicle chassis or installations. Fig. 6.11.3.7-1: PVK-UK installation location 6.11.
Installation 6.11.5 Connection of the external radiator see Kapitel 6.13, “Installation schematics,” auf Seite 89 6.11.6 Coolant expansion tank Coolant expansion tank for systems with a radiator below the generator. For operation, a coolant expansion tank must be installed at least 100 mm above the level of the exhaust manifold and the radiator. The ventilation line of the radiator and the generator shall be installed on the top connection.
Installation • The coolant pump is designed so that a max. distance of 5 m between pump and radiator is possible. If the necessary coolant volume flow is not achieved (e.g. Note: due to a special installation situation), an external coolant pump with the corresponding output must be installed in the coolant circuit to increase the coolant volume flow. The pressure in the coolant circuit must not exceed 0.7°bar! Warning: Required coolant volume flow: Fig. 6.11.
Installation 1. Coolant feed line max. 70 °C in permanent operation mode at maximum load 2. Coolant return line max. 85 °C in permanent operation mode. 3. Differential of the two values: This item is of particular importance and provides information on the circulation of the coolant. The difference should be max. 17 K for a coolant water system with an integrated water-cooled muffler. It should, however, typically be between 10 and 12 °K.
Installation 6.13 Installation schematics 6.13.1 Installation for vertical radiator installation Fig. 6.13.1-1: Vertical radiator - schematic 3 4 1 5 6 2 01. Coolant expansion tank 02. Engine bleed line 03. Fan for radiator 29.11.13 04. Radiator 05. Thermal switch (on the hot side) 06. T-fitting Panda_5000i_PVMV-N_Book_eng.
Installation 6.13.2 Installation for mounting the radiator under the vehicle Fig. 6.13.2-1: Underfloor radiator - schematic 6 5 1 3 2 4 01. Ventilation line 02. Coolant expansion tank 03. T-fitting with connection for thermal switch Seite/Page 90 04. T-fitting 05. Radiator 06. Fan for radiator Panda_5000i_PVMV-N_Book_eng.R02 - Kapitel/Chapter 6: Installation 29.11.
Installation 6.13.3 Installation schematic for roof mounted radiator with expansion tank Fig. 6.13.3-1: Roof-mounted radiator - schematic 3 4 5 2 1 1. Engine bleed line 2. Radiator (horizontal) 3. Coolant expansion tank (integrated) 29.11.13 4. T-fitting for bleed line 5. T-fitting with connection for thermal switch Panda_5000i_PVMV-N_Book_eng.
Installation 6.14 Exhaust installation 6.14.1 Exhaust connection for roof outlet Fig. 6.14.1-1: Exhaust installation - scheme 3 4 6 5 8 7 2 1 1. Exhaust outlet 2. Generator 3. Roof through fitting 4. Vibration damper 5. External pre-silencer 6. Exhaust pipe 7. External series silencer 8. End pipe 6.14.2 Exhaust connection for mounting below the vehicle Fig. 6.14.2-1: Exhaust installation - scheme 1 1. Generator 2. Exhaust outlet 3. Compensator 4.
Installation 6.15 Radiator fan control / electronic fan control To control the radiator fan, various controls/electronic controls can be chosen from the Fischer Panda delivery program. In the following the basic functions of the fan controls are described. The original manual/ data sheet with further informations of the fan control must be respected. Note!: 6.16 Standard fan control for 1-phase and 3-phase generators. In the standard kit, the generators will be equipped with a one step fan control.
Installation Fig. 6.16.0-2: Fan control 230V Seite/Page 94 Panda_5000i_PVMV-N_Book_eng.R02 - Kapitel/Chapter 6: Installation 29.11.
Installation 6.17 Electronic fan control for DC fans RE 0201 For DC Fans the fan control RE 0201 can be used. Fig. 6.17-1: 6.18 Brief description Temperature-dependent continuous speed controlling device for one or two DC-fans. 6.18.1 Function The speed regulation of the fan is made by pulse tracing modulation (PWM) of the operating voltage. Pulse/no pulse ratio becomes over an external temperature sensor (NTC resistance to attach at clamp 7 and 8) dependent on the coolant temperature.
Installation Poti Start: Adjusting the starting temperature (fan start-up). The start temperature is with left stop 60°C and with right stop 80°C. Ex factory a starting temperature of 70°C is adjusted (potentiometer position: In the middle). Poti Window: Adjusting the temperature window: With the potentiometer „Window“ the size of the window between starting temperature and temperature for full number of revolutions (upper limit temperature) can be adjusted.
Installation Fig. 6.18.2-1: 6.18.3 Function of the clamps for the Master-Slave-Operation Clamp 11+12: Control input for slave operation. Clamp 11 is the positive input. Clamp 12 is the negative input. The input is floating, so that via this input connected fan controllers of the same source can be supplied, without a ground loop develops. Clamp 13+14: Output for the master-slave-operation. At clamp 13 is the signal and at clamp 14 is ground. 6.18.
Installation 6.19 Technical Data Characteristics closed current (electronics off) 0,5mA closed current (electronics on) 10 - 15mA Benchmark figure of the temperature control: fan start-up 60°C - 80°C max. number of revolution 65°C - 100°C tolerance of the temperatures ± 5% Maximum ratings maximum ambient temperature (for operation) 50°C Maximum ratings: Battery operation 12V nominal load operating voltage (continuity) 11 VDC - 14.4 VDC load operating voltage (15min) - 16.
Installation maximum load current (3 sec) 28 A nominal voltage fan 24 VDC *1) The maximum input and/or output peak voltage is measured over the appropriate clamps of the fan controller. It may be exceeded at no time. This applies independently of whether a voltage increased height was possibly caused by the fan controller or an external component.
Installation 6.20 Electronic fan control for single phase fans PKE-2.5V_Ziehl Abegg The electronic fan control variety the fan rpm stepless. 6.20.1 Preset for the use with Fischer Panda generators The Ziehl Abegg fan control is preset for the use with Fischer Panda generators. For the preset following data and jumper settings are used. Fig. 6.20-1: Preset Seite/Page 100 Panda_5000i_PVMV-N_Book_eng.R02 - Kapitel/Chapter 6: Installation 29.11.
Installation 6.20.2 Connection of the sensor (Ziehl Abegg KTY) The sensor is connected to E/GND. A resistor 4,2kOhm must be connected parallel to the sensor. L1 N temperature sensor 1 fan 2 -A PE R1 PE n-min line 230V 50Hz U1 R2 U2 fan control 4,2kOhm E PKE-2,5V(E) GND Ziehl-Abegg +24V n-max Set J4 Pband J5 R3 A B -R 1 -M M PE -R 2 T Fig. 6.20.2-1: Connection plan 29.11.13 Panda_5000i_PVMV-N_Book_eng.
Installation 6.21 Electronic fan control for single phase fans PXET6Q_Ziehl Abegg The electronic fan control variety the fan rpm stepless. 6.21.1 Preset for the use with Fischer Panda generators The Ziehl Abegg fan control is preset for the use with Fischer Panda generators. For the preset following data and jumper settings are used. Fig. 6.21-1: Preset Seite/Page 102 Panda_5000i_PVMV-N_Book_eng.R02 - Kapitel/Chapter 6: Installation 29.11.
Zust. -F N L1 PE N PE Panda_5000i_PVMV-N_Book_eng.R02 - Kapitel/Chapter 6: Installation Datum line 230V 50Hz . U1 U1 Name 1 11 U2 U2 Datum Bearb. Gepr. Norm 14 12 TB Bröckling Schönberger 26.08.2010 TB 1 on 10 GND GND A1 D1 D1 E1 3 4,2kOhm -R 2 1 -M fan M 4 PE Urspr.070367_00_00 Ers.f --- Ers.d --- connectionplan - fan control ZA PXET6Q / PXET6Q E1 Ziehl Abegg PXET6Q 24V 2 GND 29.11.13 Änderung -A 0 5 1 2 T Otto-Hahn-Str.
Installation 6.22 Electronic fan control for 3 phase fans PKD T5 Ziehl Abegg The electronic fan control variety the fan rpm stepless. Fan control PKD T5 Fig. 6.22.0-1: Fan control PKD T5 representative picture Seite/Page 104 Panda_5000i_PVMV-N_Book_eng.R02 - Kapitel/Chapter 6: Installation 29.11.
Installation 6.22.1 Configuration of the electronic fan control PKD T5 for Fischer Panda Generators Fig. 6.22.1-1: Configuration of the fan control PKD T5 for Fischer Panda Generators 29.11.13 Panda_5000i_PVMV-N_Book_eng.
Installation 6.23 Isolation test After installation, but before the generator is set into nor- ATTENTION! mal operation and handed to the customer, an isolation test must be performed as followed: 1. Disconnect all load. 2. Start the generator. 3. Measure with a voltmeter (AC) the voltage between: a. Generator housing and PMGi housing. b. Generator housing and ground of the vehicle. c. The measured voltage must be lower than 50 mV. 4. Test the installed protective devices (like RCD).
Maintenance Instructions 7. Maintenance Instructions 7.1 Personal requirements All maintenance, if not special marked, can be done by the trained persons. Further maintenance must be done by technical personal or Fischer Panda service points. 7.2 Hazard notes for the maintenance Follow the general safety instruction at the front of this manual. Notice!: Danger for life! - The generator can be equipped with a automatic start device. This means the generator can be started by an external signal.
Maintenance Instructions Oil and fuel vapours can ignite on contact with ignition sources. Therefore: Warning!: Danger of fire • No open flames during work on the generator. • Do not smoke. • Remove oil and fuel residues from the generator and floor. Contact with engine oil, antifreeze and fuel can result in damage to health. Therefor: Danger!: Danger of poisoning • Avoid skin contact with engine oil, fuel and antifreeze. • Remove oil and fuel splashes and antifreeze from the skin immediately.
Maintenance Instructions manufacturer. Batteries contain corrosive acids and lyes. Improper handling can cause the batteries to heat up and burst. Corrosive acid/lye may leak. Under unfavorable conditions, the battery may explode. Observe the instructions from your battery manufacturer. 7.3 Environmental protection Danger to the environment due to mishandling! Environmental protection.
Maintenance Instructions 7.6 Oil circuit maintenance The first oil change is to be accomplished after a period of operation from 35 to 50 hours. Afterwards the oil is to be changed after 150 hours. For this the oil SAE30 for temperatures over 20°C and SAE20 for temperatures between 5°C and 20°C is to be used. At temperatures under 5°C oil of the viscosity SAE10W or 10W-30 is prescribed. Type and amount of required oil see: section 8.4, “Engine oil,” on page 126 and section 7.
Maintenance Instructions Oil filler cap Fig. 7.7-3: Oil filler cap Refill the engine with new oil here Check the oil level with the oil dip stick. Fig. 7.7-4: Oil dip stick Do not fill the oil over the max. mark. Fischer Panda recommend 2/3 oil level. 7.8 Venting the cooling water circiut After draining the coolant or if the system has sucked air in, the circiut must be de aerated. Special notes: Open the venting screws only, when the generator is not running. Els air will be sucked in .
Maintenance Instructions Open venting screw exhaust elbow Fig. 7.8-2: Venting screw exhaust elbow Wrench size: SW10mm Open venting screw pre silencer Fig. 7.8-3: Venting screw pre silencer Wrench size: SW10mm Fill the cooling water into the Radiator Fig. 7.8-4: Cooling water filler cap Sample picture • When the cooling water is filled to the max level and the level do not drop anymore, close the venting screws. • Run the generator for max 60 sec. Stop the generator. • Repeat the filling procedure.
Maintenance Instructions 7.8.1 Ventilating the fuel system Normally, the fuel system is designed to ventilate air itself i.e. as soon as the electric starter motor starts operation the fuel pump starts working and the fuel system will be de-aerated after some time automatically. It is nevertheless essential to ventilate the system as follows prior to the first operation (as all hoses are empty): Start the fuel pump The external fuel pump can be started manual by an option in the iControl2 panel.
Maintenance Instructions 7.8.2 Replacement of the fuel filter Exchanging the filter, depending upon fuel contamination, should take place after 300 operational hours at the very least. The inlet must be clamped, before exchanging the filter. Fig. 7.8.2-1: Fuel 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. 7.8.2.
Maintenance Instructions Unscrew the filter element from the mount (left hand rotation). Fig. 7.8.2.1-3: Fuel filter Screw the new filter element into the mount. Fig. 7.8.2.1-4: Fuel filter 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). 7.9 Replacement of the air filter matt Open the air filter housing by removing the six hexagon screws Fig. 7.
Maintenance Instructions Replace the Air filter matt Fig. 7.9-2: Air filter matt Close the Air filter housing. Leere Seite / Intentionally blank Seite/Page 116 Panda_5000i_PVMV-N_Book_eng.R02 - 29.11.
Tables 8. Tables 8.1 Troubleshooting GENERATOR OUTPUT VOLTAGE TOO LOW If the generator delivers less than 24V current ("undervoltage"), there can be various reasons for this: Cause Solution PGMi is overloaded. Reduce the electrical load. (Switch off load) Motor is not reaching the rated rpm. Refer to "motor faults" section. MOTOR DOES NOT TURN OVER WHEN STARTING Cause Solution Battery main switch is switched off. Check the position of the battery main switch, if necessary switch on..
Tables Cooling water in combustion chamber. 1. Turn generator "OFF" at control panel. 2. Remove the glow plug (see Kubota-manual). 3. Rotate the motor by hand carefully. 4. Check if there is water in the oil and change both oil and filter if necessary. 5. Determine cause for excess water in the combustion chamber. The excess water can be caused by a defective air vent in the cooling water system, which should be checked and cleaned, or replaced if faulty.
Tables SOOTY, BLACK EXHAUST Cause Solution Generator is overloaded. Check electrical load and switch off unnecessary load. Insufficient intake air. Check intake air filter; clean if necessary. Fuel injector nozzles faulty. Replace injector nozzles. Valve clearance incorrect. Readjust valve clearance to correct value (refer to Kubota-manual). Poor fuel quality. Use better quality diesel (recommended: 2-D Diesel). Poor combustion. Incorrect AFR (air/fuel ratio) due to motor timing adjustment.
Tables Panda 4000s Recommend starter battery size Panda 4200 FCB 4500FCB 12V 28Ah equiva- 12V 28Ah equiva- 12V 36Ah equivalent lent lent Recommend cable cross size starter battery 25mm² cable Length 4 meter max. 25mm² 25mm² Max. exhaust back pressure 9,3 kPa 93 Millibar² 9,3 kPa 93 Millibar 9,3 kPa 93 Millibar ² progressive speed by VCS ³ 0,35l/kW electrical power, the randomized values between 30% and 80% of the rated speed Fig. 8.
Tables Panda 14000 NE Panda 15000 NE Panda 18 NE Panda 24 NE Panda 30 NE Stroke volume 782 cm³ 898 cm³ 1123 cm³ 1498 cm³ 1498 cm³ Max.
Tables Panda 30 IC PMS Panda 40 LN Panda 47 LN Panda 60 MB PVM-NE Panda 75 MB PVM-NE 70mm² 70mm² Recommend cable cross size starter battery 25mm² cable Length 4 meter max. 50mm² 50mm“ Max. exhaust back pressure 10 kPa 100 Millibar 10kPa 100 Millibar 10,7 kPa 107 Millibar ² progressive speed by VCS ³ 0,35l/kW electrical power, the randomized values between 30% and 80% of the rated speed Fig. 8.
Tables Stroke volume Panda 30/4 Panda 30/4 Panda 40/4 3331 3620 ccm 3620 ccm 3769 ccm 4764 45,8 kW 58,8 kW 62,0 kW 85,0 kW Max. power (DIN 6271-NB) at 3000rpm Panda 50/4 Panda 70/4 Rated speed 1500 rpm 1500 rpm 1500 rpm 1500 rpm 1500 rpm Idle running speed ² 1500 rpm 1800 rpm 2800 rpm 1800 rpm 1800 rpm Valve clearance (engine cold) 0,25mm 0,2 mm 0,2 mm 0,2 mm Inlet 0,3 + 0,1 / Outlet 0,5 + 0,1 Cylinder head nut torque 118 68 Nm 68 Nm 68 Nm Compression ratio 20.
Tables Panda 5000i Panda 8000i Panda 10000i Panda 15000i Panda 25i Recommend cable cross size starter battery 25mm² cable Length 4 meter max. 25mm² 25mm² 25mm² 25mm² Max. exhaust back pressure 9,3 kPa 93 Millibar² 9,3 kPa 93 Millibar 9,3 kPa 93 Millibar² 10,7 kPa 107 Millibar -- ³ 0,35l/kW electrical power, the randomized values between 30% and 80% of the rated speed Fig. 8.
Tables Generatortyp Generator type Kühlwasser Cooling water Abgas Exhaust Kraftstoff Fuel Zulauf Feed Rücklauf Return Panda PVMV-N 6000i/8000i 20 40 8 8 Panda PVMV-N 8000 NE 25 40 8 8 Panda PVMV-N 9000 ND 25 40 8 8 Panda PVMV-N 12000NE 25 40 8 8 Panda PVMV-N 14000 NE 25 40 8 8 Panda PVMV-N 15000 NE / 15000i 25 40 8 8 Panda PVMV-N 18 NE 25 40 8 8 Panda PVMV-N 24 NE 25 40 8 8 Panda PVMV-N 30 NE 25 40 8 8 Panda PVMV-N 35 YA 30 50 8 8 Panda PVMV-N 22/4 30
Tables Generatortyp Generator type Kühlwasser Cooling water Abgas Exhaust Kraftstoff Fuel Zulauf Feed Rücklauf Return Panda PVK-U 5000 LPE 20 40 8 8 Panda PVK-U 6000 ND 25 40 8 8 Panda PVK-U 6000i/8000i 20 40 8 8 Panda PVK-U 8000 NE 25 40 8 8 Panda PVK-U 9000 ND 25 40 8 8 Panda PVK-U 12000 NE 25 40 8 8 Panda PVK-U 14000 NE 25 40 8 8 Panda PVK-U 15000 NE / 15000i 25 40 8 8 Panda PVK-U 18 NE 25 40 8 8 Panda PVK-U 24 NE 25 40 8 8 Panda PVK-U 30 NE 25 40
Tables ber = more highly liquidly) e.g. to 0W, 10W, 15W, 20, 30, 40. The first number shows the liquid of the oil with cold weather, the second number refers to the fluidity with heat. Complete yearly oils have usually SAE classes of SAE 10W-40, SAE 15W-40 etc. 8.4.1.2 Quality of oil: The quality of an engine oil is specified by the API standard („American Petroleum Institutes“). The API designation is to be found on each engine oil bundle. The first letter is always a C.
Tables tion must be regularly checked in the interests of safety. Fischer Panda recommend to use the product: GLYSANTIN PROTECT PLUS/G 48 Engine coolant automotive industry Product description Product name GLYSANTIN ® PROTECT PLUS / G48 Chemical nature Monoethylenglycol with inhibitors Physical form Liquid Chemical and physical properties Reserve alkalinity of 10ml ASTM D 1121 13 – 15 ml HCl 01 mol/l Density, 20°C DIN 51 757 procedure 4 1,121 – 1,123 g/cm3 Water content DIN 51 777 part 1 max.
Inverter Panda PMGi 5000 9. Fischer Panda Datenblatt / Datasheet Inverter Panda PMGi 5000 Document Actual: R03 Replace: R02 PGMi 5000_eng.fm Art Nr.. 21.07.03.034P Bez.
Inverter Panda PMGi 5000 Fischer Panda Datenblatt / Datasheet 9.1 Safety instruction The generator may not be taken into use with the cover removed. The rotating parts (belt-pulley, belts, etc) must be covered and protected so that there is no danger to life and body! If a sound insulation cover must be produced at the place of installation, then well-placed signs must show that the generator can only be switched on with a closed capsule.
Inverter Panda PMGi 5000 Fischer Panda Datenblatt / Datasheet Fig. 9.2-2: Type plate 230V 50 Hz version Fig. 9.2-3: Type plate 120V 60 Hz version PGMi 5000_eng.
Inverter Panda PMGi 5000 Fischer Panda Datenblatt / Datasheet 9.3 Front side/connection side Fig. 9.3-1: Connection side 230V Version 3 1 4 2 Fig. 9.3-2: To connect the PMGi 5000 use the prepared cable with t he 4pin plug and connect to socket 3 (PMGi in-450V/400Hz) Connect your termination box with the socket 1. Use a 3pin plug (230V/50Hz AC - PMGi out) Fig. 9.3-3: Connection side 120V Version 3 1 Do not cover the Air out grille (2) 1. Socket for Load 2. Air out grille 3.
Inverter Panda PMGi 5000 Fischer Panda Datenblatt / Datasheet 9.3.1 Socket pins of the PMGi 5000 Socket 1 - 230V / 50Hz AC - PMGi out Fig. 9.3-1: Socket 1 1. Ground (cabel green/yellow) 2. Live (cabel brown) 3 3. Neutral (cabel blue) 2 1 Attention! Connecting one of the three Phase with the earth pin will destroy the PGMi Socket 3 - PMGi in Fig. 9.3-2: Socket 3 1. Ground 2-4. Phase 1-3 PGMi 5000_eng.
Inverter Panda PMGi 5000 Fischer Panda Datenblatt / Datasheet 9.4 Back side - Top side Fig. 9.4-1: Back side 1 Inside of the PMGi a fan is mounted. The air holes and air grille should not be covered. 01. Air holes Inside of the PMGi are up to 550VAC. The cover of the PMGi should only be opened by special trained persons !!! Danger for Live“ Attention! Make sure that the connection between the generater and the PMGi is secured. Never connect or disconnect the PMGi while the generator is running.
Inverter Panda PMGi 5000 Fischer Panda Datenblatt / Datasheet 9.5 Settings for the use of iGenerators with power inverter For the use of power inverter with the PMGi, the settings of the power inverter must be modified. ATTENTION: Wrong settings can destroy the PMGi Wrong settings can damage or destroy the PMGi. The settings for the Victron power inverter must be adapted for the power inverters of other brands. 9.5.1 Settings in the Victron VE Configure II Software - General Fig. 9.5.
Inverter Panda PMGi 5000 Fischer Panda Datenblatt / Datasheet 9.5.2 Settings in the Victron VE Configure II Software - Inverter Fig. 9.5.2-1: Settings in the Victron VE configure II Software 9.5.2.1 Assist current boost factor To reduce the action of the power inverter on the iGenerator, the Assist current boost factor must be reduced from 2.0 to1.3. Wrong settings will cause bad rpm control of the generator. Seite/Page 136 - Kapitel/Chapter 9: Inverter Panda PMGi 5000 PGMi 5000_eng.
Inverter Panda PMGi 5000 Fischer Panda Datenblatt / Datasheet 9.6 Operation manual 9.6.1 Primary remarks / Winter operation The PGMi can operate in the range of -20°C to +40°C. 9.6.2 Load at the PMGi Do not overload the PMGi. It will go on error. 9.6.
Inverter Panda PMGi 5000 Fischer Panda Datenblatt / Datasheet 9.9 Installation of the PMGi The PMGi must be mounted vertical, with the electrical connection down. So you can read the writing on the PMGi. The surface where the PMGi is mounted should be smoothed and support the heat transfer. The Air holes and Air grille must be not covered and enough cooling air must be pleasant at any time for the PMGi. To mount the PMGi use the four fixing holes diameter 6,5mm.
Inverter Panda PMGi 5000 http://www.fischerpanda.de/images/gensets/M_AC_50_INV_PMS_8000i/operatormanual/PMGi/ Modification_PMGi_isolation_control.eng.pdf 9.10 Technical Data 9.10.1 General Data PMGi is part of the Panda i-series generator. It´s not allowed to be used with other generators or aplications. Storage temperature PMGi -20°C to +55°C Working temperature PMGi Minimum: -20°C Maximum: +40°C Maximale internel temperature of the PMGi: +60°C 9.10.
Inverter Panda PMGi 5000 9.10.3 PMGi out Fig. 9.10.
Inverter Panda PMGi 5000 Fig. 9.10.
Inverter Panda PMGi 5000 Fig. 9.10.
Inverter Panda PMGi 5000 Fig. 9.10.
Inverter Panda PMGi 5000 9.10.4 Overload - switch point Output type Max. current Comments 230VAC 30,0A +/- 0.5A When protection takes place the engine must be switched off and all apliances detached 9.10.5 Short circiut To operate the short circiut protection a fuse must be put in series with the live wire. The minimum requested feature for this fuse are the following. Rated current 1.2 1.5 2.75 4.0 10.
Panda iControl2 Operating Manual Open-loop and closed-loop control system for Fischer Panda generators Fischer Panda GmbH Panda iControl2_eng.R07 29.11.
Current revision status Document Current: Panda iControl2_eng.R07_29.11.13 Replaces: Panda iControl2_eng.R06 Revision Page Kontrolltätigkeiten vor dem Start eingefügt Hardware Generator Revision Modification Strike Plate Date Upgrade Created by Fischer Panda GmbH - Head of Technical Documentation Otto-Hahn-Str. 32-34 33104 Paderborn - Germany Phone: +49 (0) 5254-9202-0 E-mail: info@fischerpanda.de web: www.fischerpanda.
Safety instructions for the Panda iControl2 10. Safety instructions for the Panda iControl2 10.1 Personnel The settings described here can be performed by the operator unless highlighted differently. The installation should be implemented by specially trained technical personnel or by authorised workshops (Fischer Panda Service Points), only. 10.2 Safety instructions Ensure compliance with the safety instructions in the Fischer Panda genset manual.
Safety instructions for the Panda iControl2 Disconnect battery before working on the generator WARNING: The battery must always be disconnected (first the negative terminal, then the positive terminal) if work on the generator or electrical system is to be carried out, so that the generator cannot be unintentionally started. This applies in particular to systems with an automatic startup function. The automatic start-up function shall be deactivated before starting work.
General operation 11. General operation 11.1 The Panda iControl2 panel The "Panda iControl2 panel" control panel is the control and display unit for the Panda iControl2 control system and represents the interface between the user and the Panda iControl2 controller. The integrated display serves to present the most important data of the system as well as warnings and error messages. The control panel is equipped with four buttons for operating the Panda iControl2 controller: Fig. 11.
General operation 11.2 Starting preparation / Checks (daily) 11.2.1 Marine version 1. Oil level control (ideal level: 2/3 MAX). The level should be about 2/3 of the maximum level of a cold engine. Further, if installed, the oil level of the oil-cooled bearing must be controlled before each start - see sediment bowl at generator front cover!. 2. State of cooling water. The external expansion tank should be filled up to 1/3 of the maximum in a cold state.
General operation 11.3 Operation 11.3.1 Switching the controller on and off The Panda iControl2 controller is switched on and off with the On/Off button on the Panda iControl2 panel. Press and hold the On/Off button until the start screen with the panda bear appears on the display. The controller is switched off by actuating the On/Off button once more. On the start screen, the hardware version, the generator type, and the software version are shown at the bottom left. Fig. 11.3.1-1: .
General operation • Oil pressure status • Cylinder head temperature • Temperature of exhaust manifold • Winding temperature • Speed/RPM • Utilisation in percent Fig. 11.3.2-1: Default display screen The Display shows the iControl board input voltage. Note: At generator systems with 12 V starter system these is equal with the starter battery voltage. At generator system with 24 V starter system the starter battery voltage can not be displayed. 11.3.
General operation Fig. 11.3.3.1-1: Service information screen The total operating hours of the generator are given on the default display screen and on the service information screen. By actuating the cursor-up and cursor-down button in stand-by mode, the service screen can be accessed. This screen is marked with a screwdriver/spanner symbol. Here, the time until the next service is given. By actuating the cursor-up or cursor-down button, you can return to the default screen.
General operation The controller will only perform one starting attempt. If the generator could not be started, the text output "STARTING FAILS" informs you of the failure of the generator starting attempt. Note: Acknowledging the message with the cursor-up, cursor-down, or the Start/Stop button on the Panda iControl2 panel will return the system to stand-by mode.
General operation Display screen for single phase generators With the single phase i-series generators, there is an additional screen in operation mode for the inverter data. This screen provides the current inverter output voltage and the inverter temperature. You can access the inverter screen by actuating the cursor-up button while in operation mode. Fig. 11.3.3.
General operation This screen provides the latest inverter output voltage of the single phases with the matching conductor current and the circuit board temperature. The inverter will be switched off at a circuit board temperature of 75 °C. You can access the inverter screen by actuating the cursor-up button while in operation mode. Fig. 11.3.3.
General operation 11.3.3.5 Stop mode By activating the Start/Stop button in operation mode, i.e., while the generator is running, you will stop the generator. After stopping the generator, the system will return to stand-by mode. The display status field reads "STOPPING". If the icontrol system detect a high cylinder head temperature (for example after a long time running with high load) the icontrol start a stopping delay timer. The Display shows „Cooldown“ and a countdown.
General operation The autostart function will remain active even after the controller is switched off and on again with the On/Off button. To deactivate the autostart function, the flag in the EEPROM must be reset with "Disable". Siehe “Activating/deactivating the autostart function ("Autostart")” auf Seite 161. .Warning!: Automatic start-up If the generator is manually started up and stopped while in automatic start-up mode, it will switch to stand-by mode for safety reasons.
General operation 11.4 Other operating functions 11.4.1 Set-up menu In the set-up menu, a series of parameters can be modified directly using the control panel. To access the set-up menu, you have to actuate the cursor-down button immediately after switching on the controller with the On/Off button and while the start screen with panda bear is still being displayed. This will open a menu with the following sub-items: Fig. 11.4.
General operation 11.4.2 Setting the brightness of the backlight ("backlight" and "dimtime") The brightness of the display backlight of the Panda iControl2 panel can be varied in ten increments (0-9). Also, the display can be dimmed with a timer if no button is actuated on the control panel for a parameter is able period. To adjust the default brightness and the dimmed brightness, the set-up menu offers the items "backlight 1" (default brightness) and "backlight 2" (dimmed brightness).
General operation 11.4.3 The configuration menu ("config") Settings in this area must only be entered by Fischer Panda associates and Fischer Panda service points. STOP! The "config" sub-menu is a password protected area in which the generator type can be selected, and generator parameters in the EEPROM can be modified. 11.4.4 The network ID Settings in this area must only be entered by Fischer Panda associates and Fischer Panda service points.
General operation To activate the autostart function, select the item "Autostart" in the set-up menu using the cursor buttons and confirm the selection with the Start/Stop button. Fig. 11.4.6-1: Set-up menu In the "Autostart" sub-menu, you can select between the options "Enable" and "Disable" using the cursor buttons: Fig. 11.4.6-2: "Autostart" sub-menu To activate the autostart function, select "Enable" and again confirm your selection with the Start/Stop button.
General operation Then, the controller is shut down. After switching the controller back on, the display status field reading "AUTOSTART" indicates that the autostart function is active, or, if it reads "STANDBY", this means that the autostart function was deactivated: The autostart function will remain active even after the controller is switched off and on again with the On/Off button. To deactivate the autostart function, the flag in the EEPROM must be reset with "Disable" as described above. Fig.
General operation Resetting the time until the next service Fig. 11.4.7-1: Resetting the time until the next service By actuating the Start/Stop button again, you can reset the service interval to the original interval. The service interval for each generator type is stored in the software. The controller is switched off after resetting the service interval. After restart, the new value will be displayed in the service screen. 11.4.
Installation 12. Installation All connecting wires and instructions for installation are designed and adequate for „standard“ installation situations. WARNING: Properly dimension your system. As Fischer Panda does not know the specific installation and operating situation (e.g. special vehicle shapes, high travel speeds, and special application conditions, etc. ), this installation specification can only serve as a guideline and example.
Installation DANGER TO LIFE! - Improper operation can result in health impairment and death. WARNING: Electric voltage Electric voltages of more than 48 V are potentially lethal in any situation. The rules of the respective regional authority must be adhered to during installation. For safety reasons, only an electrician may carry out the installation of the electrical connections of the generator. Generator and cooling water may be hot during and after operation.
Installation 12.2.1 Panda iControl2 panel with installation housing Fig. 12.2.1-1: Panda iControl2 panel with panel connecting cable and closed housing 12.2.2 Terminal assignments on the Panda iControl2 panel The Panda iControl2 panel is connected via a 7-pin Phoenix jack. Fig. 12.2.
Installation 12.3 Dimensions Fig. 12.3-1: Housing of the Panda iControl2 panel Seite/Page 168 - Kaptitel/Chapter 12: Installation 29.11.
Installation Due to the terminals being exposed, the protection class IP 04 applies to the iControl2 panel. Please note! If properly installed with a seal (e.g. Sikaflex), up to IP66 can be achieved. 12.4 Wiring of the Panda iControl2 controller Fig. 12.4-1: Wiring of the Panda iControl2 controller The Panda iControl2 controller is connected to the wire harness with the 18-pin jack. The centre 6-pin jack is designed for the Fischer Panda standard bus.
Installation 12.4.1 Terminal assignments on the Panda iControl2 controller 12.4.1.1 Terminal assignment of 18-pin connector Fig. 12.4.1.
Installation 12.5 Start-up After completing the installation, the system must be started up. For this purpose, the start-up log for the generator is processed and filled in by the specialist installing the equipment. The completed log shall be handed over to the operating company. The operating company shall be instructed in the operation, maintenance, and hazards of the generator.
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Maintenance 13. Maintenance 13.1 Maintenance of the iControl2 controller The iControl2 controller is maintenance-free. The fuses of the controller are self-healing. 13.1.1 Cleaning the iControl2 controller The housing shall be cleaned within the scope of the overall generator cleaning. The housing can be wiped off with a soft, lightly dampened cloth. In doing so, it must be ensured that no moisture enters the jacks and the housing. 13.
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Warnings and error messages 14. Warnings and error messages To enable the safe operation of the generator, the Panda iControl2 controller is programmed with a series of warnings and error messages that influence the generator operation. 14.1 Warnings Warnings are issued when the variable being monitored, e.g. temperature, reaches a defined warning threshold.
Warnings and error messages 14.1.2 Warning messages All warning messages defined for the Panda iControl 2 and the corresponding display output are compiled in the subsequent table. Fig. 14.1.
Warnings and error messages 14.2.1 Error messages All error messages defined for the Panda iControl 2 and the corresponding display texts are compiled in the subsequent table. Fig. 14.2.1-1: Error messages Error message on the display Meaning of error message FAULT: CYL.
Warnings and error messages Generator type Warning/fault Warning threshold Fault threshold P8-P50 marine Cylinder head temperature Delay 90 °C 5s 95 °C 5s Winding temperature Delay 130 °C 5s 135 °C 5s Exhaust manifold temperature Delay 70 °C 1s 75 °C 1s Cylinder head temperature Delay 95 °C 5s 100 °C 5s Winding temperature Delay 160 °C 5s 165 °C 5s Exhaust manifold temperature Delay 100 °C 1s 105 °C 1s Cylinder head temperature Delay 90 °C 5s 95 °C 5s Winding temperature Delay 13
Annex 15. Annex 15.1 Technical data 15.1.1 Technical data for iControl2 control unit Fig. 15.1.1-1: Technical data for iControl 2 control unit iControl 2 control unit Supply voltage 12V-13.5V (12V automotive) Current consumption, nominal 175 mA Current consumption, stand-by 2.5 mA Operating temperature -20°C to +85°C Storage temperature -30°C*to +85°C Current sensor Hall element max. 20A max. tightening torque for connecting bolts 1.2 Nm 15.1.
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