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Marine Generator Panda PMS 4500 FCB Icemaster

1. 570 E A f mq i Se 3 N i B gt li Ley AA i L F D i C E L a IUD 59 wm PD d E S i 7 76 3 _ 55 HI 365 744 mi di SH det ch ICH a 5 mc De N N SS S 8 N Shey Sy Ss g 9 S de NE Q ES 15 7 05 PMS 4500 FCB manual V02 Chapter F Tables Page XI Ze f uo t ischer Bando Cooling water flow Panda 4500 FCB F 9 Cooling water flow Panda 4500 FCB Freshwater flow EN Raw water flow Page XII PMS 4500 FCB manual V02 Chapter F Tables 15 7 05 A A A A A 5 Safety steps to follow if someone is the victim of electrical shock Do not try to pull or grab the individual Send for help as soon as possible If possible turn off the electrical p
2. i 13 B 1 General maintenance instructions ii 13 B 1 1 i e cHe lei t aeMece P 13 B 1 2 Hose elements and rubber formed component in the sound cover 13 B 2 Oil circuit maintenance iii 13 B 5 Execution of an Oll CHANGE ici aiar 14 B 3 1 De aerating the fuel system iii 16 B 3 2 Exchange of the fuel filter iii 16 BA Checking the water separator in the fuel supply esee 17 B 4 1 Exchange the air filter Mat iii 17 B 5 De aerating of the coolant circuit freshwater iii 18 B 5 1 EAI IFC TING COCAINE Mec m 20 B 5 2 Exchange of the toothed belt for the internal cooling water pump sannsnnsnnnsnnsnnnnnnnnenennnee 20 5 6 HIG Taw water CIRC T PR Ee 21 B 6 1 Cleanrawwalerilef coil 21 B 7 Causes with frequent impeller waste iii 22 B 7 1 Exchange of the wmmpeller ii 22 B 8 Coolant connection block at generator housing in 24 B 9 Conservation at longer operation interruption i 25 B 9 1 Measures on preparation of the winter storage 25 B 9 2 Ile we aiu S n MT s 26 Generator UU EEN 27 C 1 Tools and measuring instruments
3. Technical Support by Internet info fischerpanda com iV Safety Instructions The electrical Installations may only be carried out be trained and tested personnel The generator may not be taken into use with the cover removed The rotating parts belt pulley belts etc must be so covered and protected do that there is no danger to life and body If a sound insulation covering must be produced at the place of installation then well placed signs must show that the generator can only be switched on with a closed capsule All servicing maintenance or repair work may only 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 Protective Conductor The generator is earthed as standard The centre and earth are connected by means of a bridge in the generator terminal box This is a basic safety function which offers basic safety as long as no other component has been installed It is above all conceived for supply and an eventual test run This earth PEN is only effective if all parts of the electrical system is earthed and has a common potential The bridges can be removed if this is required for technical reasons and another protection system has been i
4. iii 27 C 2 Overloading the Generator E 27 C 2 1 Monitoring the Generator Voltage i 28 C 2 2 Automatic Voltage Monitoring and Auto Shut Down 28 PMS 4500 FCB manual V02 Table of contents Page 1 Page 2 Tischer Ponda C 3 Low Generator Output Voltage iii 30 C 3 1 Discharge Me CADACIONS iii 30 C 3 2 Checking the eet 31 C 3 3 Checking the generator voltage ii 32 C 3 4 Measuring the coil resistance NEE 32 C 3 5 Checking the coil s to short CIrGult ul sale ddendendsweasuessnededwes na aeu vo Unica 33 C 3 6 Measuring the inductive resistance nennen enne nennen nennen nnns 33 C 4 Generator provides no Voltage iii 34 C 4 1 Rotor Magnetism Loss and Re magnetizing nennen 34 C3 Star ng Problems E 34 C 5 1 Starting with a weak Battery esse eeeeeeeseeeeeeeseeeseeeseueeseeeseeeseeeeseeesaees 34 C 5 2 FUSI Solenoid EE ille oi 35 C 5 3 Troubleshooting Fable 36 installation INSITUGHONS EEN 37 HN WW dieu EE 37 D 1 1 Placement and Basemount ii 37 D 1 2 Notice for optimal sound insulatioN emen ener nnns 37 D 2 Generator Connections Scheme 1 rr 38 DA Cooling System Installation Raw water_ ii 39 D 3 1 General References tege eege GE 39 D 3 2 Installation of the thru vessel fitting in
5. 15 7 05 PMS_4500_FCB_manual V02 Tischer Ponda Installation manual Installation Maintenance and Troubleshooting Ht Iis i E 1 al 311 it HIM LI Mitten Bite IH d eat fy do fi Hi n mnt a fort Marine Generator Panda PMS 4500 FCB Super silent technology 230 V 50 Hz 3 8 kW Icemaster Fischer Panda Current revision status Revision Page Foreste eng NN Co I ii since 1977 since 1978 since 1988 since 1988 since 1988 Icemaster GmbH Fischer Marine Conclusion Fischer 100 water cooled Panda Vehicle Generators Icemaster GmbH Panda generators Generators Fischer Panda FISCHER GENERATORS have been manufactured since 1978 and are a well known brand for first class diesel gene rators with especially effective sound insulation Fischer has been one of the leading manufacturers in respect of quality and know how during this period FISCHER as the worldwide manufacturer of modern marine diesel generators developed the Sailor Silent series for example and produced a GFK sound insulated capsule as early as 1979 and the basis for new generator technology The companies Fischer and Icemaster amalgamated under the direction of Icemaster in 1988 in order to concentrate on the development of new products Production was moved to Paderborn The amalgamation of the two qualified companies led to the development of a complete new programme within a short space of time The ge
6. 2 Motor disturbances 2 Refer to section Motor runs irregular GENERATOR NOT ABLE TO START ELECTRIC MOTOR e e If the generator is unable supply enough power to start Check the motor s current draw required for starting an electric motor 120V 60HZ it is usually because the switch to 380V if possible This could be remedied by motor draws too much current during starting process providing stronger capacitors or installing an optional Easy Start Booster Set See App G Enquire at your nearest Panda dealer or directly at the manufacturer 15 7 05 PMS 4500 FCB manual V02 Chapter F Tables Pagel Fischer Ponda C DIESEL MOTOR FAILS TO START CI MM Starter battery switched OFF Check position of battery switch and switch ON installed Starter battery voltage insufficient battery too weak Inspect battery terminals and cables for a good electri cal connection Inspect against corrosion tattered wires etc Starting current disrupted During the normal starting process the battery voltage drops to 11V with a fully charged battery If the voltage does not drop during starting the electrical connection is faulty If the battery voltage drops lower than 11V then the battery has been discharged STARTER IS TURNING MOTOR BUT FAILS TO START I MN Fuel inlet solenoid valve not opening Check wire connections and circuitry to solenoid valve ref DC wiring diagram Relay K2 Fuse Fuel pump
7. ES ce e Re c waterline min 300 mm 1 Generator 4 Silencer 2 Silencer Water lock 5 Sea cock 3 Exhast Water separator 6 Hull outlet If the thru hull exhaust outlet has to be mounted far from the generator an exhaust water separa tor 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 NW40mm to NW50mm in order to reduce the back pressure The exhaust may have a length of over 10m 32 ft if the exhaust hose diameter is increased to 50mm An additional outlet exhaust muffler close to the hull outlet will help further to reduce noise emissions An unfavorable installation water lock not deeply enough under the hights level of the generator distance water lock to exhaust water separator too largely Page 50 PMS 4500 FCB manual V02 Chapter D Installation Instructions 15 7 05 15 7 05 Tischer Ponda D 6 Fuel System Installation D 6 1 General References Inside the generator capsule itself there is the fuel filter installed Exception Panda 4200 and 4500 Additional fuel filters with water seperator 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 tank
8. 3 different adjustment possibilities upper switching point lower switching point and time lag of the generator In factory setting the voltage controller is in the following attitude a upper switching point disconnection 13 6V b lower switching point insertion 11 52V 15 7 05 PMS 4500 FCB_manual V02 Chapter D Installation Instructions Page 63 A upper switching point disconnection B lower switching point insertion C td time lag of the generators after achievement of the upper switching point 1 measuring voltage plus 2 measuring voltage minus 3 Charging voltage 4 Battetry lower voltage 5 not allocated 6 not allocated 7 output positive 8 output negative D 10 3 Time lag of the switching points For the upper as well as for the lower switching point a time delay is adjusted That is the voltage must have overstep or fall short of the switching point on the time lag Following values are adjusted a upper switching point 13 6V lag min 20 seconds b lower switching point 11 52V lag 40 seconds Additional notes to the recommendation External electrical voltage controller At Diesel engines count always on the fact that a diesel engine revs up due to special circum stances uncontrolled This is the case if by damage to the system engine oil arrives into the suck ing in way This is possible at many engines by the crank case exhaust A crank damage could cause for example that
9. Loose connections with transitional resistance can mean that the contact surfaces will become heated externally This can lead to faster deterioration of the capacitors PMS 4500 FCB manual V02 Chapter C Generator Failure Page 31 J Fischer Ponda Gut _ C 3 3 Checking the generator voltage In order to test whether the fixed winding produces enough voltage proceed in such a way Guarantee that the connection to the electrical system is interrupted Remove all conductions in the power terminal box of the generator Starter battery must be connected with the generator Start the generator start Measure with a voltmeter the votage between the phase s and N If the measured values are under the substantially values in Table F 3 Technical Data Generator on Page VI a coil damage is to be accepted During the measurement in the 60Hz version both partial coils must be interconnected i e a con nection must be provided between line 1 and line 3 see wiring diagram notes the voltage results from the remainder magnetism of the rotor which induced a voltage in the coil C 3 4 Measuring the coil resistance For this a measuring instrument must be used that is suitable for low impedance values Adjust the measuring instrument to resistance test If hold the poles of the measuring instru ment hold together 0 00 ohms should be indicated If the poles are isolated the display should indicate an overflow Pl
10. VCS Cause Fuse on the printed circuit board of the constant overload of the generator VCS control is melted PMS 4500 FCB manual V02 Chapter C Generator Failure Page 29 Fischer Panda iO Generator Failure _ Steps to check the voltage control by a disturbance Check the fuse on the VCS printed circuit board Check if the sense voltage is wired to the VCS printed circuit board Check if the VCS supply voltage is wired to the VCS Check if the VCS outlet signal for the actuator is wired Change the VCS printed circiut board if the points above carries no clearance C 3 Low Generator Output Voltage If the produced alternating voltage is too low switch the consumers off in order to relieve the generator Mostly the problem already solved If the output voltage is still too low even if all con sumers are switched off the generator runs without load you can assume one or more conden sers are defective C 3 1 Discharge the capacitors ATTENTION Never work at the electrical cabinet when the generator is running Do not contact the capacitor Before working on the system read the section Safety Instruc tions on Page v 1 Switch off generator 2 Disconnect starter battery 3 Open AC Control box The capacitors are discharged by short circuit the two contacts In addition use the cone end of an isolated screwdriver Page 30 PMS 4500 FCB manual V02 Chapter C Generator Failure
11. and compensates the idle current This compensation of the inductive consumers causes that the efficiency of the generator is increased By the automatic compensa tion can more engines or a larger electrical load with an inductive character be operated In other words the usable power of the generator is increased A 2 3 Compensation of 3 phases engines See Bimetallic Corrosion Electrolysis in the appendix A 3 Operation of the generator with additional units A 3 1 General references The Panda generator is arranged that the operation of additional aggregates which are flanged on directly to the front cover of the generator is possible If such aggregates are intended this if possible should be considered with the order of the generator With the mounting of additional hydraulic pumps the employment of an electrical separation clutch is always recommended The appropriate components are available for the different generator types It is caused that the addi tional hydraulic pump is in operation even if it is actually used Depending upon power of the additionally appropriate aggregates the power is reduced which can put the combustion engine to the generator at the disposal Panda generator with electrically adjusta ble clutch Page8 PMS 4500 FCB manual V02 Chapter A Mode of Operation of the Generator 15 7 05 Fischer Ponda 15 7 05 A 4 Operation of the generator with HTG generator A 4 1 General refer
12. by overpressure too much oil is pressed into the crank case so that this oil arrives into the sucking in way The engine cannot switch off itself any longer Usually then a damage to the engine is the result It would be fatal even if this damage to the engine were the cause of the destruction of all switched on electrical consumers because uncontrolled revving up of the Diesel engine leads also to an extreme increase of the voltage Only by an external voltage controller with separation contactor can be prevented such damage Page 64 PMS 4500 FCB manual V02 Chapter D Installation Instructions 15 7 05 Fischer Ponda F Tables F 1 Troubleshooting GENERATOR OUTPUT VOLTAGE TOO LOW For 60Hz versions less than 100V re mm Generator is overloaded Reduce the electrical load Switch off consumers Motor is not reaching the rated rpm Refer to motor faults section Defective capacitor s Check capacitors and replace if necessary GENERATOR VOLTAGE TOO HIGH MORE THAN 135V 60Hz If the generator is providing excessively high voltage the following potential causes should be investigated BEEN Tn Over energizing due to wrong capacitors Check capacitors type and replace if necessary Measurering voltage on the VCS circuit board is mis Check VCS System check cable connections sing GENERATOR VOLTAGE FLUCTUATES come MN 1 Disturbances on the electrical system user side 1 Check if electrical load is fluctuating
13. ee CS CI C 9 8 etes Ls 9 fo feet 7 H CNS ONE IT ni fuaitebese monte 5 s 9 ORSO ak kal I DRIN n p m o m Jo a m n m o p eessen m m p n p p p p setrmoormomingseme m p p p p p p p screws generatorengine m m mp p p p p mwWtmpofexbrtemerbad m m mp p p p P outlet temp of coolant underioad m TT egent SSS m p p p p osooso m b p p p p eck generatorcoolantbiock m bp p p p p egener m m n p p p p pmm s p p p p p p OShmdonws s m m p p p p rotage withoutioad SSS e m p h a based wm m m p p p eeng m m mp p p p p engine speed pm amp T_T p p meme e emission s m p p p p p p ede Page VII PMS 4500 FCB manual V02 Chapter F Tables 15 7 05 Fischer Ponda F 6 Engine oil Engine oil classification Operating range The operating range of an engine oil is determined by SAE class SAE is for the union of American engineers Society of Automotives Engineers The SAE class of an engine oil only informs over the viscosity of the oil lar ger number more viscous lower number more highly liquidly e g to OW 10W 15W 20 30 40 The first number shows the liquid of cold weather the second number refers to the fluidity with heat Complete yearly oils have usually SAE 10W 40 SAE 15W 40 etc Quality of
14. ends NOTE The ventilation valve must be installed directly behind the water pump If the water pump stops the valve spring provides for it air can penetrate and thus an Syphon effect is avoided The ventilation valve must be control led regularly For this it is to be opened to clean and grease 15 7 05 PMS 4500 FCB manual V02 Chapter D Installation Instructions Page 41 ee 3 Fischer Ponda D 3 6 Installation under the waterline min 600mm waterline Raw water impeller pump Freshwater pump Water cooled exhaust elbow Cooling water connection block Heat exchanger Raw water filter eee ee Page 42 PMS 4500 FCB manual vu Chapter D Installation Instructions Water cock Raw water inlet Expansion tank Vent valve Oil cooler Reducer 15 7 05 scher Ponda D 3 7 Installation over the waterline Raw water impeller pump Water cock Freshwater pump Raw water inlet Water cooled exhaust elbow Expansion tank Cooling water connection block Vent valve Heat exchanger Oil cooler Raw water filter Reducer 15 7 05 PMS 4500 FCB manual V02 Chapter D Installation Instructions Page 43 Meg e Fischer Ponda C installafionInstruetions D 4 1 Position of the external Cooling Water Expansion Tank The coolant expansion tank for the internal cooling system is to be mounted externaly The addi tional advantage of controlling this tank externaly is achieved wi
15. humidity remain in the sound cover inside casing by leakages in the raw water circuit 13 The generator housing and the housing of the engine should be sprayed with a corrosion pro tection oil before the winter storage This procedure is recommended also in the season This procedure can avoid that arising and humidity marks on the surface of the aluminum construc tion units be noticed too late 14 Disconnect the starter battery positive and negative pole PMS 4500 FCB manual V02 Chapter B Maintenance Instructions Page 25 Fischer Ponda Gee B 9 1 Measures on preparation of the winter storage 15 Lubricate the spindle for the number of revolutions adjustment device with a special lubricant Antiseize grease 16 Check cooling water connection block at the generator housing on traces of corrosion and if necessary renew only such traces are to be considered which refer to clear blossoming of the material If the surface is only grey coated this is only an indication for the fact that alumi num came into contact with condensed moisture 17 Use of a air dehumidifier The best way to protect a yacht in the winter storage against damage by humidity is to places a air dehumidifier inside the ship and locks all hatches The devices have a hygrometer which switches the device off if the humidity is under the adjusted value There is no better method in order to protect pads cable electronics wood engines etc optimally agai
16. muffler mounted next to the thru hull fitting can be installed Additionally there is component at ICEMASTER which exercise both functions of a exhaust goose neck and the water separation With this exhaust water separator the cooling water is derived over a separate pipe Thereby the exhaust noises at the exterior of the yacht are strongly decreased Particularly the water plash allocate The water flow on the exhaust water separator unit has an inner diameter ID of 30mm If the path from the water sepa rator to the sea water outlet is very short the hose can be further reduced to 1 25mm ID Raw water outlet o 30mm Hose connector 30mm Reducer 30 20mm if required Hose Hose connector Sea cock Hull outlet 1 2 3 4 di 6 f 8 Hose clips PMS 4500 FCB manual V02 Chapter D Installation Instructions Page 49 Fischer Ponda installation Instructions _ D 5 3 Installation exhaust water separator If the exhaust water separator was sufficiently highly installed a goose neck is no longer neces sary 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 water line min 100 mm
17. oil The quality of an engine oil is specified by the API standard American Petroleum Institutes The API designa tion is to be found on each engine oil bundle The first letter is always a C API C for diesel engines The second letter is for the quality of the oil The more highly the letter in the alphabet the better the quality Examples for diesel engine oil API CG Engine oil for highest demands turbo tested Engine oil types above 25 C SAE30 or SAE10W 30 SAE10W 40 0 C to 25 C SAE20 or SAE10W 30 SAE10W 40 below 0 C SAE10W or SAE10W 30 SAE10W 40 15 7 05 PMS 4500 FCB manual V02 Chapter F Tables Page IX J Fischer Ponda Coden F 7 Coolant Use a mixture of water and antifreeze The antifreeze needs to be suitable for aluminium The antifreeze concen tration must be regularly checked in the interests of safety ICEMASTER 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 HCI 01 mol l Density 20 C DIN 51 757 procedure 4 1 121 1 123 g cm Water content DIN 51 777 part 1 pH value undiluted e 71 73 Page X PMS 4500 FCB manual V02 Chapter F Tables 15 7 05 Tischer Ponda F 8 Capsule Measurements
18. on board A power source selector switch must be installed between the generator or if applicable AC Control box and the ship s electrical supply system This switch must used to ensure that all AC consumers can be switched off at once This switch should also be installed to keep the generator and shore grid power systems separate A 3 way cam type 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 Generator Il Shore power connection III Inverter Page 58 PMS 4500 FCB manual vu Chapter D Installation Instructions 15 7 05 15 7 05 Tischer Ponda 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 If the system has both single and 3 phase AC it is CRITICAL that the two systems remain SEPARATE Electrical fuses It is absolutely essential that the electrical system installation is inspected by a qualified electrical t
19. power relay By this constellation it is guaranteed that the generator switches off in each case when an error is present This measure is if possibly a circuit at the remote control panel failed Thermo switch at cylinder head 15 7 05 PMS 4500 FCB manual V02 Chapter A Mode of Operation of the Generator Page 5 Thermo switch exhaust elbow If the impeller pump should fail the raw water stream fed here tears off and the exhaust elbow heats up immediately extremely fast since the cooling water is missing The thermo switch supervises thus a functioning raw water cycle Thermo switch in the generator coil 1 Generator coil 2 Thermo switch 3 Housing For the protection of the generator coil there are two thermo switches inside the coil which are for inserted parallel and safety s sake independently from each other Fig A 1 Thermo switch coil Oil pressure switch The combustion engine possesses an oil pressure control switch which switches the engine off if the oil pressure drops under a certain value Page6 PMS 4500 FCB manual V02 Chapter A Mode of Operation of the Generator 15 7 05 eee Fischer Donde 15 7 05 A 1 1 Regulation of the generator voltage by the VCS The output voltage of the generator is permanently measured by the VCS approx 20 times per second As soon as by a consumer the voltage is affected the speed regulation provides to adapt to the changed
20. pump runs dry some seconds The raw water hose should describe a loop as near as possible to the raw water inlet of the gene rator see picture below With it the pump only sucks in air for a short time The impeller will be lubricated by the raw water and its life time will rise By the installation of a check valve in the sea water inlet line which is under the waterline this problem can be limited a little It is very important to change the impeller every few month When starting the generator you should pay attention and listen when raw water comes out from the exhaust If this lasts longer than 5 seconds the impeller has to be changed because he sucks to much air before raw water reaches the impeller and the impeller wears out strongly In this case the impeller looses its function which leads to an overheating of the engine If the impeller isn t exchanged early enough the impeller wings can break into pieces and clog the cooling circuit Therefore it is very important to change the impeller every few month NOTE Never change the impeller for many years without exchanging the old pump If the sealing ring is defective within the pump raw water runs into the sound cover of the aggregate A repair is then very expensive Replacement impeller and also a spare pump should always be on board The old pump can be sent back to ICEMASTER where it is then economically overhauled completely 1 Raw water filter 2 Water cock 3 Hul
21. the safety systems have been installed they must be checked If a leakage current relay has been installed it also has to be tested In order to ensure that the leakage voltage relay functions properly the individual generated phases from the generator must be checked bet ween each other between phase and ground the single phase or 4th phase also needs to be checked in this fashion If the generator is protected by a ground connection then ALL electrical devices must also be connected to this common ground usu ground contacts are attached to the devices metal lic housings The electrical system installation must also comply to the hook up requirements of the shore cur rent 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 be meet the required safety standard regulations In addition to a proper circuit diagrams terminal points connections electrical devices etc should also be labelled with stickers or signs 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 corre
22. 05 PMS 4500 FCB manual V02 ChapterF Tables Page V S e Tischer Ponda Technical Data Generator _ F 3 Technical Data Generator Nominal voltage 230V 50 Hz single phase 230V 400V 50 Hz 3phase Cable cross section 230V 1 phase 2x4 0 mm 400V 3 phase 4x2 5 mm ohmic resistance coll HP1 L H 0 750hm L Z 0 55 Ohm DVS L1 L2 L3 N 1 2 Ohm L1 N 0 6 Ohm inductive resistance coll HP1 L H 6 5 mH L Z 3 9 mH DVS L1 L2 L3 N 5 2mH IN 3 75 mH Voltage stator coil 1phase L N 2 4V 3phase L1 L2 L2 L3 L2 L3 2 4V IN Coolant hoses mm Fresh water raw water 12 Fuel hoseh mm Supply return 8 Page VI PMS 4500 FCB manual V02 Chapter F Tables 15 7 05 Tischer Ponda F 4 Types of coil HP1 230V 50 Hz 1 oO UO Q HP3 400V 50 Hz DVS 400V 50 Hz 15 7 05 PMS 4500 FCB manual V02 Chapter F Tables Page VII Fischer Ponda inspection checklist for services _ F 5 Inspection checklist for services Inspection Category Inspection work A frstataton check Lei set LI NEN KE Inspection Category LELE CON NN NN CN e m m p e Inspection work m p sS m b w Wb wem e bp p p p immer lt lt ee p p p b b p p am lt lt C C o p p p p p p p eg S 4 p p peera 0 p p p p Tiers SSS a 1 p p p p pomem 1 p pb p p posms 7000000 m p p p p felpressure senso SSS m o w w p p
23. 15 7 05 ED Fischer Donde 15 7 05 C 3 2 Checking the capacitors If the capacitors are to be checked it is to be made certain that the capacitors will be discharged before touching Already a visual check can give informa tion on whether the capacitors are defec tive Leaks dielectric did the capacitor became longer The capacitors can be tested with a multi meter Switch the measuring instrument to pass and connect both connections of the capacitor with the connections at the measuring instrument Touch with the test prods the two contacts of the capacitor By the internal battery a charge transfer in the capacitor should take place now If changes the poles of the capacitor with the test prods again a short beep should have to be heard This short sound is Only an indication for the fact that the capacitor is not defective Should a steady sound or no sound have to be heard the capacitor is defective and must be replaced In order to go surely that the capacitor has still its full capacity use a capacity measuring instru ment The capacitors which not achieve the imprinted capacity value at this measurement should be exchanged as fast as possible If all capacitors are still functional must be checked whether the connection to the strip is correct Checking the electrical connections to the capacitors It must be ensured that the electrical connections to the capacitor are always tight fitting
24. Capsule Measurements ri XI F 9 Cooling water flow Panda 4500 FCB iii XII PMS 4500 FCB manual V02 Table of contents Page 3 Tischer Ponda Page4 PMS 4500 FCB manual V02 Table of contents 15 7 05 Fischer Panda A Mode of Operation of the Generator A 1 Mode of operation of operating surveillance Internal monitoring switches The generator is equipped about failure switches which are indicated on the remote control panel and also about failure switch which switch off the generator automatically without indica ting a failure in the remote control panel The remote control panel supervised the following values In the case of a disturbance the gene rator is switched off in order to avoid damage to the aggregate 1 Cooling water temperature at cylinder head and exhaust connection 2 Coil temperature 3 Oil pressure The fault is transmitted if one of these switches measures a value that exceeds the required value all switches are openers The current is switched off by the main relay Fuel magnet valve closes the fuel suction pump is switched off VCS is switched off The combustion engine possesses an oil pressure control switch which switches the engine off if the oil pressure drops under a certain value The additional failure switch in the generator coil it is not indicated at the remote control panel interrupts directly the current supply to the main
25. D 7 Generator 12V DC System Installation 2 0 0 0 eee iii 54 D 7 1 Connection of the 12V starter hatten 54 D 7 2 Connection of the remote control poanel ener 55 D 7 3 Ree E e EE 56 D 4 Electronic starter control unt 56 D 8 Generator AC System Installation i 57 D 8 1 Installation with looped in AC Control DOX nennen of D 8 2 Installation AC Box distribution panel separate connected n n annnnnnoennnnnnnennnnrnnenrnnnnnni 58 PMS 4500 FCB manual V02 Table of contents 15 7 05 15 7 05 D 8 3 AC Control box with VCS and ASB e 60 D 8 4 Booster elecTONlC TIRE Tm 61 D 8 5 Jump start at hight starting current Booster i 62 D9 mISHIQUON geet 62 HN Le EE de EE 63 D 10 1 Adjustment of the rated voltage i 63 D 10 2 Functional decription of the voltage controller cccccsecceeeeseeeeee cess eeeeeeseeeeeeeaeeesaeeeaes 63 D 10 3 Time lag of the switching points 64 Ee Fil PRFCUDICSNOOUING eer H l F2 Technical CR re Un E V F 3 Technical Data Generator VI Fd A eue Mer VII F 5 Inspection checklist for services nena nennen ahhh E RENE VIII O te UC e eme IX Fa COO t ee X F 8
26. ST Generator is overloaded Check electrical load and switch off unnecessary con sumers Insufficient intake air Check intake air filter clean if necessary Fuel injector faulty Replace injector Valve clearance incorrect Readjust valve clearance to correct value refer to Farymann manual Poor fuel quality Use better quality diesel recommended 2 D Diesel Poor combustion Incorrect AFR air fuel ratio due to motor timing adjust ment Have motor serviced by Farymann GENERATOR MUST BE SHUT OFF IMMEDIATELY IF e MN motor rpm suddenly rises or drops Refer to respective section of manual and if necessary unusual noise comes from genset have repaired by Farymann Service or Panda repre exhaust colour suddenly becomes dark sentative leakage in the cooling water system Page IV PMS 4500 FCB manual V02 Chapter F Tables 15 7 05 Fischer Ponda F 2 Technical Data Engine max power DIN 6271 IFN ISO 5 7 kW Nominal speed 60 Hz 3600 rpm Valve clearance engine cold Lubrication oil capacity 1 25 Fuel consumption P approx 0 42 1 121 Oil consumption max 1 of the fuel comsumption Cooling water requirement for raw water circuit 10 12 l min Permissible max permanent tilt of engine a 25 across the longitudinal axis b 20 in the longitudinal direction a progressive govenor by VCS b 0 35I kW electrical power the randomized values between 30 and 80 of the rating power 15 7
27. Yachts esses 39 D 3 3 Quality of the raw water sucking mme 39 D 3 4 Installation above waterline nennen nennen nnne nnns 40 D 3 5 Installation below waterline iii 41 D 3 6 Installation under the waterline i 42 D 3 7 Installation over the waterline sessi nnns 43 DA The Freshwater Coolant Circuit i 44 D 4 1 Position of the external Cooling Water Expansion Tank 44 D 4 2 Scheme for fresh water circuit ii 44 D 4 3 De aerating at the first filling of the internal cooling water circuit 45 D 4 4 Filling and de aerating of the internal cooling water CIFCUIt 46 D 4 5 Pressure test for control of cooling water CIFCUIL 47 D 5 Watercooled Exhaust System ten Zeg steen iii caiano 48 D 5 1 Installation of the standard exhaust system nne nennen 48 D 5 2 Exhaust water SCI AN ALON RETREAT 49 D 5 3 Installation exhaust water separaior enne nnne nnne nnns 50 D o ATTEN ONE CET E 51 D 6 1 General References eieiei ina 51 D 6 2 The electrical fuel pump nennen nennen nnne nnnm nnus n anis sa rana ns 52 D 6 3 Connection of the fuel lines at the tank e 52 D 6 4 Position of the pre filter with water separator cece cece eeeaeesseeeseeesaeeeseeeaeesees 53 D 6 5 De aerating the fuel svetem ii 53
28. ans The raw water inlet must be removed at the water cock Over a hose connector the anti freeze protection mixture is to be sucked in from a container The leaked cooling water with the exhaust is to be led back into the sucking in container The circuit must be kept upright some minutes to guaranteed that the anti freeze protection mixture reaches all ranges of the cooling system 2 The concentration of the anti freeze mixture in the internal cooling circuit must be checked with a suitable measuring instrument The concentration must be furnished according to the lowest temperatures which can be expected 3 Clean raw water filter and check seal 4 Check water cock for practicability And spray with a corrosion protection oil from the inside or lubricate with acidless grease 5 Check all hoses and hose connectors for good condition The rubber hoses are very sensitive to enviromental influences They can age fast with dry air in environment of light oil and fuel steams and increased temperature The hoses must be checked regularly for elasticity There are operating situations which the hoses must be renewed once in the year 6 Check the hose connectors at all raw water valves doubly and if possible protect them with double hose clamps 7 Dismount the impeller of the cooling water pump and check for wear The impeller may not remain in the pump It must be greased with vaseline and be kept at a dark place It can be reintragrated in
29. ass exists The contacts which can be measured depend on the type of the generator see identification plate MR Fischer Ponda KO Panda 4200 SCB E2 2003 HP3 60Hz L1 L2 L3 1 2 3 4 d Panda asynchron et B02 019 049 DVS 60Hz L1 L2 L3 L1 1 2 3 4 Goes Phi EI CE If a pass beep should be determined the generator must be returned for examination in the plant or it can also be wound again locally For this coil datas can be requested C 3 6 Measuring the inductive resistance Unfortunately the checking of the ohmic resistance permits still no reliable statement about the condition of the coil If the ohmic resistance values arise inequalities between the coils that is a safe indication for the fact that the coil is defective To be exactly sure the inductive resistance of the coil have to be measured For this a special measuring instrument is necessary which mea sures the inductance of a coil Inductance is measured in the same way as the ohmic resistance i e the coils are compared The value is indicated in mH milli Henry The arranging value for the inductive resistance can take from the Table F 3 Technical Data Generator on Page VI Note These values depends strongly from the measuring method kind of the measuring instru ment PMS 4500 FCB manual V02 Chapter C Generator Failure Page 33 Fischer Ponda O Generator Failure _ C 4 Generator provides no Voltage C 4 1 Rotor Mag
30. at least once per year In this case the coolant connection block is to be seen as wearing part It should always be available in each case as spare part on board In order to protect the generator housing against corrosion and against elecrolysis the connection block with the cooling water connecting pieces takes the function of a sacrificial anode Replacement of the coolant connection block The coolant connection block is put on with a Spezial sealant The fixing bolts are not intended in order to stretch the coolant connection block closely on the surface area These screws serve only for the adjustment of the coolant connection block until the sealant is hardened and it rea ched its final firmness The fixing bolts may be tightened therefore only sturdy ATTENTION At the side the fixing bolts with an electrically neutral fat e g anti seize must be used If the fixing bolts high grade steel turned in without this fat into the alumi num threads the danger of a corrosion exists and it is possible that the thread root out when unscrewing the screws Page 24 PMS 4500 FCB manual V02 Chapter B Maintenance Instructions Fischer Honda Maintenance Instructions 15 7 05 15 7 05 Tischer Ponda B 9 Conservation at longer operation interruption B 9 1 Measures on preparation of the winter storage 1 Rinse raw water circuit with an anti freeze solution even if this contains a corrosion protection me
31. at which the diesel drive motor can provide Overloading causes the engine to run rough burn oil creates excessive exhaust environmentally unfriendly and even to stall Extra caution should be practised with multi power units single and 3 phase current generation to avoid overloading the diesel drive engine The generator should only be loaded at the peak rated power for short periods only A high peak current is required to start many electrical devices especially electric motors and compressors from a still stand state In order to prolong the genset s life expectancy the nominal electrical demand on the system should not be more than 70 of the rated genset peak load Keep PEAK LOADING demand in mind when switching on electrical devices esp fridge com pressors electric motors battery chargers kettles etc which are fed by the generator Careful powering up gradual loading of the electrical demand on the generator will help prolong the life of your genset The genset can be run for several hours at partial load i e 2 3 of rated power however it is not advised that it is run for more than 2 3 hours at full load The Panda is designed so as not to overheat even under extreme conditions Note The exhaust gas will become sooty during peak load operation Effects of Short Circuiting and Overloading on the Generator The generator cannot be damaged by short circuiting or overloading Short circuiting and over loading suppr
32. ce Instructions Page 15 B 3 1 De aerating the fuel system Fischer Panda 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 4 Are I np ge gas j Y ca LI AE mz o e 1 T B 3 2 Exchange of the fuel filter Page 16 PMS 4500 FCB manual V02 Chapter B Maintenance Instructions 1 Main power switch OFF Disconnect clamp no 5 of the DC terr block Main power switch ON for appro minutes the electrical fuel pump prc and airs out automatically the fuel inle Do not press the START button Main power switch OFF Reconnect lamp no 5 of the DC terr block If still bubbles are in the fuel inlets the ventilation screw at the fuel solenoid valve or the union nut at the injection line at the cylinder head should opened and the procedure has to be accomplished again It is advisable to hold an absorbent paper or cloth under the screw so that the fuel does not run in the sound cover The fuel pump must run only until nonporously fuel withdraws As soon as the system is aired out the open screw must be tightened again The exchange of the filter depends on the contamination of the fuel shoul
33. ct labelling is especially critical for terminals L1 L2 L3 N amp 1 2 3 4 for the 60Hz 120V models The electrician is there fore 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 run ning Page 62 PMS 4500 FCB manual vu Chapter D Installation Instructions 15 7 05 Tischer Ponda D 10 Voltage controller With a engine operated generator set count always on the fact that through disturbances at the controlling of the diesel engine the control of the number of revolutions monitoring is lost In this case the diesel engine could wind up without limitation and produce a voltage which becomes substantially larger than the electrical consumers can process This can destroy very expensive items of equipment It must be take for granted that for the protection of the electrical consumers a voltage controller with isolating relays is used for a solid installation The appropriate accessory components are available at Icemaster If itis about a duo combination generator the voltage control for both output parts single phase AC and three phase AC should be planned At different PANDA generators a voltage control is
34. d on board it is recommend that an automatic voltage monitoring unit be installed to protect this equipment from possible sharp voltage drops The voltage monitoring system shuts down the entire system and therefore all users by means of a circuit breaker relay as soon as the voltage falls below a set value the monitor will also shut down the on board grid automatically when the generator is stop ped Such a relay with contactor can be obtained from the installator or as a complete unit from your Panda dealer Page28 PMS 4500 FCB manual V02 Chapter C Generator Failure 15 7 05 Fischer Ponda Landstrom 1 Load 5 Voltage relay 2 Selector switch Shore power Generator 6 Fuel pump 3 Generator 7 AC Controll box 4 Starter battery 8 Remote control panel During any operation at the generator all consumers have to be switched off to avoid damages at the equipments Also the solid state relay which is installed in the AC control box must be disconnected to avoid an accidentally activation of the booster capacitors Re connect the connections if the electrical supply lines in the AC control box were also be dis connected The generator can t be damaged by an overload because the winding is overload and short cir cuit safety But damages are possible in the periphery Especially connected consumers are endangered because a lower voltage can damage them by order Possible disturbances in the area of the rev regulation
35. d take place at least all 300 operation hours Before the exchange of the filter the inlet must be clamped 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 15 7 05 Fischer Ponda B 4 Checking the water separator in the fuel supply The pre filter with water separator has a cock at its lower surface with this cock the downward sunk water can be discharged This is simply possible water is heavier due to its density than the Diesel This pre filter does not belong to the scope of supply B 4 1 Exchange the air filter mat Open the air suction housing by loosen the six screws on the housing cover Change the air filter mat 15 7 05 PMS 4500 FCB manual V02 Chapter B Maintenance Instructions Page 17 ce L Tischer Ponda Maintenance Instructions _ B 5 De aerating of the coolant circuit freshwater Special notes for the ventilation of the cooling system If the cooling water is drained or if other air should have arrived into the cooling system it is necessary to de aerate the cooling system This de aerate procedure must be repeated several times ATTENTION Before opening the de aerating points the generator must be stagnant Pay attention that the external coolant expansion tank is connected with the generator by the
36. e 1 0 Recheck Pulse Every Minute e Keep head tilted back Feelfor pulse for 5 to 10 seconds e f victim has pulse not breathing continue rescue breathing If no pulse begin CPR
37. e aeration procedure also after some days again to guarantee that in the system remained bubbles are removed B 5 1 Draining the coolant In principle only describes here how the cooling water of the raw water cycle can be drained The mixture of the fresh water circuit should not be drained in principle See measures for the prepa ration of the winter storage The simplest and cleanest method consists of the fact to bring the external ventilation valve below the generator level and hold over a collec ting basin Open the valve now the water from the raw water circuit flows downward into the container B 5 2 Exchange of the toothed belt for the internal cooling water pump The relative high ambient temperature in the closed sound insulated capsule about 85 C can be a reason for a reduced lifespan of the toothed belts It is possible that the softener in the rubber compound lose their effect after a short operating time because the air in the sound insulated capsule can be relative warm and dry The toothed belt must be controlled in a very short time interval It can be happen to change the toothed belt after some weeks because of unfavorably conditions Therefore the control is nee ded in an interval of 100 operating hours The toothed belt ia a wearing part It should be enough spare toothed belts on board We suggest to stand by the according service packet Page 20 PMS 4500 FCB manual V02 Chapter B Maintenance Instruc
38. ease implement this test in order to examine the equipment Measure of the resistance within the individual windings Wenn hier starke Abweichungen in den einzelnen Wicklungsteilen gemessen werden mu man davon ausgehen da es in einer Wicklung einen Wicklungsschluf amp gibt Auch dies f hrt dazu da der Generator sich nicht mehr erregt Die tatsachlichen Werte zwischen den Wicklungsteilen und Masse sind jedoch nicht so genau zu bestimmen Es kommt in erster Linie darauf an da die Werte aller drei Messungen m glichst gleich sind Abweichungen untereinander weisen auf einen Wicklungsschluf hin In diesem Fall muf der Generator von einem Fachmann neu gewickelt werden Page32 PMS 4500 FCB manual V02 Chapter C Generator Failure 15 7 05 ED Fischer Donde 15 7 05 C 3 5 Checking the coil s to short circuit In order to check the coils for short circuit first all lines which lead to the electrical system must be interrupted This happens on the power terminal box of the generator or if available in the electrical system junction box Guarantee that no voltage lies at the lines before they are inter rupted see Discharge the capacitors on Page 30 Now remove the bridge between N and PE so that coils and housing are electrically separate from each other Check with a circuit indicator multimeter in the power terminal box if between the individual con nection points of the coil and the housing PE a p
39. echnician 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 excee ded by more than 25 The fuses must be of the slow type A 3 way motor protection switch must be installed to protect the electrical motor Required cable cross sections The following recommended electrical cable dimensions cross sections are the minimum requi red sizes for a safe installation see Table F 3 Technical Data Generator on page VI PMS 4500 FCB manual V02 Chapter D Installation Instructions Page 59 Tischer Ponda installation Instructions D 8 3 AC Control box with VCS and ASB In the AC Control box the needed capacitors for the excitation of the generator are placed as well as the electronic control for voltage speed regulation VCS and the starting current reinforcement ASB The AC Control box must be connected with the conductions high voltage and low voltage to the generator The front panel must always be closed since the AC Control box produces 400V during operation Danger High voltage ATTENTION Before working on the System read the section Safety Instructions on page v in this Manual ATTENTION Never touch the terminals of the Solid State Relays capacitors or booster electronic HIGH VOLTAGE DANGER OF LIFE 1 Solid state relay for booster capacitor 2 Capacitors for excitation and b
40. ection Safety Instruc tions on page v in this Manual AC con Control trol Box panel Starterbattery Ale m m D y Connection for exhaust Starter battery positive cable Cable for AC Control box VCS control Connection fuel IN Cable for remote control panel Connection fuel OUT Cable for external fuel pump Connection external expansion tank Starter battery negative cable Raw water intake 1 Connection for external ventilation valve Page38 PMS 4500 FCB manual V02 Chapter D Installation Instructions 15 7 05 Tischer Ponda D 3 Cooling System Installation Raw water D 3 1 General References The genset should have its own sea water coolant water inlet and should not be connected to any other engine systems Ensure that the following installation instructions are complied with Avoid galvanic corrosion For the avoidance of galvanic corrosion the chapter Service instruction for marine aggregates corrosion protection is to be considered D 3 2 Installation of the thru vessel fitting in Yachts It is good practice for yachts to use a hull inlet fit ting with an integrated strainer The thru vessel Fahrtrichtung fitting raw water intake is often mounted against the sailing direction to induce more water intake Borddurchlan for cooling EE For Panda generators the thru vessel inlet should NOT point in the sailing direction When sailing at higher soeeds more water will be forced i
41. ences Beside the alternating current aggregates ICEMASTER supplies also the super compact High tech battery load aggregates from the series of PANDA AGT in sound insulated construction which represent a very interesting alternative solution in a DC AC power technology merged for generation of current within the mobile range The new HTG generators with 280 A charging cur rent offer themselves a alternative for an onboard current generator if a diesel set is not inten ded These generators differ according to the technology very substantially from all conventional products The size is so compact that you can exchange it also against a generator according to standard This generator can ensure a 230V alternating current supply up to 3 000W power in connection with a PANDA HD inverter also in continuous operation A 5 Operation of generator with installation under the waterline If the generator cannot be installed clearly at least 600mm over the waterline a ventilation valve must be installed into the raw water line At installation beside the midship s line a possible hee ling must be considered The water hose in the sound cover is split on the pressure side of the pump and extended in each case in the sound cover at both ends with a connecting nipple by a hose end Both hose ends must led out from the sound cover to a point which is at least for 600mm over the waterline if possible in the midship s line The valve is inserted at the h
42. erators are equipped with an independent 12V DC starter motor The connecting lines cross section from the battery to the DC system should mea sure Zomm 1 Solenoid switch for starter motor 2 Starter motor D 7 2 Connection of the remote control panel As standard a 7 core connection cable 7m long is included in the supply Cores are numbered from 1 to 7 The control cables are securely connected to the gen set On the back of the control panel there are terminals numbered from 1 7 Con nect the cores of the control cable in respective order Please ensure that the remote control panel is installed in a protected dry and easily accessible place 15 7 05 PMS 4500 FCB manual V02 Chapter D Installation Instructions Page 55 Speed sensor Installation of the speed sensor The speed sensor tip must have between 0 3 to 0 8mm of clearance air gap from the gear tooth tips In order to achieve this clearance the speed sensor tip should be aligned with the tip of a gear tooth and screwed in until it touches the tip of the tooth ATTENTION Ensure that when inserting the sensor that the sensor tip is not screwed into the root of the gear tooth The screw is subsequently turned anticlockwise by half a turn 0 3 to 0 8mm and held by a counter nut 1 Speed sensor on threaded seat 2 Engine Flywheel with gear teeth 3 Generator housing 4 Retention tightening nut 1 Speed sensor on threaded seat 2 E
43. ess the magnetic excitation of the generator thus no current is generated and the voltage will collapse This condition is immediately offset once the short circuit has been elimina ted and or the electrical overload removed PMS 4500 FCB manual V02 Chapter C Generator Failure Page 27 J Fischer Ponda Gut _ Overloading the Generator with Electric Motors With the operation of electric motors it must be considered that these take up a multiple of their rated output as starting current six to tenfold If the power of the generator for the engine is not sufficient the voltage in the generator breaks down after switching on the engine For special approach problems the manufacturer can give recommendations regarding the accomplishment of the situation e g amplified capacitors gra dual start switch or extra developed starting unit for electric motors The system efficiency can be improved up to 50 and the starting current can be improved up to 100 by a professional adjustment of the engines If the inductive load electrical motors etc lies over 20 of the generator rated output a compensation is appropriate see in addition also the writing Operation Instructions for Generators with Inductive Loads C 2 1 Monitoring the Generator Voltage ATTENTION See Safety Instructions on Page v The voltage range of the power stations normally lies between 100V and 130V in the 60Hz ver sion In some countries even subs
44. f the raw water pump by loosen the 4 wing screws from the hou sing 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 instal lation 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 Attention this is very important because the impeller can dissolve otherwise very fast The 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 15 7 05 PMS 4500 FCB manual V02 Chapter B Maintenance Instructions Page 23 Ze H Il B 8 Coolant connection block at generator housing Monitoring of the coolant connection block as sacrificial anode At all raw watercooled aggregates the coolant connection block at the side of the generator hou sing must be well controlled This coolant connection block is manufactured from a special alumi num alloy and serves also as sacrificial anode If by the influences of electrical DC voltage the aluminum alloy of the generator is endangered first the coolant connection block is concerned If visibly corrosion is identifiable from the outside of the coolant connection block the block must be changed in regular intervals
45. follows prior to the first operation as all hoses are empty 1 Main power switch OFF 2 Disconnect clamp no 5 of the DC terminal block N 3 Main power switch ON for approx qum 5 minutes the electrical fuel pump propels and airs out automatically SST AW p 7 D T HE 5T Ren ut ott ER NA AS the fuel inlets Do not press the START button 4 Main power switch OFF 5 Reconnect lamp no 5 of the DC ter minal block If still bubbles are in the fuel inlets the ventilation screw at the fuel solenoid valve or the union nut at the injection line at the cylinder head should opened and the procedure has to be accomplished again It is advisable to hold an absorbent paper or cloth under the screw so that the fuel does not run in the sound cover The fuel pump must run only until nonporously fuel withdraws As soon as the system is aired out the open screw must be tightened again 15 7 05 PMS 4500 FCB manual V02 Chapter D Installation Instructions Page 53 Fischer Panda GE The Panda 4500 needs a battery with a capacity of at least 44Ah for the start The generator can be attached to the existing starting battery of the main engine or be supplied with its own battery The Panda 4500 is not equipped with its own 12V battery loading installation Thus that the star ting battery is charged during the generator operation at the exit of the generator a battery char ger is ensured
46. ient ventilation openings are present so that the aggregate cannot overheat High temperature of the intake air decline the power of the aggregate 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 these effects as small as possible the temperature in the engine room should not be higher than 15 C in relation to the outside temperature D 1 2 Notice for optimal sound insulation The convenient base consists of a stable fra mework on which the generator is fastened by means of shock mounts oince 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 PMS 4500 FCB manual V02 Chapter D Installation Instructions Page 37 Fischer Panda CMS The generator comes supplied with all supply lines i e electric cables fuel lines etc already connected to the motor and generator The supply lines are fed through the capsule s front base panel and are shielded at the capsule inlets with water proof grommets All electrical connections cable types and sizes must comply to the appropriate regulati ons The supplied cables are rated for ambient temperatures up to 70 C 160 F If the cables are required to meet higher temperature requirements they must be run through conduits ATTENTION Before working installation on the System read the s
47. ighest place at least 600mm over the waterline PMS 4500 FCB manual V02 Chapter A Mode of Operation of the Generator Page 9 CA oy Fischer Ponda min 600mm Il 1 Raw water impeller pump 7 Water cock 2 Freshwater pump 8 Raw water inlet 3 Water cooled exhaust elbow 9 Expansion tank 4 Cooling water connection block 10 Vent valve 5 Heat exchanger 11 Oil cooler 6 Raw water filter 12 Reducer A 5 1 Control of the ventilation valve 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 lead to destruction of the engine Page 10 PMS 4500 FCB manual V02 Chapter A Mode of Operation of the Generator 15 7 05 15 7 05 Tischer Ponda A 6 Operation of generator with installation over the waterline Generator over the waterline If the generator is installed over the waterline a stronger impeller wear is possible the pump can run after the start some seconds dry It is very important that the impeller is exchanged every few months When starting the generator attention should be always paid and heard to it when raw water withdraws from the exhaust neck If this takes longer than 5 seconds the impeller must exchanged he sucks in air before raw water reaches the impeller see picture below and the impeller then
48. integrated This voltage control affects only the diesel engine If the rated voltage exceed approx 1596 this voltage control is activated as the diesel engine is turned off This is only possible with the delay of some seconds consumers could be damaged in the meantime The only safe method for the protection of the electrical devices is the installation of an external voltage controller with separation contactor We recommend this measure with all reproduction and point out also that the generator manufac turer is not responsible for damage which are caused by overvoltage at external devices Protect your valuable devices by an external voltage controller Position of the external voltage controller Reasonable the external voltage controller is mounted in such a way it works not only for the generator but for all AC voltage supplies in the electrical system also for shore power and inver ter In these cases usually a selector switch is intended which can be determined which voltage supply is switched to the electrical system The voltage conteroller must be installed at the exit of the selector switch thus in the electrical system D 10 1 Adjustment of the rated voltage The voltage controller must be ordered for the appropriate rated voltage 12 24 32 48 42 V DC Other voltage on request Changing between these voltages is not possible D 10 2 Functional decription of the voltage controller o O The voltage controller has
49. intended connection point Further it should be guatanteed that the expansion tank is attached in sufficient height 600mm over the level of the generator exhaust elbow union Open the cooling water filler screw The coolant must be refilled so long up to recognizes that the cooling water level Cl does not sag any longer Then close the screw again and start the generator Run the generator about 1 min and switch off again Page 18 PMS 4500 FCB manual V02 Chapter B Maintenance Instructions 15 7 05 15 7 05 Now the cooling water is only filled over the external expansion tank This is con nected by a hose with the aggregate The external expansion tank should be fil led in the cold condition only up to maxi mally 20 It is very important that a large extension space over the cooling water level remains Open the ventilation screw at the piipe od the cooling water pump The out stepping water must be observed This must be nonporous in order to place surely that no air is in the water circula tion Close the screw again firmly The ventilation screw above the heat exchanger can remain closed PMS 4500 FCB manual V02 Chapter B Maintenance Instructions Page 19 Fischer Ponda Maintenance Instructions If no change of the cooling water level can be determined the generator is started for 5 minutes Afterwards repeat the de aeration two three times It is meaningful to repeat the d
50. is normally attached This battery charger should be selected in such a way that the rated output approx 10 of battery capacity correspond 120Ah starting battery requires a battery charger with approx 10 12A charging current In the Panda accessories program special battery chargers are available which are designed to load in connection with the generator particularly effectively This is however necessary only if the electrical system is to be loaded hereby For loading the generator and or starting battery a sim ple low priced battery charger is sufficient D 7 1 Connection of the 12V starter battery The positive battery cable is connec ted direcly to the solenoid switch of the 4 Starter The negative battery cable is connec G ted to the engine foot Note the battery negative pole may not be connected with the boat ground or with the protective grounding of the 120V installation Otherwise the danger exists with bad i contact at the battery minus the termi nal box burns out Page54 PMS 4500 FCB manual V02 Chapter D Installation Instructions 15 7 05 Ze LA The Panda generators 4500 SCB FCB are equipped with two various DC relays and one electrical fuse which can be found at the terminal strip The various relays and fuse have the following tasks also see the DC circuit diagram 1 Starter relay K1 2 Fuel pump start relay K3 3 Electrical fuse 25A All Panda gen
51. l inlet Make certain that the raw water filter lies above the water level otherwise with cleaning water can penetrate by the hull inlet An external pre pump can relieve the impeller Wasserlinie waterline Page 40 PMS 4500 FCB manual vu Chapter D Installation Instructions 15 7 05 D 3 5 Installation below waterline If the generator can not be attached at least 600mm over the waterline a vent valve must be installed into the raw water 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 cover 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 cover to one point if possi ble 600mm 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 Cut the hose for the external vent valve and bent it upwards Both hose ends must be led out outside of the sound cover to one point if possible 600mm over the waterline in the midship line The valve is connected at the highest place with the two hose
52. l lines bleed if necessary Lack of intake air Check air intake paths Check and clean air filter and intake muffler if instal led Generator overloaded by too many consumers Reduce the electrical load switch off consumers Generator overloaded by over energizing Check that the proper capacitor type is installed and that they are connected correctly Defective generator windings bearings or other Generator must be sent to manufacturer for repair of damaged bearings or winding Damaged engine Repair of bearing damage etc by Farymann Service MOTOR RUNS IN OFF POSITION me ae Fuel inlet solenoid valve or throttle shut solenoid is not Check wire connections to solenoid Check valve switching off functions as in the Fuel Solenoid Valve or in the trottle shut off solenoid sections Replace if necessary 15 7 05 PMS 4500 FCB manual V02 Chapter F Tables Page III Fischer Ponda C MOTOR STOPS BY ITSELF BEEN w E RN Lack of fuel Check fuel supply system Excess heat in cooling system thermo switch tripped Check cooling water system flow water pump inlet lack of cooling water Is indicated on the remote control water filter extra heat exchanger coolant flow panel Lack of oil oil pressure sensor tripped Is indicated on Check oil level and if necessary top up the remote control panel Check motor s oil pressure and have repaired by Fary mann Service if necessary SOOTY BLACK EXHAU
53. l solenoid valve and should be inspected first A check of the fuel solenoid valve by removing the plug from the fuel solenoid valve for a short period whilst in operation first remove the small retention screw and replace it immediately The motor should react immediately by revving high If the motor does not react sharply to the reconnection of the solenoid wire it is a sign that the solenoid valve could be faulty 1 Fuel solenoid valve 2 Ventilation screw PMS 4500 FCB manual V02 Chapter C Generator Failure Page 35 Damage to starter motor The starter is fitted with a free wheel or axial rotating spring cog which prevents the starter being driven externally by means of the motor The free wheel will be heavily worn if the starter still operates thereby causing damage to the springs roller bearings or cog teeth This could lead to complete destruction of the starter It is important that every person who operates the generator is informed of this situation This is practically the only handling error that can be made on board that can lead to fatal consequences for both generator and operator C 5 3 Troubleshooting Table For troubleshooting see Troubleshooting on Page I Page 36 PMS 4500 FCB manual V02 Chapter C Generator Failure Fischer Ponda i GeneratorFailure_ 15 7 05 15 7 05 Tischer Ponda D Installation Instructions D 1 Placement D 1 1 Placement and Basemount Since Pa
54. n 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 Again de aerating process in the few days after the first startup Also after the first implementing a small amount of air can be reside in the cooling circuit To ensure an imaculate und actual operating of the cooling system the de aerating process must be repeated casual in the next few days if necessary weaks Small amount of air will be still exit out of the de aerating openings especially if the generator stood still for a long time 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 D 4 5 Pressure test for control of cooling water circuit i I Check with the hand if a temperature difference exists whether between cooling water in flow and cooling water return Feel the cooling water in flow line at the internal cooling water pump Feel the cooling water return pipe either at the outlet of the water cooled exhaust elbow union or at the side where this pipe entry at the heat exchanger The temperature difference between in flow and return is approx 10 degrees 15 7 05 PMS 4500 FCB manual V02 Chapter D Installati
55. n page IX and Technical Data Engine on page V PMS 4500 FCB manual V02 Chapter B Maintenance Instructions Page 13 Oil drain screw For the oil change an oil drain hose is lead through the sound cover The oil can be discharged by opening the oil drain screw For countering use a second wrench Oil drain pump If discharging of the oil is not possible we recommend the employment of a hand pump which can be attached to the oil drain hose Afterwards the oil drain screw is closed again Oil strainer The Farymann engine type 18W430 is not equipped with a replaceable oil filter Instead the engine has an oil strainer at the face down see picture The strainer is to be cleaned every 500 hours For this the engine must be lifted with the front i from the sound cover The Panda 4200 possesses an oil drain hose at the oil strainer for discharging the engine oil with the oil change Pagel4 PMS 4500 FCB manual V02 Chapter B Maintenance Instructions 15 7 05 Ze e Fischer Ponda Open the oil filler neck After opening the cap of the oil filler neck the new oil is refilled Please wait instant before measure the oil level the oil must set off in the sump Oil dipstick With the help of the engine oil dipstick the oil level is to examined The prescribed fil ling level may not exceed the Max mar king We recommend 2 3 oil level 15 7 05 PMS 4500 FCB manual V02 Chapter B Maintenan
56. nda generators have extremely compact dimensions they can be installed in tight locati ons attempts are sometimes made to install them in almost inaccessible places Please consider that even almost maintenance free machinery must still remain accessible at least at the front drive belt water pump and the service side actuator dipstick Please also note that in spite of the automatic oil pressure sensor it is still essential that the oil level has to be checked regularly The generator should not be installed in the proximity of light walls which can get into resonant vibrations by airborne sound If this is not possible these surfaces should line with 1mm lead foil so the mass and the swinging behavior are changed Avoid to install the generator on a smooth surface with small mass e g plywood plate This affects in the unfavorable case like an amplifier the airborne sound waves An improvement obtains by compound these surfaces by ribs Also break throughs should be sawed which inter rupt the surface Disguising the surrounding walls with a heavy layer e g lead plus foam mate rial improves the conditions additionally The engine draws its inlet combustion air through several holes in the capsule base Therefore the capsule must be fitted with sufficient clearance between the capsule underside and the base plate min 12mm 72 The generator sucks its air from the surrounding engine room Therefore it must be ensured that suffic
57. netism Loss and Re magnetizing ATTENTION See Safety Instructions on Page v With asynchronous generators it can be the fact that the generator can not build up indepen dently voltage after longer service lives or if it were switched off under full load The cause lies in the fact that the rotor lost its remainder magnetism This remainder magnetism can be restored in a simple manner by a DC bat tery In addition the shore power must be switched off and any connection to a AC source must be interrupted Likewise the aggregate must be switched off i e also the starter may not be operated The power source selector is switched to generator Only the plug socket must be connected with the generator Now the two poles of a 9V battery are connected with the plug socket or held to the appropriate contacts in the on board current distribution Use not a battery bank or the generator starter battery this could damage the coil The DC voltage may be applied only for a short time 1 2 seconds In the coil the remainder magnetism is restored by the short current pulse and the generator can be normally started C 5 Starting Problems C 5 1 Starting with a weak Battery The Panda can even be started with an almost completely discharged battery if the cylinder com pression release switch is used The engine can be easily rotated turned over when cylinder valves are opened i e in the decompression position The fuel i
58. ngine Flywheel with gear teeth D 7 4 Electronic starter control unit If there is an automatic starting require ment and if the remote control panel is switched off then this automatic starting es requirement is ignored Automatic star AnlaBwiederholsperre ting is only possible if after switching on of ELECTRONIC STARTER CONTROL UNIT the remote control panel the automatic 35104 Paderbern Germain starting requirement takes place Panda Mobil Power Page56 PMS 4500 FCB manual V02 Chapter D Installation Instructions 15 7 05 Tischer Ponda D 8 Generator AC System Installation ATTENTION Before the electrical system is installed READ the Safety Instructions on page v 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 lightnening conductor personal protection switch etc D 8 1 Installation with looped in AC Control box CDD C_ OO 1 Generator 4 Distribustion panel 2 Starter battery 5 Remote control panel 3 AC Control box 6 Fuel pump All electrical safety installations have to be made on board 15 7 05 PMS 4500 FCB manual V02 Chapter D Installation Instructions Page 57 DDDDDD OO co 00 ll 6 a 1 Generator 4 Distribustion box 2 Starter battery 5 Remote control panel 3 AC Control box 6 Fuel pump All electrical safety installations have to be made
59. nk 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 swit ched 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 be placing it in the tank The instructions Table B 3 1 De aerating the fuel system on page 16 must be read after initial operation or after it has stood still for a long period 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 non return valve must be installed into the fuel return pipe to guaranteed that through the return pipe no fuel is led into the injection pump Page 52 PMS 4500 FCB manual V02 Chapter D Installation Instructions 15 7 05 Additionally to the standard fine filter a pre filter with water separator must be installed outside of the sound cover in the fuel system line is not included in delivery D 6 5 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
60. nlet solenoid valve requires however a minimum amount of battery charge to be opened The Farymann engine is equipped with an automatic cylinder compression release lever The black release knob is mounted on the diesel motor s right side when observed from the diesel motor end in front of the air inlet This knob has two positions The first position holds opens the cylinder valves open pressure release position and in this position the engine can be rotated easily by hand The second position is the normal operating position full compression position When starting the engine in the pressure release position the starter can easily rotate the engine even with a weak battery and after 5 revolutions the compression release knob switches automatically to the normal full compression position ATTENTION The fuel solenoid valve must be oppened by an additional voltage Page34 PMS 4500 FCB manual V02 Chapter C Generator Failure 15 7 05 15 7 05 Decrompression lever C 5 2 Fuel Solenoid Valve The fuel solenoid valve is located in front of the injection pump It opens automatically if the yo TART button is pressed on remote control panel If the generator is switched to OFF the solenoid valve closes It takes some seconds before the generator stops If the generator fails to start runs rough does not reach the proper RPM or does not stop pro perly the first item to suspect in most cases is the fue
61. not working Check fuel filter and pump clean if necessary Lack of fuel Check fuel supply Glow plugs not working correctly Check glow plugs and heating time Too much air in fuel lines Test fuel system for leakage Bleed air from fuel system refer to section Bleeding Air from Fuel System Fuel filter blocked Replace fuel filter MOTOR RUNS IRREGULARLY me ae NM Faulty centrifugal injector governor Have the centrifugal governor inspected by a Fary mann Service technician Too much air in fuel lines Bleed air from fuel system Page II PMS 4500 FCB manual V02 Chapter F Tables 15 7 05 Tischer Ponda MOTOR DOES ACHIEVE ENOUGH SPEED DURING STARTING PROCESS D E Starter battery voltage insufficient Check battery Damaged bearing s piston seized Repairs need to be carried out by Farymann Service refer to Farymann motor manual Cooling water in combustion chamber Turn generator OFF at control panel Remove the glow plug see Farymann manual Rotate the motor by hand carefully Check if there is water in the oil and change both oil and filter if necessary Determine cause for excess water in the combustion chamber The excess water can be caused by a defective air vent in the cooling water system which should be checked and cleaned or replaced if faulty MOTOR SPEED DROPS re e Lack of fuel Check fuel supply system fuel filter renew if necessary check fuel pump check fue
62. nsets developed at that time set new technological standards worldwide The gensets became more efficient and powerful than other gensets 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 stabi lity and starting values A Panda generator with the same drive motor produces 15 more effective output than the majority of conventional generators This superiority in efficiency also ensures a fuel saving to the same extent The 100 water cooled Panda gensets are currently manufactured in the performance range from 2 to 100 kW in various versions Fast running motors are preferred for performances up to approx 30 kW Nominal speed 3000 rpm The heavier slow runners are preferred for the higher range The fast running gensets 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 Icemaster also supply the super compact high tech sound insulated battery charging genset from the DC AC Panda AGT series which is a very interesting solution for the production of mobile powe
63. nst any rotting by humidity B 9 2 Initiation at spring Before the first start turn the engine once with the hand in order to eliminate necessary existing corrosion beginnings in the bushing If necessarily carry out normal engine inspection Change engine oil and engine oil filters Reintegrate the impeller of the cooling water pump and check pump for leakage Charge starter battery of the generator connect cables and check battery voltage Start generator and check the basic adjustments of the generator such as voltage speed regu lation etc Check all switching off devices for function by operational procedures Page26 PMS 4500 FCB manual V02 Chapter B Maintenance Instructions Icemaster does not take over adhesion for possible damages 15 7 05 15 7 05 Tischer Ponda C Generator Failure C 1 Tools and measuring instruments In order to be able to manage disturbances while driving following tools and measuring instruments should belong to the equipment on board Multimeter for voltage AC frequency and resistance Measuring instrument for inductance Measuring instrument for capacity Current absorbing clamps Thermometer ideal is a infrared thermometer Pressure device pincer fur coolant circuit C 2 Overloading the Generator Please ensure that the genset is not overloaded Overloading occurs when the electrical load demand induces a load torque in the generator which is higher than th
64. nstalled The full voltage is exploited at the AC control box when the generator is run It must therefore be ensured that the control box is closed and cannot be tampered with if 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 It is not allowed to disconnect the battery during operation After the generator has stopped the battery can be disconnected Switch off all load when working on the generator All load must be disconnected in order to avoid damages to the devices In addition the semi conductors in the AC control box must be disconnected in order to avoid the boat capacitors being activated The minus pole of the battery ought to be removed 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 dis connection from the circuit The contacts my not be touched for safety reasons If the capacitors are to be exchanged or checked 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
65. ntire procedure the external cooling water expansion tank remains opened i e the cap must be removed After the first stopping of the the generator wait about one minute until the air in the cooling water can be drop off and raise to the highest point ventilation point Now open all three ventilation points one after another as long as cooling water exit Then the clo sure screw must be closed immediately Turn on only lightly to treat the thread Pay attention that the external cooling water expansion tank is filled with enough cooling water during the de aerating If necessary refill over and over One de aerating step will be last as a rule max 2 minutes and following steps contained The generator runs approx 1 minute Stop the generator Hold on one minute for drop of air The collected air is led out over the two de aeration points The ahead described de aerating process must be repeated as long as after the stopping and drop off air none air exit out of the de aerating ports only cooling water Page 46 PMS 4500 FCB manual vu Chapter D Installation Instructions 15 7 05 Tischer Ponda Anti freeze In the interest of safety the freezing point of the closed circuit coolant should be checked on regular basis Be sure that the coolant antifreeze mixture is good for at least 15 C 5 F and if is possible that your genset experiences lower temperatures for example during storage or trans portatio
66. nto the inlet than what the pump can handle and your generator will overflood D 3 3 Quality of the raw water sucking in line E 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 sea water filter etc The intake suction line should be kept as short as possible Install the sea water inlet in close pro ximity to the genset After start up the cooling water quantity must be measured e g by catching at the exhaust The flow rate as well as the necessary cross section of the cooling water pipe take from Table F 3 Technical Data Generator on page VI PMS 4500 FCB manual V02 Chapter D Installation Instructions Page 39 J Fischer Ponda Gat D 3 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 will likely require repla cement after some time Ensure that the genset is installed such that the intake pump can be easily accessed If this is not possible an external intake pump could be installed in an easily accessed location If the generator is installed above the waterline it is possible that the impeller wearout will be stronger After the start the
67. of the machine guideline 98 37 EG The generator is in such a way developed that all assembly groups correspond to the CE guidelines If machine gui deline 98 37 EG is applicable then it is forbidden to bring the generator into operation until it has been determined that the system into which the generator is to be installed in also corresponds to the regulations of the machine gui deline 98 37 EG This concerns among other things the exhaust system cooling system and the electrical installa tion The evaluation of the protection against contact can only be accomplished in connection with the respective system Likewise among other things responsibility for correct electrical connections a safe ground wire connection foreign body and humidity protection protection against humidity due to excessive condensation as well as the over heating through appropriate and inappropriate use in its installed state on the respective machine lies within the responsibility of those who undertake installation of the generator in the system Use the advantages of the customer registration Thus you receive to extended product informations which are sometimes safety relevant you receive if necessarily free Upgrades Far advantages By your full information Fischer Panda technicians can give you fast assistance since 90 of the disturbances result from errors in the periphery Problems due to errors in the installation can be recognized in the apron
68. on Instructions Page 47 D 5 Watercooled Exhaust System By injecting the outlet seawater into the exhaust manifold the exhaust gases are cooled and the noise emissions from the exhaust system are reduced D 5 1 Installation of the standard exhaust system The generator exhaust system must remain completely independent and separate from the exhaust system of any other unit s on board The exhaust hose has an inner diameter of 30mm 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 Gm 20 ft Exhaust diameter see Table F 3 Technical Data Generator on page VI Wasserlinie waterline 1 Generator 4 Silencer 2 Water lock 5 Hull outlet 3 Goose neck Page 48 PMS 4500 FCB manual V02 Chapter D Installation Instructions Fischer Ponda installation Instructions _ 15 7 05 15 7 05 Tischer Ponda D 5 2 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
69. ooster 3 Booster electronic RE 0502 Terminal block X4 Page 60 PMS 4500 FCB manual vu Chapter D Installation Instructions 15 7 05 Fischer Panda D 8 4 Booster electronic The booster electronic regulates the electrical voltage of the generator It includes the number of revolutions of the engine All control signals are processed on the measuring plate in the AC Control box Auto Boost RE0502 V0 1 A2 00009 ef Terminal designation a 089 0 39 03 ow 15 7 05 PMS 4500 FCB manual V02 Chapter D Installation Instructions Page 61 Fischer Ponda O O installation Instructions _ D 8 5 Jump start at hight starting current Booster Additionally the automatic start booster is located on the circuit control board The starting cur rent is increased by connecting a second group of capacitors C2 if the voltage drops below a pre set voltage The starting current can be increased by 300 for a short period by combining both components voltage speed control and ASB Start booster D 9 Insulation test ATTENTION Once the electrical system installation is complete a ground insulation test must be performed as follows Switch off all on board electrical devices 2 Start the generator 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 exeed 50mV millivolts Once
70. ower If you cannot turn off the electrical power pull push or lift the person to safety using a wooden pole rope or some nonconductive material After the injured person is free of contact with the source of electrical shock move them a short distance away and immediately start necessary first aid procedures XIII WHEN AN ADULT STOPS BREATHING DO NOT attempt to perform the rescue breathing techniques provided on this page unless certified Perfor mance of these techniques by uncertified personnel could result in further injury or death to the victim 1 Does the Person Respond e Tap or gently shake victim e Shout Are you OK 3 Roll Person onto Back e Roll victim toward you by pulling slowly 4 Open Airway e Tilt head back and lift chin e Shout Are you OK O Give 2 Full Breaths Keep head tilted back e Pinch nose shut Seal your lips tight around victim s mouth Give 2 full breaths for 1 to 175 secon ds each T Check for Pulse at side of Neck Feelfor pulse for 5 to 10 seconds 9 Begin Rescue Breathing Keep head tilted back Lift chin e Pinch nose shut Give 1 full breath every 5 seconds e Look listen and feel for breathing between breaths 2 Shout Help Call people who can phone for help D Check for Breathing Look listen and feel for brea thing for 3 to 5 seconds 8 Phone EMS for Help e Send someone to call an ambu lanc
71. power demand by appropriate change of the engine speed Not only by the excitation of the generator it is worked against to the initiating voltage drop but also by the raising of the number of revolutions whereby the drive potential improves A 1 2 Overloading of engine during longer operation Please ensure that the genset is not overloaded Overloading occurs when the electrical load demand induces a load torque in the generator which is higher than that which the diesel drive motor can provide Overloading causes the engine to run rough burn oil creates excessive exhaust environmentally unfriendly and even to stall Extra caution should be practised with multi power units single and 3 phase current generation to avoid overloading the diesel drive engine The generator should only be loaded at the peak em e rated power for short periods only A high peak E F h M A current is required to start many electrical isl Er DI D devices especially electric motors and compres iy Panda 4200 SCB E212003 sors from a still stand state Pandaasynchron The height of the rated output P can taken from the identification plate attached on the housing In order to guarantee a long life span the conti nuous load should not exceed 80 of the nominal load By continuous output we understand the 1 continuous operation of the generator over many EB 29 IDEM 35 5 17 7 ane f hours It is harmless for the engine to
72. r The new HTG alternators ensure that a charging rate of 285 amps is achieved that was scarcely thought possible for this compact construction This alternator replaces a separate shipboard generators constant 230 volts AC with up to 3500 kW from the main machine ICEMASTER GmbH 33104 Paderborn reserves all rights regarding text and graphics Details are given to the best of our knowledge No liability is accepted for correct ness Technical modifications for improving the product without previous notice may be undertaken without notice Before installation it must be ensured that the Pictures diagrams and related material are applicable to the genset supplied Enquiries must be made in case o doubt iii CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Attention Important Directions regarding Operation 1 The installation certificate must be completed when taken into use and certified by a signature 2 The installation certificate must be despatched within two weeks of use to ICEMASTER 3 The official guaranty confirmation will be completed by ICEMASTER after receipt and sent to the customer 4 A guaranty must be shown to make any claims Claims against the guaranty will not be accepted of the above said instructions are not or only partially carried out Manufacturer declaration in terms
73. s 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 12V 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 5m max 600 mm 1 Generator 5 Condensation water suction pump 2 Fuel stop cock 6 Fuel tank 3 Fuel filter 7 Fuel supply 4 Fuel return 8 Electrical fuel pump 12V DC PMS 4500 FCB manual V02 Chapter D Installation Instructions Page 51 e 3 Fischer Ponda insttttion Instructions _ D 6 2 The electrical fuel pump Electrical fuel pump With the Panda generator is usually supp lied an external electrical fuel pump 12V DC The fuel pump must be installed close at the fuel tank The electrical con nections are preloaded at the generator with the lead planned Suction hight of the pump max 1 2m at 02 bar Diameter of fuel lines Table F 3 Tech nical Data Generator on page VI D 6 3 Connection of the fuel lines at the tank Lead the return fuel pipe connected to the day tank to the floor The return pipe connected to the tank must be dropped to the same depth as the suction pipe the generfator is mounted higher than the ta
74. s comple tely filled Open the screw and examine whether the liquid stand up to the container upper edge If this should not be the case refill coolant cooling water with freeze protec tion additive according to the intended mixture and close the screw Afterwards the cooling water catch must be screwed on firmly Likewise the vent screws at the heat exchanger and at the exit of the elec trical cooling water pump must be closed Ventilation screw at the cooling water pipe PMS 4500 FCB manual V02 Chapter D Installation Instructions Page 45 Ze s Fischer Ponda iO rostallationInstruetions_ Ventilation screw on the heat exchanger Fill up the external cooling water expan sion tank with cooling water Note consider maximum level according to marking The cover on the external coo ling water container must remain provisio nally opened all other catches are however now closed Start of the generator After filling the generator must be started During this first phase of start up the generator may not be loaded Switch the generator off after maximally 2 minutes of period of operation again Note The external cooling water expansion tank may be filled in the maximum filling in the cold condition only up to the max marking First de aerating The cooling water circuit of the generator must be de aerated now by multiple repeating of the de aerating procedure During the e
75. 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 por tion of Suspended matters The use of the impeller pump is particularly critical in coral waterbo dies 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 coo ling 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 B 7 1 Exchange of the impeller Close the raw water stop cock gt Raw water pump on the front side of the genset Page 22 PMS 4500 FCB manual V02 Chapter B Maintenance Instructions 15 7 05 e y iB Tischer Ponda Remove the cover o
76. supply for 2 3 hours the full rated output cos Phi WG CEMA TER Paderborn Germi The total conception of the Panda generator guarantees that the continuous load operation does not release superelevated temperatures of the engine also with extreme conditions It is to be considered that the exhaust gas values in the full load operation become more unfavorable soot formation A 2 Operation of electric motors with high starting current A 2 1 General references Electric motors can need for a very short time an increased starting current when starting The starting current can amount to up to 10 times of the rated current This applies in particular to 2 pole engines and particularly to fan engines with larger power in addition to engines which com pressor with flywheels or the like propels If such engines are to be operated contact the techni cian of Fischer Panda in order to find suitable measures which work against the high starting current and or layout the generator for the higher starting current PMS 4500 FCB manual V02 Chapter A Mode of Operation of the Generator Page 7 CI 8 Tischer Ponda Merde of Operation of the Generator A 2 2 Compensation of 1 phases engines If inductive electrical consumers are connected then there is a phase shift between current and voltage the portion of the blind current becomes larger This effect meets by automatic activating of additional capacitors
77. tantially larger tension deviations are being called normally The PANDA generators are aligned that they keep these default values during normal load With high load or overload it can occur that the voltage drops on 95V in the 60Hz version and partly still more deeply That can become critical for certain devices e g for electric motors coo ling compressors and possibly for electronic devices It must be paid attention that the voltage for such consumers are sufficient This can be supervised by a voltmeter The voltmeter should be always installed behind the change over switch generator land power so that each voltage source is shown No further voltmeter is provided for the generator itself If additional consumers are switched on the voltage must be controlled in each case at the volt meter Sensitive devices must be switched off so long until the voltage exceed the critical para meter Under certain circumstances the generator provides overvoltage This arises if the number of revolutions of the generator is increased Changing the number of revolutions may be made only with a tachometer and or a voltmeter If sensitive and or valuable devices are used which are to be protected against this risk an auto matic overvoltage protection must be mounted voltage control with disconnection C 2 2 Automatic Voltage Monitoring and Auto Shut Down If air conditioning units Compressors or other such valuable equipment is installe
78. the spring again into the pump if it is in good condition The impeller is a wea ring part it is recommended to renew it always in the spring independently how many opera ting hours the aggregate ran 8 Control of the vent valve at the raw water inlet If the generator is installed below the waterline always a vent valve is necessary The vent valve must be checked also during the season regularly In the winter storage the vent valve should always be disassembled checked and greased Hardens or got parts dirty are to be replaced 9 Check water lock If the generator were rinsed with an anti freeze mixture the antifreeze mix ture can leave in the water lock If the generator were rinsed with fresh water the water in the water lock must be drained Otherwise the danger exists that the collector is blown up and destroyed by ice 10 Check the exhaust water separator on leakage and if the hose connectors at the lower surface of the separation unit are in normal condition with extremely sulfureous fuels it is possible that also high grade steel tube ends are attacked 11 Check all construction units at the generator inside the sound cover for leakages If there are traces of humidity in the sound cover the cover must be dried Further the cause for the wet ness must be surched and eliminated 12 During the winter storage the upper section of the sound cover must be taken off in order to avoid condensed moisture formation if traces of
79. 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 Vi 15 7 05 Tischer Ponda Table of contents Mode of Operation of the Generator rr 5 A 1 Mode of operation of operating surveillance i 5 A 1 1 Regulation of the generator voltage by the VCS nennen nnns 7 A 1 2 Overloading of engine during longer operation i 7 A 2 Operation of electric motors with high starting Current 7 A 2 1 E ER 7 A 2 2 Compensation of 1 phases engines iii 8 A 2 3 Compensation of 3 phases engines eene nennen nennen nnne nnne nnn a nnne nnn ans 8 A 3 Operation of the generator with additional units cesses 8 A 3 1 E ac E Rec MERE EE air 8 AA Operation of the generator with HTG generator iii 9 A 4 1 General le 9 A 5 Operation of generator with installation under the waterline 9 A 5 1 Control of the ventilation valve nnne nnne nnn nennen nnn nnns 10 Ap Operation of generator with installation over the waterline 11 Maintenance Instructions
80. thout having to remove the sound insulating capsule The tank is made of a transparent material so that the coolant level is visible The connection between the coolant tank and the generator must be a heat resistant rubber hose with an internal diameter of 10mm It must be insured that the hose inclines continually upwards when fitted to ensure that existing air bubbles in the system can rise The coolant tank must be mounted above the water line the higher the better Should it not be possible to place the cooling tank directly above the generator by using an upwards inclining hose because of lack of space at least during running operation i e while fil ling the generator Experienced fitters therefore suspend the water compensation tank with an upwards inclining hose at least one meter above the generator so that it can be placed in its final point of destination later D 4 2 Scheme for fresh water circuit 1 Cooling water expansion tank 4 Heat exchanger 2 Fresh water pump 5 Engine Farymann 3 Coolant connection block Page 44 PMS 4500 FCB manual vu Chapter D Installation Instructions 15 7 05 15 7 05 Open the cooling water filler screw The first filling of the cooling system is made by the filler plug on the heat exchanger The cooling system is filled e Y LL Tischer fonda before the distribution normally with coo lant The customer must make sure before start up that the cooling system i
81. tions 15 7 05 15 7 05 Ze oy Push the toothed belt carefully down with a screwdriver of the pulley toward water pump The new toothed belt can fit in by careful moving back and forth again on the pulley Also here a screwdriver can be helpful Type of belt Gates Power Grip GT MR L660 5MR 475 6 692 B 6 The raw water circuit B 6 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 hol ders must be exchanged PMS 4500 FCB manual V02 Chapter B Maintenance Instructions Fischer Ponda Page 21 Ze e I Fischer Ponda qup B 7 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 revo lutions 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
82. tructions B 1 1 Checks before starting e Oil level e Cooling system leaks Visual check for any changes leaks oil drain system v belt cable connections hose clips air filter fuel lines B 1 2 Hose elements and rubber formed component in the sound cover Check all hoses and hose connections for good condition The rubber hoses are very sensitive to enviromental influences They can season fast with dry air in which environment of muted oil and fuel steams and increased temperature The hoses must be checked regularly for elasticity There are operating situations at which the hoses must be renewed once in the year Additionally to usual tasks of maintenance oil level check oil filter control etc further mainte nance activities are to be accomplished for marine aggregates It belongs control of the sacrificial anode cooling water connection block and the front seal cover at the generator For maintenance intervalls see Table F 5 Inspection checklist for services on Page VIII B 2 Oil circuit maintenance The first oil change is to be accomplished after a period of operation from 35 to 50 hours After wards the oil is to be changed after 100 hours For this the oil SAE30 for temperatures over 20 C and SAE20 for temperatures between 5 C and 20 C is to be used At temperatures under 5 C oil of the viscosity SAE10W or 10W 30 is prescribed Type and amount of required oil see See Engine oil o
83. wears strongly In this case the impeller loses his effect and raw water can penetrate into the engine as well as substantially destroy it If the impeller is not exchanged early enough the entire pump must be replaced Otherwise the impeller wings breaks in pieces and it stresses some time to remove these again Replacement impeller should always be on board With the installation of the generator it must be paid attention that the impeller pump is well accessible since the impeller is a wearing part If this place at the location can be reached not well an external pump with electric drive can be used instead of the pump built firmly in the sound cover which should be installed in a well accessible place 1 Raw water filter 2 Water cock 3 Hull inlet Make certain that the raw water filter lies above the water level otherwise with cleaning water can penetrate by the hull inlet An external pre pump can relieve the impeller Wasserlinie waterline PMS 4500 FCB manual V02 Chapter A Mode of Operation of the Generator Page 11 Page 12 Raw water impeller pump Freshwater pump Water cooled exhaust elbow Cooling water connection block Heat exchanger Raw water filter Water cock Raw water inlet Expansion tank Vent valve Oil cooler Reducer PMS 4500 FCB manual V02 Chapter A Mode of Operation of the Generator 15 7 05 15 7 05 Tischer Ponda B Maintenance Instructions B 1 General maintenance ins

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