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Manual Panda 5000i PVK-U
230V 50Hz 5kW
120V 60Hz 5kW
Super silent technology
Fischer Panda GmbH
Panda_5000i_System_PVK-U_eng.R04 30.10.12
Page 2
Current revision status
Document
Actual: Panda_5000i_System_PVK-U_eng.R04_30.10.12
Replace:
Revision Page
iControl 2 eingepflegt
PMGi mit Lade/Wechselrichtern (R04)
Erstellt durch / created by
Fischer Panda GmbH - Leiter Technische Dokumentation
Otto-Hahn-Str. 32-34
33104 Paderborn - Germany
Tel.: +49 (0) 5254-9202-0
email: [email protected]
web: www.fischerpanda.de
Copyright
Duplication and change of the manual is permitted only
in consultation with the manufacturer!
Fischer Panda GmbH, 33104 Paderborn, reserves all rights regarding text and graphics. Details are given to the
best of our knowledge. No liability is accepted for correctness. Technical modifications for improving the product
without previous notice may be undertaken without notice. Before installation, it must be ensured that the pictures,
diagrams and related material are applicable to the genset supplied. Enquiries must be made in case of doubt.
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Manual Panda 5000i PVK-U......................................................................................................................... ....... 1
Current revision status . ... ... .... .......................................... ... ... ... .... ... ... ........................................................ ....... 2
1 General Instructions and Regulations.................................................................................................. ..... 10
1.1 Safety first!...................................................................................................................... 10
1.2 Tools ................................................................................................................................ 14
1.3 Manufacturer declaration in accordance with the Machinery Directive 98/37/EC .... 16
1.4 Customer registration and guarantee.......................................................................... 16
1.4.1 Technical support ............................................................................................................. 16
1.4.2 Caution, important information for start-up! ...................................................................... 16
1.5 Safety Instructions - Safety First! ................................................................................. 17
1.5.1 Safe operation ............................................... ... ... ... .... ... ... ................................................ 17
1.5.2 Observe safety instructions! .......................................... ... ... ... .......................................... 17
1.5.3 Personal protective clothing (PPE) ................................................................................... 17
1.5.4 Cleanliness ensures safety .............................................................................................. 17
1.5.5 Safe handling of fuels and lubricants ................................................................................ 18
1.5.6 Exhaust fumes and fire protection .................................................................................... 18
1.5.7 Safety precautions against burns and battery explosions ................................................. 19
1.5.8 Protect your hands and body from rotating parts! ............................................................ 19
1.5.9 Anti-freeze and disposal of fluids ..................................................................................... 19
1.5.10 Implementation of safety inspections and maintenance ...................... .......................... .... 20
1.6 Warning and instruction signs...................................................................................... 20
1.6.1 Special instructions and hazards of generators ............................................................... 20
1.6.1.1 Protective conductor and potential equalisation:........................................................................21
1.6.1.2 Protective conductor for Panda AC generators:........................................................................ 21
1.6.1.3 Switch off all loads while working on the generator................................................................... 21
1.6.1.4 Potential equalisation for Panda AGT DC generators............................................................... 21
1.6.1.5 Safety instructions concerning cables........................................................................................22
1.6.2 Recommended starter battery sizes ................................................................................. 22
1.6.3 Important instructions for batteries - starter and/or traction batteries ............ ... ... .... ... ... ... 22
1.6.4 General safety instructions for handling batteries ......... ... ... ... .... ... ... ... ............................. 23
2 In case of Emergency First Aid / Im Notfall - Erste Hilfe................................ .... ... ... ... .... ... ... .............. ..... 25
2.7 WHEN AN ADULT STOPS BREATHING ....................................................................... 26
3 Basics ...................................................................................................................................................... ..... 27
3.1 Intended use of the machine......................................................................................... 27
3.2 Purpose of the manual and description of the definitions of the trained persons/
operators/users 27
3.2.1 Trained persons ............................................ .......................................... ... ... ... ... .... ... ...... 27
3.2.2 Operator ........................................................................................................................... 27
3.2.3 User ..................................... ....................................................... ...................................... 27
3.3 Components of the i system......................................................................................... 28
3.4 Range of operation......................................................................................................... 29
3.5 Panda transport box ...................................................................................................... 29
3.5.1 Bolted Fischer Panda transport box ................................................................................. 29
3.5.2 Fischer Panda transport box with metal tab closure ........................................................ 29
3.6 Opening the MPL sound insulation capsule................................................................ 30
3.6.1 Opening the GFK sound insulation capsule ..................................................................... 30
3.7 Transport and Loading/Unloading................................................................................ 31
3.7.1 Transporting the generator ............................................................................................... 31
3.7.2 Loading/unloading of the generator .................................. .......................... ...................... 31
3.8 Special Service Instructions and Measures for Extended Machine Downtimes and
Decommissioning 32
3.8.1 Instructions for the starter battery for extended downtimes .......................... ... ... .... ... ... ... 32
3.8.2 Measures for short downtimes ......................................................................................... 33
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3.8.3 Measures for medium term downtimes / hibernation ........ .......................... ...................... 33
3.8.3.1 Courses for preservation:......................................................................................................... 33
3.8.3.2 Measures for removing surface protection after medium term downtimes (3 to 6 months)...... 34
3.8.4 Measures for extended downtimes / decommissioning .................................................... 34
3.8.4.1 Courses for preservation:......................................................................................................... 34
3.8.4.2 Measures for removing surface protection after extended downtimes / recommissioning (over 6
months): 35
4 The Panda Generator.............................................................................................................................. ..... 37
4.1 Type plate at the Generator........................................................................................... 37
4.2 Description of the Generator......................................................................................... 38
4.2.1 Front view ......................................................................................................................... 38
4.2.2 Rear View ................................... ... ... ... ... .... ... ... ....................................... ... ... .... ... ............ 39
4.2.3 Top view ....... .... ... ... ... .... ... .......................................... ...................................................... 40
4.2.4 Side view right .................................................................................................................. 41
4.3 Details of function units................................................................................................. 42
4.3.1 Remote control panel see iControl datasheet .................................................................. 42
4.3.2 Components of the cooling system .................................................................................. 42
4.3.3 Components of the fuel system ........................................................................................ 43
4.3.4 The combustion air circle ............ ... ... ... ... .... ... ... ... .... ... ... ... .... ... ......................................... 44
4.3.5 The electrical system .............. .... ... ... ... ... .......................................... .... ... ... ... .... ............... 45
4.3.6 Thermosensor/switches ................. .......................... ...................... ....................... ............ 46
4.3.7 The oil circle ............................... ... ....................................... ... ... ... ... .... ... ......................... 47
4.4 Operation Instructions - see separate control panel manual..................................... 47
4.4.1 Daily routine checks before starting - See iControl manual. ................. ... ... ... .... ... ... ... ... ... 47
4.4.2 Starting Generator - See iControl manual. ....... ... .... ... ... ... .... ... ... ... ... ................................ 47
4.4.3 Stopping the Generator - See iControl manual. ............................................................... 47
5 Generator operation instruction............................................................................................................ ..... 49
5.1 Personal requirements................................................................................................... 49
5.2 Hazard notes for the operation ..................................................................................... 49
5.3 General operating instruction ....................................................................................... 49
5.3.1 Operation at low temperatures ......................................................................................... 49
5.3.1.1 Pre-heating the diesel motor .................................................................................................... 50
5.3.1.2 Tips regarding starter battery ................................................................................................... 50
5.3.2 Light load operation and engine idle ................................................................................. 50
5.3.2.1 The soot of the generator is due to the fact that:...................................................................... 50
5.3.2.2 To prevent the soot of the generator following steps should be observed:.............................. 50
5.3.3 Generator load for a longer period and overload .............................................................. 50
5.3.4 Protection conductor: . .... ... ... ... .... .......................................... ... ... ...................................... 51
5.3.5 Operating control system on the Fischer Panda generator .............................................. 51
5.4 Instructions for capacitors - not present at all models............................................... 51
5.5 Checks before start - see remote control panel data sheet........................................ 51
5.6 Starting the generator - see remote control panel data sheet.................................... 52
5.7 Stopping the generator - see remote control panel data sheet.................................. 52
6 Installation Instructions.......................................................................................................................... ..... 53
6.1 Personal requirements................................................................................................... 53
6.2 Generator instructions ...................................................................................................55
6.3 Preparing the base - Placement.................................................................................... 55
6.3.1 Advice for optimal sound insulation .................................................................................. 55
6.4 Connections .................................................................................................................... 57
6.5 Fuel system installation................................................................................................. 58
6.5.1 Fischer Panda installation kit - Fuel system ..... ... .... ... ... ... .... ... ... ... ................................... 58
6.5.2 The following items need to be installed: .......................................................................... 60
6.5.3 Connection of the fuel lines at the tank ............................................................................ 63
6.5.4 Position of the pre-filter with water separator ................................................................... 64
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6.6 Generator DC system installation................................................................................. 64
6.6.1 Connection of the starter battery block ................ ... .... ... ... ... ... .... ...................................... 64
6.6.2 How to connect two 12V batteries to a 24V battery bank ................................................. 68
6.6.3 Connection of the remote control panel - see separate control panel manual ................. 70
6.7 Connection of electrical components.......................................................................... 70
6.7.1 Connection of the external radiator ........ .......................................................................... 71
6.7.2 Installation PMGi inverter - See separate PMGi 8000 inverter manual ................... ......... 72
6.8 Installation of the cooling system ................................................................................ 72
6.8.1 General instructions ......................................... ... ... .... ... ... ... ... .... ... ... ... ............................. 72
6.8.2 Fischer Panda installation kit - cooling system .............................. .......................... ......... 72
6.8.3 Determing the size of the radiator .................................................................................... 74
6.8.4 Radiator position ........................................................................................ ... ... ... .... ......... 74
6.8.5 Permitted coolant temperatures ....................................................................................... 75
6.8.6 Essential coolant amounts: .............................................................................................. 75
6.8.7 Construction and position of the radiator .......................................................................... 75
6.8.8 Pay attention to the following item at the horizontal assembly of the radiator: .................. 77
6.8.9 Distance from the radiator to the unit ............................................................................... 77
6.8.10 Coolant expansion tank .................................................................................................... 77
6.8.11 Antifreeze ......................................................................................................................... 77
6.8.12 ATTENTION! Temperature restriction! ............................................................................. 78
6.8.13 Installation with special air separator ............................................................................... 78
6.8.14 Monitoring the Temperature ................................................... .... ... ... ... .... ... ... ... ... .... ... ... ... 78
6.8.15 Installing a Coolant Temperature Display ........................................................................ 78
6.8.16 Monitoring of temperature: ............... ... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ...................... 79
6.8.17 Recording the temperature values ................................................................................... 79
6.9 Radiator fan control / electronic fan control................................................................ 83
6.10 Standard fan control for 1-phase and 3-phase generators........................................ 83
6.11 Electronic fan control for DC fans RE 0201................................................................. 84
6.12 Brief description............................................................................................................. 85
6.12.1 Function .................................. ....................... ...................... .......................... ................... 85
6.12.2 Master - Slave - Operation ............................................................................................... 86
6.12.3 Function of the clamps for the Master-Slave-Operation ...................... ............................. 87
6.12.4 Remote controlled switching on and off of the fan controller ............................................ 87
6.12.5 12V / 24V - Operation ....................................................................................................... 87
6.13 Technical Data................................................................................................................ 88
6.14 Electronic fan control for single phase fans PKE-2.5V_Ziehl Abegg ........................ 90
6.14.1 Preset for the use with Fischer Panda generators ........................................................... 90
6.14.2 Connection of the sensor (Ziehl Abegg KTY) ............................. ....................................... 91
6.15 Electronic fan control for single phase fans PXET6Q_Ziehl Abegg .......................... 92
6.15.1 Preset for the use with Fischer Panda generators ........................................................... 92
6.15.2 Connection of the sensor (Ziehl Abegg KTY) ............................. ....................................... 93
6.16 Electronic fan control for 3 phase fans PKD T5 Ziehl Abegg .................................... 94
6.16.1 Configuration of the electronic fan control PKD T5 for Fischer Panda Generators . ...... ... 95
6.17 Exhaust installation .......................................................................................................97
6.18 Isolation test................................................................................................................... 97
6.19 Set into operation........................................................................................................... 98
6.20 ......................................................................................................................................... 98
7 Maintainence ........................................................................................................................................... ..... 99
7.1 Personal requirements .................................................................................................. 99
7.2 Hazard notes for the maintenance................................................................................ 99
7.3 Environmental protection............................................................................................ 101
7.4 Maintenance Requirements......................................................................................... 101
7.5 Maintenance interval.................................................................................................... 101
7.6 De-aerating of the coolant circuit............................................................................... 101
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7.6.1 Ventilating the fuel system .............................................................................................. 103
7.6.2 Replacement of the fuel filter .......................................................................................... 104
7.6.2.1 Optional fuel filter with sight glass .......................................................................................... 105
7.7 Checking oil-level......................................................................................................... 106
7.7.1 Refilling Oil ..................................................................................................................... 107
7.7.2 After the oil level check and refilling the oil .................... ....................... ......................... . 108
7.8 Replacement of engine oil and engine oil filter......................................................... 108
7.8.1 After the oil change ......................................................................................................... 110
7.9 Verifying the starter battery and (if necessary) the battery bank............................ 111
7.9.1 Battery ............................................................................................................................ 111
7.9.1.1 Check battery and cable connections..................................................................................... 111
7.9.1.2 Check electrolyte level............................................................................................................ 111
7.9.1.3 Check electrolyte density........................................................................................................ 111
7.9.2 Replacement of the air filter matt .................................................................................... 112
7.10 Trouble shooting .......................................................................................................... 113
8 Generator Tables..................................................................................................................................... ... 117
8.1 Technical Data .............................................................................................................. 117
8.2 Diameter of conduits vehicle generators................................................................... 121
8.3 Fuel ................................................................................................................................ 123
8.4 Engine oil ...................................................................................................................... 123
8.4.1 Engine oil classification .................................................................................................. 123
8.4.1.1 Operating range:..................................................................................................................... 123
8.4.1.2 Quality of oil:........................................................................................................................... 124
8.5 Coolant specifications ................................................................................................. 125
8.5.1 Coolant mixture ratio .................................. ... ... ... .... ... ... .......................................... ... .... 125
8.6 Cable cross section for vehicle generator................................................................. 125
Panda iControl2............................................................................................................................................ ... 127
Current revision status................................................................................................................................ ... 128
Hardware....................................................................................................................................................... ... 128
9 Safety instructions for the Panda iControl2......................................................................................... ... 129
9.1 Personnel ...................................................................................................................... 129
9.2 Safety instructions ....................................................................................................... 129
10 General operation ................................................................................................................................... ... 131
10.1 The Panda iControl2 panel .......................................................................................... 131
10.1.1 Switching the controller on and off ................................................................................. 131
10.1.2 The default display screen ............. ... ... ... .... ... ... ... .... .......................................... ... ... ....... 132
10.1.3 Operating modes ............................................................................................................ 133
10.1.3.1 Stand-by mode .......................................................... ... .......................................................... 133
10.1.3.2 Start-up mode......................................................................................................................... 134
10.1.3.3 Override mode........................................................................................................................ 134
10.1.3.4 Operation mode...................................................................................................................... 135
10.1.3.5 Stop mode .............................................................................................................................. 135
10.1.3.6 Autostart mode .......................................................... ... .......................................................... 135
10.2 Other operating functions ........................................................................................... 136
10.2.1 Set-up menu ................................................................................................................... 136
10.2.2 Setting the brightness of the backlight ("backlight" and "dimtime") ................................ 137
10.2.3 The configuration menu ("config") .................................................................................. 138
10.2.4 The network ID ............................................................................................................... 138
10.2.5 Saving settings and exiting the set-up menu ("Save & Exit") ......................................... 139
10.2.6 Activating/deactivating the autostart function ("Autostart") ............................................. 139
10.2.7 Resetting the service interval ("Service") ........................................................................ 141
10.2.8 Priming the fuel system ("Prime Fuel") ... .... ... ... ... .... ... .......................................... ... ... ... . 141
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10.2.9 Selecting and saving a unit for the temperature value output ........................................ 142
11 Installation............................................................................................................................................... ... 143
11.1 Personnel...................................................................................................................... 143
11.2 Disposal of the components....................................................................................... 144
11.2.1 Panda iControl2 panel with installation housing ............................................................. 145
11.2.2 Terminal assignments on the Panda iControl2 panel ....... ... ... .... ... ... ... .... ... ... ... ... .... ... ... . 145
11.3 Dimensions................................................................................................................... 146
11.4 Wiring of the Panda iControl2 controller................................................................... 147
11.4.1 Terminal assignments on the Panda iControl2 controller . ... ... .... ... ... ... .... ... ... ... ... .... ... ... . 148
11.4.1.1 Terminal assignment of 18-pin connector............................................................................... 148
11.4.1.2 Fisch er Panda standard bus ................................................................................................... 148
11.4.1.3 Fischer Panda CAN bu s.......................................................................................................... 148
11.5 Start-up.......................................................................................................................... 149
12 Maintenance ............................................................................................................................................ ... 151
12.1 Maintenance of the iControl2 controller .................................................................... 151
12.1.1 Cleaning the iControl2 controller .................................................................................... 151
12.2 Maintenance of the iControl2 remote control panel ................................................. 151
12.2.1 Cleaning the iControl2 controller .................................................................................... 151
13 Warnings and error messages .............................................................................................................. ... 153
13.1 Warnings....................................................................................................................... 153
13.1.1 Examples of warnings on the display: ............................................................................ 153
13.1.2 Warning messages ......................................................................................................... 153
13.2 Faults............................................................................................................................. 154
13.2.1 Error messages .............................................................................................................. 154
13.2.2 Warning and fault thresholds .......................................................................................... 155
13.2.3 Bus errors ....................................................................................................................... 156
14 Annex....................................................................................................................................................... ... 157
14.1 Technical data .............................................................................................................. 157
14.1.1 Technical data for iControl 2 control unit ........................................................................ 157
14.1.2 Technical data for iControl2 remote control panel .......................................................... 157
15 Inverter Panda PMGi 5000............. ... .......................................... ... ... .... ... ... ... ... .... ... ... ... .... .................... ... 159
15.1 Safety instruction......................................................................................................... 160
15.2 Type plate...................................................................................................................... 160
15.3 Front side/connection side.......................................................................................... 162
15.3.1 Socket pins of the PMGi 5000 ......................................................................................... 163
15.4 Back side - Top side..................................................................................................... 164
15.5 Settings for the use of iGenerators with power inverter .......................................... 165
15.5.1 Settings in the Victron VE Configure II Software - General ............................................ 165
15.5.1.1 Uninterrupted AC power (UPS function) ................................................................................. 165
15.5.1.2 Dynamic current limiter............................................................................................................ 165
15.5.2 Settings in the Victron VE Configure II Software - Inverter ............................................ 166
15.5.2.1 Assist current boost factor....................................................................................................... 166
15.6 Operation manual ......................................................................................................... 167
15.6.1 Primary remarks / Winter operation ................................................................................ 167
15.6.2 Load at the PMGi .......................................... ... ... ... .... ... ... .......................................... .... 167
15.6.3 Automatic start ....................................... ... .... ... ... ... .......................................... ... .... ....... 167
15.7 Status LED´s................................................................................................................. 167
15.8 Cooling of the PMGi..................................................................................................... 167
15.9 Installation of the PMGi ............................................................................................... 168
15.9.1 Electrical connection. .................................... ... ... ... .... ... ... ... ... .... .................................... 168
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15.9.1.1 Connection to a system with RCD.......................................................................................... 168
15.9.1.2 Connection to a system with isolation control......................................................................... 168
15.10Technical Data .............................................................................................................. 169
15.10.1 General Data .................................................................................................................. 169
15.10.2 Generator Spezification . ... ... .......................................... ... .......................................... .... 169
15.10.3 PMGi out ..........................................................................................................................170
15.10.4 Overload - switch point ................................................................................................... 173
15.10.5 Short circiut .................................... ... ... ... .... .......................................... ... ... .................... 173
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Dear Customer,
Thank you for purchasing a Fischer Panda Generator and ch oo sing Fisch er Panda as your p artne r for mobile powe r
on board. With your generator, you now have the means to produce your own power – wherever you are - and
experience even greater independence. Not only do you have a Fischer Panda generator on board, you also have
worldwide support from the Fischer Panda Team. Please take the time to read this and find how we can support you
further.
Installation Approval and Warranty
Every generator has a worldwide warranty. You can apply for this warranty through your dealer when the installation
is approved. If you have purchased an extended warranty, please ensure that it is kept in a safe place and that the
dealer has your current address. Consult your dealer about warranty options especially if you have purchased a
used generator. He will be able to advise about authorised Fischer Panda Services worldwide.
Service and Support
To ensure that your generator operates reliably, regular maintenance checks and tasks as specified in this manual
must be carried out. Fischer Panda can supply Service Kits which are ideal for regular servicing tasks. We only
supply the highest quality components which are guaranteed to be the RIGHT parts for your generator. Service
“Plus” Kits are also available and ideal for longer trips where more than one service interval may be required.
If you require assistance – please contact your Fischer Pan da Dealer. Please do not attempt to undertake any rep a ir
work yourself, as this may affect your generator warranty. Your dealer will also be able to assist in finding your
nearest Fischer Panda service sta tio n. Your nearest service station can also be found in our Global Service Network
which can be downloaded from our homepage.
Product Registration
Please take the time to register your Fischer Panda Generator on our website at
http://www.fischerpanda.de/mypanda
By registering, you will ensure that you will be kept up to date on any technical upgrades or specific information on
the operation or servicing of your generator. We can even let you know about new Fischer Panda products –
especially helpful if you are planning to upgrade or expand your installation at a later date.
Fischer Panda Quality - Tried and Tested
DIN-certified according DIN ISO 9001
Thank you for purchasing a Fischer Panda Generator.
Your Fischer Panda Team
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Page 10
General Instructions and Regulations
1. General Instructions and Regulations
1.1 Safety first!
These symbols are used throughout this manual and on labels on the machine itself to warn of the possibility of
personal injury of lethal danger during certain maintenance work or operations. Read these instructions carefully.
WARNING: Hazardous materials Can cause acute or chronic health impairments or death
even in very small quantities if inhaled, swallowed, or
absorbed through the skin.
WARNING: Important information! This warning symbol draws attention to special warnings,
instructions or procedures which, if not strictly observed, may
result in damage or destruction of equipment.
ignition source (cigarettes, hot surfaces, sparks, etc.).
smoking is prohibited.
avoided.
is in progress.
WARNING: Fire hazard Warning of materials that may ignite in the presence of an
PROHIBITED: No smoking In the environment described / during the work specified,
PROHIBITED: No fire or naked light Fire and naked light are ignition sources that must be
PROHIBITED: Do not activate/start up The equipment shall not be activated or started up while work
Seite/Page 10 - Kaptitel/Chapter 1: General Instruct ions and Regulations 30.10.12
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General Instructions and Regulations
prohibited.
draws attention to special warnings, instructions or
procedures which, if not strictly observed, may result in
severe personal injury or loss of life due to electric shock.
PROHIBITED: Do not touch Touching of the corresponding parts and systems is
DANGER: Automatic start-up An external signal may trigger an automatic start-up.
WARNING: Hazardous electric voltage This danger symbol refers to the danger of electric shock and
Can cause acute or chronic health impairments or death
even in very small quantities if inhaled or ingested.
contact. Especially dangerous for persons with heart
problems or pacemakers.
WARNING: General warning General warning of a hazard area
WARNING: Danger due to inhalation and/or
ingestion
WARNING: Risk of electric shock upon contactWarning of live parts that may cause electric shock upon
WARNING: Danger due to rotating parts Danger of injury due to being pulled into equipment. Bruising
and torn off body p art s possible. Risk of b eing pulled i n when
touching with body part, loose-fitting clothing, scarf, tie, etc.
30.10.12 Kapitel/Chapter 1: General Instructions and Regulations - Seite/Page 11
Page 12
certain conditions, e.g. presence of heat or ignition sources.
General Instructions and Regulations
WARNING: Explosion hazard Warning of substances that may cause an explosion under
WARNING: Hot surface Warning of hot surfaces and liquids. Burn/scalding hazard.
Warning of substances that cause chemical burns upon
contact. These substances can act as contaminants if
introduced into the body.
abruptly and expel hot gases and fluids. Risk of injury due to
parts flying about, burn hazard due to liquids and gases.
WARNING: Danger due to corrosive substances,
potential contamination of person
WARNING: System may be pressurised! When the system is opened, the pressure can be relieved
WARNING: Hearing damage
WARNING: Magnetic field
WARNING: Overpressure
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General Instructions and Regulations
Wearing the applicable snugly fitting protective clothing
provides protection from hazards and can prevent damage to
your health.
Wearing hearing protection provides protection from acute
and gradual hearing loss.
Wearing safety goggles protects the eyes from damage.
Optical spectacles are not a replacement for the
corresponding safety goggles.
MANDATORY INSTRUCTION: Wear snugly fitting
protective clothing (PPE).
MANDATORY INSTRUCTION: Wear hearing
protection (PPE).
MANDATORY INSTRUCTION: Wear safety
goggles (PPE).
Wearing protective gloves provides the hands from hazards
like friction, graze, punctures or deep cuts and protects them
from contact with hot surfaces.
Compliance with the instructions in the manual can avert
danger and prevent accidents. This will protect you and the
generator.
Environmental protection saves our living environment. For
you and for your children.
MANDATORY INSTRUCTION: Wear protective
gloves (PPE).
MANDATORY INSTRUCTION: Observe the
instructions in the manual.
MANDATORY INSTRUCTION: Comply with
environmental protection requirements.
30.10.12 Kapitel/Chapter 1: General Instructions and Regulations - Seite/Page 13
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General Instructions and Regulations
1.2 Tools
These symbols are used throughout this manual to show which tool must be used for maintenance or installation.
Spanners
W.A.F X = width across flats of X mm
Hook wrench for oil filter
Screw driver, for slotted head screws and for Phillips head screws
Multimeter, multimeter with capacitor measuring unit
Socket wrench set
Hexagon socket wrench set
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Page 15
General Instructions and Regulations
Clamp-on ammeter (DC for synchronous generators; AC for asynchronous
generators)
Torque wrench
30.10.12 Kapitel/Chapter 1: General Instructions and Regulations - Seite/Page 15
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General Instructions and Regulations
1.3 Manufacturer declaration in accordance with the Machinery Directive
98/37/EC
Manufacturer declaration in accordance with the Machinery Directive 98/37/EC
The generator was designed in such a way that all assemblies correspond with the CE guidelines. If Machinery
Directive 98/37/EC is applied, then it is forbidden to start the generator until it has been ascertained that the system
into which the generator is to be integrated also complies wit h the Mach inery Directive 98/37/EC. This includes the
exhaust system, cooling system and electrical installations.
The evaluation of „protection agai nst contact“ must be carried out when installed, in conjunction with the respective
system. This also includes correct electrical connections, a safe ground wire connection, foreign body and humidity
protection, protection against moisture due to excessive condensation, as well as overheating through appropriate
and inappropriate use of the equipment in its installed state. The responsibility for implementing these measures lies
with those who undertake the installation of the generator in the final system.
1.4 Customer registration and guarantee
Use the advantages of registering your product:
• you will receive a Guarantee Certificate after approval of your installation data
• you will receive extended product information that may be relevant to safety.
• You will receive free upgrades as necessary.
Additional advantages:
Based on your complete data record, Fischer Panda technicians can provide you with fast assistance, since 90% of
the disturbances result from defects in the periphery.
Problems due to installation errors can be recognized in advance.
1.4.1 Technical support
Technical Support via the Internet: [email protected]
1.4.2 Caution, important information for start-up!
1. The commissioning log shall be filled in immediately after initial operation and shall be confirmed by signature.
2. The commissioning log must be received by Fischer Panda GmbH at Paderborn within 4 weeks of initial
operation.
3. After receiving the commissioning log, Fischer Panda will make out the official guarantee certificate and send it to
the customer.
4. If warranty claims are made, the document with the guarantee certification must be submitted.
If the above requirements are not or only partly fulfilled, the warranty claim shall become void.
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General Instructions and Regulations
1.5 Safety Instructions - Safety First!
1.5.1 Safe operation
Careful handling of the equipment is the best insurance against an accident. Read the manual
diligently, and make sure you understand it before starting up the equipment. All operators,
regardless of their experience level, shall read this manual and additional pertinent manuals before
commissioning the equipment or installing an attachment. The owner shall be responsible for
ensuring that all operators receive this information and are instructed on safe handling practices.
1.5.2 Observe safety instructions!
Read and understand this manual and the safety instructions on the generator before trying to start up and operate
the generator. Learn the operating practices and ensure work safety. Familiarise yourself with the equipment and its
limits. Keep the generator in good condition.
1.5.3 Personal protective clothing (PPE)
For maintenance and repair work on the equipment, do not wear loose, torn, or ill-fitting clothing
that may catch on protruding parts or come into contact with pulleys, cooling disks, or other rotating
parts, which can cause severe injury.
Wear appropriate safety and protective clothing during work.
Do not operate the generator while under the influence of alcohol, medications, or drugs.
Do not wear head phones or ear buds while operating, servicing, or repairing the equipment.
1.5.4 Cleanliness ensures safety
Keep the generator and its environment clean.
Before cleaning the generator, shut down the equipment and secure it against accidental start-up.
Keep the generator free from dirt, grease, and waste. Store flammable liquids in suitable
containers only and ensure adequate distance to the generator. Check the lines regularly for
leakage and eliminate leaks immediately as applicable.
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General Instructions and Regulations
1.5.5 Safe handling of fuels and lubricants
Keep fuels and lubricants away from naked fire.
Before filling up the tank and/or applying lubricant, always shut down the generator and secure it
against accidental start-up.
Do not smoke and avoid naked flame and sparking near fuels and the generator. Fuel is highly
flammable and may explode under certain conditions.
Refuel in well-ventilated open spaces only. If fuel/lubricant was spilled, eliminate fluids
immediately.
Do not mix diesel fuel with petrol or alcohol. Such a mixture can cause fire and will damage the
generator.
Use only approved fuel containers and ta nk syst ems. Old bottle s and can iste rs ar e not a deq uate.
1.5.6 Exhaust fumes and fire protection
Engine fumes can be hazardous to your health if they accumulate. Ensure that the generator
exhaust fumes are vented appropriately (leak-proof system), and that an adequate fresh air
supply is available for the generator and the operator (forced ventilation).
Check the system regularly for leakage and eliminate leaks as applicable.
Exhaust gases and parts containing such fumes are very hot; they may cause burns under
certain circumstances. Always keep flamma ble parts away from the generato r and the exhaust
system.
To prevent fire, ensure that electrical connections are not short-circuited. Check regularly that all
lines and cables are in good condition and that there is no chafing. Bare wires, open chafing spots,
frayed insulation, and loose cable connections can cause dangerous electric shocks, short-circuit,
and fire.
The generator shall be integrated in the existing fire safety system by the operating company.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer, birth defects, and other reproductive harm.
Exhaust gases from diesel motors and some components are carcinogenic and can cause
deformities and other genetic defects.
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General Instructions and Regulations
1.5.7 Safety precautions against burns and battery explosio ns
The generator and its cooling agents and lubricants as well as the fuel can get hot while the
generator is operated. Use caution around hot components such as parts containing exhaust
fumes, radiator, hoses, and engine block during operation and after the generator was shut
down.
The cooling system may be pressurised. Open the cooling system only after letting the engine
and the coolant cool down. Wear appropriate protective clothing (e.g.safety goggles, gloves).
Prior to operation, ensure that the cooling system is sealed and that all hose clamps are
tightened.
The battery represents an explosion hazard, this applies both to the starter battery and the
battery bank of the AGT generators. While batteries are being charged, a hydrogen-oxygen
mixture is generated, which is highly explosive (electrolytic gas).
Do not use or charge batteries if the fluid level is below the MINIMUM marking. The life span of
the battery is significantly reduced, and the risk of explosion increases. Refill to a fluid level
between maximum and minimum level without delay.
Especially during charging, keep sparks and naked fire away from the batteries. Ensure that the
battery terminals are tightly connected and not corroded to avoid sparking. Use an appropriate
terminal grease.
Check the charge level with an adequate voltmeter or acid siphon. Contact of a metal object
across the terminals will result in short-circuiting, battery damage, and high explosion risk.
Do not charge frozen batteries. Heat the batteries to +16 °C (61 °F) prior to charging.
1.5.8 Protect your hands and body from rotating parts!
Always keep the capsule closed while operating the generator.
To check the V-belt tension, always shut down the generator.
Keep your hands and body away from rotating parts such as V-belt, fans, pulleys, and flywheel.
Contact can cause severe injury.
Do not run the engine without the safety devices in place. Prior to start-up, mount all safety
devices securely and check for proper attachment and function.
1.5.9 Anti-freeze and disposal of fluids
Anti-freeze contains toxic substances. To prevent injury, wear rubber gloves and wash off any
anti-freeze immediately in case of skin contact. Do not mix different anti-freeze agents. The
mixture may cause a chemical reaction generating harmful substances. Use only anti-freeze that
was approved by Fischer Panda.
Protect the environment. Collect drained fluids (lubricants, anti-freeze, fuel), and dispose of them
properly. Observe the local regulations for the respective country. Ensure that no fluids (not even
very small quantities) can drain into the soil, sewers, or bo die s of wate r.
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General Instructions and Regulations
1.5.10 Implementation of safety inspections and maintenance
Disconnect the battery from the engine before performing service work. Affix a sign to the control
panel - both the main and the corresponding slave p anel - with the instruction „ DO NOT START UP
- MAINTENANCE IN PROGRESS“ to prevent unintentio n al start-up.
To prevent sparking due to accidental short-circuiting, always remove the earthing cable (-) first and
reconnect it last. Do not start work until the generator and all fluids and exhaust system parts have
cooled down.
Use only suitable tooling and appliances and familiarise yourself with their functions to prevent
secondary damage and/or injury.
Always keep a fire extinguisher and a first aid box handy while performing maintenance work.
1.6 Warning and instruction signs
Keep warning and instruction signs clean and legible.
Clean the signs with water and soap and dry them with a soft cloth.
Immediately replace damaged or missing warning and instruction signs. This also applies to the installation of spare
parts.
1.6.1 Special instructions and hazards of generators
The electrical installations may only be carried out by trained and qualified personnel!
The generator must not be operated with the cover removed.
If the generator is being installed without a sound insulation capsule, it must be ensured that all
rotating parts (belt-pulley, belts etc.) are covered and protected so that there is no danger to life
and body!
If a sound insulation covering will be produced at the place of installation, then easily visible signs
must show that the generator must only be switched on while the capsule is closed.
All servicing, maintenance, or repair work may only be carried out when the motor is not running.
Electrical voltages above 48 volts (battery chargers greater than 36 volts) are always dangerous
to life. The rules of the respective regional authority must be adhered to during installation. For
safety reasons, only an electrician may carry out the installation of the electrical connections of
the generator.
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General Instructions and Regulations
1.6.1.1 Protective conductor and potential equalisation:
Electric current below 48 V may be life-threatening. Fort this reason systems are grounde d with a prote ctive
conductor. In connection with a RCD the current supply will be disconnected in case of a failure.
Appropriate safety precautions like the RCD and corresponding fuses have to be provided by the customer
to guarantee a save operation of the generator.
1.6.1.2 Protective conductor for Panda AC generators:
The generator is „earthed“ as a standard (centre and ground are interconnected in the generator
terminal box by a shunt). This is a basic first-level safety measure, which offers protection as long
as no other measures are installed. Above all, it is designed for delivery and a possible test run.
This „neutralisation“ (Protective Earthing Neutral - PEN) is only effective if all parts of the electrical
system are jointly „earthed“ to a common potential. The shunt can be removed if this is necessary
for technical reasons and another protective system has been set up instead.
While the generator is being operated, the full voltage is applied to the AC control box, as
well. Therefore, it is essential to ensure that the control box is closed and secured against
touch while the generator is running.
The battery must always be disconnected if work on the generator or electrical system is to
be carried out, so that the generator cannot be started up unintentionally.
1.6.1.3 Switch off all loads while working on the generator
All loads must be disconnected prior to working on the generator to avoid damage to the devices. In addition, the
semiconductor relays in the AC control box must be disconnected in order to avoid the booster capacitors being
activated during set-up. The negative te rminal of the battery must be disconnected.
Capacitors are required to run the generator. These have two varying functions:
A) The working capacitors
B) The booster capacitors
Both groups are located in a separate AC control box.
Capacitors store electrical energy. High voltages may remain across the capacitor contacts even after they have
been disconnected from the mains. As a safety precaution, do not touch the contacts. If the capacitors must be
replaced or inspected, the contacts shall be short-circuited by connecting an electrical conductor to discharge
potentially remaining potential differences.
If the generator is switched off normally, the working capacitors are automatic ally discharged vi a the winding of the
generator. The booster capacitors are discharged by means of internal discharge resistors.
For safety reasons, all capacitors must be discharged through short-circuiting before work is carried out on the AC
control box.
1.6.1.4 Potential equalisation for Panda AGT DC generators
For further information specific to your generator, see the chapter installation.
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General Instructions and Regulations
1.6.1.5 Safety instructions concerning cables
Cable types
It is recommended to use cables that are in compliance with the standard UL 1426 (BC-5W2) with type 3 (ABYC
section E-11).
Cable cross-section
The cable shall be selected taking into account the amperage, cable type, and conductor length (from the positive
power source connection to the electrical device and back to the negative power source conn ection).
Cable installation
It is recommended to install a self-draining cable conduit classified as V-2 or higher in compliance with UL 94 in the
area of the cable guide inside the capsule. It must be ensured that the cable guide is not routed along hot surfaces
such as the exhaust manifold or the engine oil drain screw but instead is installed free from any influence due to
friction and crushing.
1.6.2 Recommended starter battery sizes
Use only batteries approved by the manufacturer as starter batteries.
Use the battery capacity recommended by the engine manufacturer.
ATTENTION!
Prior to installation, verify that the voltage of the starter battery complies with the start-up system
voltage.
e.g. 12 V starter battery for 12 V start-up system
e.g. 24 V starter battery for 24 V start-up system (e. g. 2x 12 V in series)
1.6.3 Important instructions for batteries - starter and/or traction batteries
ATTENTION!!! Start-up:
Installation of battery connection lines.
Observe the instructions installation guidelines of the battery manufacturer.
Observe the regulations „ABYC regulation E11 AC and DC electrical systems on boats“, as EN
ISO 10133:2000 „Small craft -- Electrical systems -- Extra-low-voltage DC installations“, as
applicable!
The battery compartment and the corresponding installation shall be dimensioned
adequately.
The batteries can be separated mechanically or with an adequate power relay.
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General Instructions and Regulations
Observe the applicable instructions concerning fire and explosion protection of the battery
manufacturer.
Install a fuse of appropriate size in the positive connection of the st arter batter y. Install as close to
the battery as possible but with a max. distance of 300 mm (12 in) fro m th e ba tte ry.
The cable from the battery to the fuse shall be protected with a conduit/protective sleeve against
fraying.
Use self-extinguishing and fire-protected cables for installation that are designed for max. temperatures of 90 °C,
195 °F.
Install the battery cables in such a way that the insulation cannot be removed by chafing or other mechanical
stresses.
The battery terminals must be protected against accidental short-circuiting.
Inside the Fischer Panda generator capsule, the positive battery cable must be routed so that it is protected from
heat and vibrations by means of an adequate conduit/protective sleeve. It must be installed so that it does not come
into contact with rotating parts or such that heat up during operation such as pulley, exhaust manifold, exhaust pipe,
and motor itself. Do not overtighten the cable, as it may be damaged otherwise.
After completing the installation, perform a test run of the generator and check the battery cable installation during
and after the test run. Implement corrections as necessary.
Fig. 1.6-1: Sample diagram for starter battery installation
1.6.4 General safety instructions for handling batteries
These instructions shall apply in addition to the instructions of the battery manufacturer:
• While you are working on the batteries, a second person should be within earshot to help you if
necessary.
• Keep water and soap ready in case battery acid is burning your skin.
• Wear ey e pr otection and protective clothing. Do not touch you r ey es while ha nd lin g ba tte r ies.
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General Instructions and Regulations
• If you have acid splashes on the skin or clothing, wash them out with lots of water and soap.
• If acid sprays into your eyes, immediately flush them with clean water until no more burning is
felt. Immediately seek medical assistance.
• Do not smoke near the batteries. Avoid naked fire. The area around batteries is a potentially
explosive atmosphere.
• Ensure that no tools are dropped on the battery terminals; cover them as necessary.
• Do not wear jewellery or watches on your arms during installation that might short-circuit the
battery. Otherwise, there is a risk of skin burns.
• Protect all battery contacts against accidental contact.
• For battery banks: Use only deep cycle batteries. Starter batteries are not suitable. Lead-acid
gel batteries are recommended. They are maintenance-free, cycle stable, and do not release
gases.
• Never charge a frozen battery.
• Avoid battery short-circuits.
• Ensure proper ventilation of the battery to vent gases that may be released.
• Battery connection terminals must be checked for proper seating before operation.
• Battery connection cables shall be installed with utmost care and shall b e checked for excessive
heating under load. Check the battery near vibrating components regularly for chafing and
insulation defects.
ATTENTION! For battery charger generators (Fischer Panda AGT- DC)!
Prior to installation, verify that the voltage of the ba ttery bank complies with the output
voltage of the generator.
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Page 25
In case of Emergency First Aid / Im Notfall -
11
1
2
1
3
1
4
1
5
Erste Hilfe
2. In case of Emergency First Aid / Im Notfall - Erste Hilfe
First Aid in case of accidents by electrical shocks
5 Safety steps to follow if someone is the victim of electrical shock
Do not touch the injured person while the generator is running.
Switch off the generator immediately.
If you cannot switch off the generator, pull, push, or lift the person to safety using a
wooden pole, rope or some nonconducting material.
Call an emergency doctor as soon as possible.
Immediately start necessary first aid procedures.
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Page 26
2.7 WHEN AN ADULT STOPS BREATHING
Warning:DO NOT attempt to perform the rescue breathing
techniques provided on this page, unless certified.
Performance of these techniques by uncertified
personnel could result in further injury or death to the
victim.
In case of Emergency First Aid / Im Notfall -
Erste Hilfe
Does the Person Respond?
1
Tap or gently shake victim.
Shout, „Are you OK?“
Roll Person onto Back.
3
Roll victim towards you by pulling slowly.
Open Airway.
4
Tilt head back, and lift chin.
Shout, „Are you OK?“
Give 2 Full Breaths.
6
Keep head tilted back.
Pinch nose shut.
Seal your lips tight around victim's mouth.
Give 2 full breaths for 1 to 1½ seconds each.
Shout, „Help!“
2
Call people who can phone for help.
Check for Breathing.
5
Look, listen, and feel for breathing for 3 to 5
seconds.
Check for Pulse at side of Neck.
7
Feel for pulse for 5 to 10 seconds.
Begin Rescue Breathing.
9
Keep head tilted back.
Lift chin.
Pinch nose shut.
Give 1 full breath every 5 seconds.
Look, listen, and feel for breathing between breaths.
Phone EMS for Help.
8
Send someone to call an ambulance.
Recheck Pulse Every Minute.
10
Keep head tilted back.
Feel for pulse for 5 to 10 seconds.
If victim has pulse, not breathing, continue
rescue breathing. If no pulse, begin CPR.
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Page 27
Basics
3. Basics
3.1 Intended use of the machine
The Fischer Panda generator is made to produce electrical energy out of diesel fuel.
The diesel fuel is converted to mechanical energy by the diesel engine. This mechanical energy drives the genera-
tor. In the genset, the mechanical energy is converted to electrical energy. This process is controlled by (sometimes
external) components, the remote control panel and the VCS (voltage control system).
Sufficient amount of fuel and combustion air is necessary for this process. Arising exhaust and heat must be conducted according to the specification.
If the electrical power is fed to a local net, the regulations and installation instructions of the system operator and the
regional authorities with reference to the power network/shipboard power supply system must be respected. Safety
applications and safety devices (including lightening conduc tor, personal protection switch, ect.) have to be installed.
Misapplication of the product can damage and destroy the product and the electrical net inclusive all load which is
attached to the net, and contain hazards like short circuit, ect. It is not allowed to modify the product in any ca se.
Never open the sound cover during operation! The safety and hazard notes of the manual must be respected !
3.2 Purpose of the manual and description of the definitions of the trained persons/operators/users
This manual contains the working instructions and operating guidelines for the owner and user of Fischer Panda
generators.
The manual is the base and the guideline for the correct installation and maintenance of Fischer Panda generators.
It does not substitute the technical evaluation and should be used as an example guide only. The installation must
be undertaken and proved by a suitable qualified/trained person and should be in accordance with the law as
required by the country and special situation. All work has to be undertaken a cco rd ing to the state of the technology.
3.2.1 Trained persons
Qualified persons for the mechanical components are motor mechanics or persons with similar qualification and training.
Trained persons for the electrical components are electricians or persons with similar qualification and training.
After the installation the trained person has to instruct the ow ner about the op eration and m aintenan ce of the generator. This must include the hazards of the generator use.
3.2.2 Operator
The operator is responsible for the operation of the generator.
After the installation, the operator must be instructed concerning the operation and maintenance of the generator.
This has to include the hazards during operation of the generator, different operating conditions, and instructions for
the maintenance.
The operator must read and follow the manual and must respect the hazard notes and safe ty instructions.
3.2.3 User
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Basics
Users are persons, established by the operator, to operate the generator.
The operator has to ensure that the user has read and understood the manual and that all hazard notes and safety
instructions are respected. The user must be instructed by the operator regarding his activity at the generator, especially concerning the maintenance.
3.3 Components of the i system
Fig. 3.3-1: Panda i generator1. Panda i PMS Generator
Permanent-Magnet-Generator
representative picture
tor
representative picture
representative picture
Fig. 3.3-2: iControl panel2. Panel Panda iControl with electronic board at the genera-
Fig. 3.3-3: PMGi inverter3. Panda PMGi Inverter AC/AC
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Page 29
Basics
The Fischer Panda manual comprises the following components:
a.- Transparent envelope with general information, war-
ranty terms, installation certificates, and service list.
b.- Generator manual
c.- Spare parts catalogue „Installation & Service Guide“
d.- Engine manual from the engine manufacturer
e.- Generator circuit diagram
representative picture
3.4 Range of operation
Fig. 3.3-4: Manual4. Fischer Panda manual
Reliable power supply on sailing boats.
3.5 Panda transport box
3.5.1 Bolted Fischer Panda transport box
1. Remove the bolts for cover / sidewalls
2. Remove the cover
3. Remove the loose accessories
4. Remove the bolts for sidewalls / floor pallet
5. Remove the sidewalls
6. Open the generator attachment
3.5.2 Fischer Panda transport box with metal tab closure
1. Bend up the metal tab closures on the tr ansport box lid
2. Remove the cover
3. Remove the loose
4. Bend open the metal tab closures at the bottom of the transport box
5. Remove the sidewalls
6. Open the generator attachment
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3.6 Opening the MPL sound insulation capsule
be rotated roughly 180° counter-clockwise. Use a flat
head screwdriver . Pull th e sidewalls out by g rip ping into
the slots.
Basics
Fig. 3.6-1: Sound insulation capsule, side partT o open the sound insulation cap sule, the clo sures must
Fig. 3.6-2: Closure lockedClosure locked
Fig. 3.6-3: Closure openClosure open
3.6.1 Opening the GFK sound insulation capsule
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Basics
tion and lift the lash of the closure pin. Af ter lif ting off the
lashes, the sound isolation cover upper part can be
removed.
Fig. 3.6-1: Lash closuresGFK sound insulation capsule with lash closures
Fig. 3.6-2: Lash closuresTo open the lash closures pull the handle in arrow direc-
3.7 Transport and Loading/Unloading
3.7.1 Transporting the generator
• The generator must always be upright for transport.
• For transport, the Fischer Panda transport box shall be used for the generator. The generator shall be se cu re ly at tached to the bottom of the box.
• For loading/unloading, an adequate industrial truck shall be used.
• Depending on the transport distance (e.g. air cargo), the generator fluids (coolant, engine oil, fuel) may have to be
drained. The corresponding instructions and warnings must be fitted to the transport packaging.
3.7.2 Loading/unloading of the generator
For loading/unloading the generator, appropriate ring eye bolts shall be installed in the holes in the support ra ils. The
load bearing capacity of each ring eye bolt must at least equal the generator weight.
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Fig. 3.7-1: Lifting yoke (example)An adequate lifting yoke shall be used for transport/
loading
3.8 Special Service Instructions and Measures for Extended Machine Downtimes and Decommissioning
Basics
Note: The decommissioning and storage mu st be un de rtaken and
proved regarding the operation and storage situation.
Fischer Panda takes no responsibilty for damages
through wrong decommissioning and storage.
Downtimes are categorised in the following groups:
• Short downtime (1 to 3 months)
• Medium term downtime / hibernation (3 to 6 months)
• Extended downtime / decommissioning (more than 6 months)
3.8.1 Instructions for the starter battery for extended downtimes
Note: Information starter batteryStarter batteries
Self-discharge of batteries is a physical and chemical process and cannot be avoided even if the battery is disconnected
• For extended downtimes, the battery shall be disconnected from the genset.
• Charge battery regularly. Observe instructions of the battery manufacturer.
Depending on the battery type, check the acid level before charging and refill each cell up to the marking using
distilled water as necessary.
Modern starter batteries are typically maintenance-free.
Deep discharge will damage the battery and can render it unusable.
Keep battery clean and dry. Clean battery poles (+ and -) and terminals regularly and coat with acid-free and acidresistant grease. During assembly, ensure good contact of the terminal connections.
General limits for lead-acid batteries:
2.1 V / cell corresponds with full battery (charged).
1.95 V / cell corresponds with empty battery - recharge.
For a 12 V battery, the following applies:
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Basics
- 11.7 V lower open-circuit voltage (battery empty), recharge battery.
- 12.6 V upper open-circuit voltage (full battery) - trickle charge full battery at 13.2 V.
For a 24 V battery, the following applies:
- 23.4 V lower open-circuit voltage (battery empty), recharge battery.
- 25.2 V upper open-circuit voltage (full battery) - trickle charge full battery at 26.4 V.
These values are based on a battery temperature of 20-25°C. Observe the instructions from the battery manufacturer.
Note: Starter battery recommendationFischer Panda recommends:
• Install battery circuit breaker and switch to OFF on the machine. (Cutting the battery circuit.)
• Secure the battery plus terminal close to the battery.
• Regularly check contacts for corrosion.
3.8.2 Measures for short downtimes
Short downtime (1 to 3 months)
• Measure battery charge status based on open-circuit voltage.
• During downtimes >7 days, disconnect battery (e.g. battery main switch to position 0).
• Check the battery within 2 months and allow the engine to warm up for min. 10 min.
3.8.3 Measures for medium term downtimes / hibernation
Medium term downtimes (3 to 6 months)
3.8.3.1 Courses for preservation:
• Check battery charge status and recharge regularly, roughly every 2 months, as necessary. Observe instructions
of the battery manufacturer.
• Check cooling water anti-freeze level and refill as necessary.
The anti-freeze agent must not be older than 2 years. The anti-free ze content shall be betwe en 40 % and 60 % to
ensure corrosion protection of the cooling wa ter ci rcu it. Top off coolant if necessary.
If the cooling water is drained, e.g. after engine surface protec tion is applied, no water may remain inside the
engine during the downtime. The control unit must be marked accordingly with a note specifying „NO COOLING
WATER“.
• Drain engine oil as specified. Refill engine with preservative oil to the max. level on the oil dipstick.
• Drain diesel from tank and refill with a protective mixture (90 % diesel and 10 % preservative oil) (level to full).
Crank engine without start.
• Dismount V-belt as specified, wrap and store in a dry location. Protect against UV radiation.
Attention! Cover alternator apertures.
Cleaning fluids and preservatives must not enter the alternator. Risk of destroying the alternator.
• Clean engine as per manufacturer's instructions.
• Spray engine parts and V-belt disks with preservative.
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Page 34
• Clean air filter housing and spray with preservative (metal housing only).
• Close off intake and exhaust apertures (e.g. with tape or end caps).
Attention! Before recommissioning, remove preservative s and pro-
tective measures.
3.8.3.2 Measures for removing surface protection after medium term downtimes (3 to 6 months).
• Check battery charge status and recharge if necessary. Observe instructions of the battery manufacturer.
• Check cooling water anti-freeze level and cooling water level and refill as necessary.
• Drain engine oil. Replace oil filter and engine oil as per the specification.
• Remove preservatives from the engine with petroleum spirit.
• Degrease V-belt disks and mount V-belt according to instructions. Check V-belt tension!
Basics
• If applicable, open turbocharger oil pressure line and fill clean engine oil into channel.
• Hold engine stop lever in zero delivery position and crank engine manually several times.
• Clean air filter housing with petroleum spirit, check air filter and replace if necessary.
• Remove covers from exhaust aperture and intake apertures.
• Connect battery. Close battery main switch.
• Hold stop lever on generator motor in neutral position and crank starter for approx. 10 seconds. Then, pause for 10
seconds. Repeat this procedure 2 times.
• Perform visual check of the generator similar to initial commissioning and start up generator.
3.8.4 Measures for extended downtimes / decommissioning
Downtimes (more than 6 months)
3.8.4.1 Courses for preservation:
• Check battery charge status and recharge regularly, roughly every 3 months, as necessary. Observe instructions
of the battery manufacturer.
• Check cooling water anti-freeze level and refill as necessary.
The anti-freeze agent must not be older than 2 years. The anti-freeze conte nt shall be between 40 % and 60 % to
ensure corrosion protection of the cooling water circuit. Top off coolant if necessary.
If the cooling water is drained, e.g. after engine surface protection is applied, no water may remain inside the
engine during the downtime. The control unit must be marked accordingly with a note specifying „NO COOLING
WATER“.
• Drain engine oil as specified. Refill engine with preservative oil to the max. level on the oil dipstick.
• Drain diesel from tank and refill with a protective mixture (90 % diesel and 10 % preservative oil) (level to full).
Crank engine without start.
• Dismount V-belt as specified, wrap and store in a dry location. Protect against UV radiation.
• Disconnect battery. Coat terminals with acid-free grease.
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Basics
Attention! Cover alternator apertures.
Cleaning fluids and preservatives must not enter the alternator. Risk of destroying the alternator.
• Clean engine as per manufacturer's instructions.
• Spray engine parts and V-belt disks with preservative.
• Clean air filter housing and spray with preservative (metal housing only).
• Spray preservative on intake and exhaust side of exhaust tu rbocharger (where applicable) an d reconnect the lines.
• Remove valve cover and spray inside of valve cover, valve stems, springs, rocker, etc. with preservative oil.
• Remove injection nozzle and coat cylinder surface with preservative oil. Hold stop lever in zero delivery position
and crank engine manually several times. Refit injection nozzles with new seals (at an operation hour of min. 100
hours after the last change). Observe torque values.
• Spray radiator cover and tank cover or radiator cover on expansion tank lightly with preservative oil and refit.
• Close off intake and exhaust apertures (e.g. with tape or end caps).
Note: For storage for more than 12 months, the preservation
measures shall be checked annually and supplemented
as necessary.
Attention! Before recommissioning, remove preservatives and protective measures.
3.8.4.2 Measures for removing surface protection after extended downtimes / recommis-
sioning (over 6 months):
• Check battery charge status and recharge if necessary. Observe instructions of the battery manufacturer.
• Check cooling water anti-freez e level and cooling water level and refill as necessary.
• Drain en g ine oil. Rep lac e oil filte r an d oil as per th e sp ecif ica tio n.
• Remove preservatives from the engine with petroleum spirit.
• Degrease V-belt disks and mount V-belt according to instructions. Check V-belt tension!
• If applicable, open turbocharger oil pressure line and fill clean engine oil into channel.
• Hold engine stop lever in zero delivery position and crank engine manually several times.
• Clean air filter housing with petroleum spirit, check air filter and replace if necessary.
• Remove covers from exhaust aperture and intake apertures.
• Connect battery. Close battery main switch.
• Hold stop lever on generator motor in neutral position and crank starter for approx. 10 seconds. Then, pause for 10
seconds. Repeat this procedure 2 times.
• Perform visual check of the generator similar to initial commissioning and start up generator.
Note: Fischer Panda recommends:
After extended downtimes, a full 150 h inspection as per the
inspection list should be performed.
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Basics
Leere Seite / Intentionally blank
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The Panda Generator
4. The Panda Generator
4.1 Type plate at the Generator
Fig. 4.1-1: Type plate
Fig. 4.1-2: Discription type plate
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Page 38
4.2 Description of the Generator
01
02
06
12
13
03
04
05
07
08
14
09
10
11
01. Watercooled silencer
02. Venting screw at the silencer
03. Combustion air intake
04. Air filter housing with filter
05. Protective resistor for thermoswitch 75°C/70°C
06. Starter
07. Actuator
08. iControl elektronic board „DO NOT OPEN - Danger to life“
09. Electric fuse (white=25A; green=30A;
10. Fuel solonoid
11. Oil filler cap
12. Oil dip stick
13. Ground connection point
14. Sound cover base part
4.2.1 Front view
Fig. 4.2.1-1: Frant view
The Panda Generator
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The Panda Generator
01
02
05
09
03
04
10
06
07
08
01. Generator housing with stator winding
02. Generator housing front cover
03: Ventilation screw at cylinder head
04. Connection point for external expansion tank
05. Sound cover base part
06. Cooling water intake (cold side)
07. Watercooled exhaust elbow
08. Compensator under heat isolation
09. Cooling water out (hot side)
10. Exhaust out
4.2.2 Rear View
Fig. 4.2.2-1: Rear View
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Page 40
4.2.3 Top view
10
0201 04
11 12 13 14
06
09
03
05
07
08
01. Watercooled pre silencer
02. Compensator under heat isolation
03. Watercooled exhaust elbow
04 Generator housing with stator winding
05 Cooling water pump
06. Thermo switch 75°C/70°C
07. Thermo switch 82°C/77°C
08. Thermo sensor at engine
09. iControl elektronic board „DO NOT OPEN - Danger to life“
10. Venting screw pre silencer
11. Air suction housing
12. Ait filter housing
13. Protective resistor for thermo switch 75°C/70°C
14. Starter motor
The Panda Generator
Fig. 4.2.3-1: Top view
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Page 41
The Panda Generator
03 04
01
02
05
06
07
08
01. iControl elektronic board „DO NOT OPEN - Danger to life“
02. Fuel in connection
03. Fuel out (backflow) connection
04. Battery cable negative (-)
05. Battery cable positive (+)
06. Cable to PMGi 4000
07. Cable to Fuel pump
08. Cable to Panel iControl
4.2.4 Side view right
Fig. 4.2.4-1: Side view rightt
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Page 42
4.3 Details of function units
Ex pansion t ank wit h filler cap
integrated in the Radiator
Radiator
elect. water pump
Engine Kubota EA 300
water co oled
exhaus t elbow
water co oled
pre-silencer
overflow hose
at filler cap
Overpres s ure valve
in the filler cap
´the rm o s e ns o r
at engine
Thermo sens or
at pre-silencer
iControl elektronic board
Thermo switch
at pre si lenc er
"82°C fan fast"
"75°C fan slow"
fan
cold
air
hot
air
cold
side
hot
side
coolan t
4.3.1 Remote control panel see iControl datasheet
4.3.2 Components of the cooling system
Fig. 4.3.2-1: Cooling circiut
The Panda Generator
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The Panda Generator
ext ernal Tank
ext ernal elec . fuelpum p
fuel stop solonoid
fuel injection nozz le
fuel
in
fuel
out
air filter housi ng
engine
Kubot a EA 300
exhaus t elbow
pre-silencer
glow
plug
automat ic venting
filler cap with strainer
injection pump
Fuel filter +
water seperator
fuel in
exhaust
out
combustion
air in
4.3.3 Components of the fuel system
Fig. 4.3.3-1: The fuel system
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Page 44
4.3.4 The combustion air circle
ext ernal Tank
ext ernal elec . fuelpum p
fuel stop solonoid
fuel injection nozz le
fuel
in
fuel
out
air filter housi ng
engine
Kubot a EA 300
exhaus t elbow
pre-silencer
glow
plug
automat ic venting
filler cap with strainer
injection pump
Fuel filter +
water seperator
fuel in
exhaust
out
combustion
air in
The Panda Generator
Fig. 4.3.4-1: The combustion air circle
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Page 45
The Panda Generator
4.3.5 The electrical system
Fig. 4.3.5-1: The electrical system
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Page 46
4.3.6 Thermosensor/switches
1
2
3
1
The Panda Generator
Fig. 4.3.6-1: Thermosensor cylinderheadThermosensor engine
At this point the cooling water has normal the highest temp.
1. Thermosensor
2. 82°C/77°C (Fan fast)
3. 75°C/70°C (Fan slow)
01. The resistor is connected in row with the Thermo switch
75°C/70°C.
Fig. 4.3.6-2: Thermoswitch/sensorThermoswitch/Thermosensor pre silencer
Fig. 4.3.6-3: ResistorResistor
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The Panda Generator
oil filler cap
engine
Kubota EA300
oil strainer
oil dipsti c k
oil
pressure
switch
oil drain hose
iControl electronic board
operator control
oil in
oil
out
Another Thermosensor is build into the winding
4.3.7 The oil circle
Fig. 4.3.6-4: Thermosensor windingWinding- Thermosensor
Fig. 4.3.7-1: The oil circle
4.4 Operation Instructions - see separate control panel manual
4.4.1 Daily routine checks before starting - See iControl manual.
4.4.2 Starting Generator - See iControl manual.
4.4.3 Stopping the Generator - See iControl manual.
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Page 48
The Panda Generator
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5. Generator operation instruction
5.1 Personal requirements
Only instructed persons are allowed to run the generator. Instructed Persons has read the manual of the generator
and all ancillary components and external equipment. He must be acquaint with the specific risks and safety instructions.
Only persons who are expected to perform their tasks reliably are permitted as personnel. Persons whose reaction
capability is impaired, e.g. through drugs, alcohol or medication are not permitted.
When selecting the personnel, the stipulations regarding age and occupation applying at the location must be
observed.
5.2 Hazard notes for the operation
Notice!:Please note the safety first instructions in front of this manual.
automatic start device. This means the generator can be
started by an external signal.
To avoid an unexpected starting of the generator, the starter
battery must be disconnected before start working at the
generator.
Rotating parts inside of the generator
Do not run the generator with removed sound cove r. If it is
necessary to test the generator without sound cover, pay
special attention. Never do this work alone. Do all service,
maintenance and repair with engine stopped.
Danger for Life. Improper handling, operation, installation and
maintenance can result in severe personal injury and/or
material damage.
Electrical voltages above 48 volts (battery chargers greater
than 36 volts) are always dangerous to life). The rules of the
respective regional authority must be adhered to. Only an
electrician may carry out installation of the electrical
connections for safety reasons.
Warning!: Automatic startDanger for life! - The generator can be equipped with a
Attention!: Danger to life
Attention!: Danger to Life - High voltage
5.3 General operating instruction
5.3.1 Operation at low temperatures
The Generator can be started at temperatures down to - 20 °C, therefor the operation fluids like fuel, cooling water,
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Page 50
lubricant oil ect. must be suitable for this temperatures. These should be checked before start. Cold start spray ect.
are not allowed to use, or the warranty will be lost.
5.3.1.1 Pre-heating the diesel motor
Pre.champer diesel engines are equipped with a quick gl ow plug. The maximu m pre glow time sho uld not exceed 20
sec. At 20 °C or more the pre glow time should be about 5-6 sec. Below 20 °C the pre glow time should be
increased,
If the operation fluids have been drained and then filled with
cold weather fluids, always run the generator for 10 minutes to
ensure the new fuel is present throughout the system.
Note:
5.3.1.2 Tips regarding starter battery
Fischer Panda recommends normal starter battery use. If an genset is required for extreme winter conditions, then
the starter battery capacity should b e doubled. It is recommended that the starter battery be regularly charged by a
suitable battery-charging device (i.e., at least every 2 Months). A correctly charged starter battery is necessary for
low temperatures.
5.3.2 Light load operation and engine idle
If an engine is operated on a load less than 25-30% of its rated output, the soot of the generator will be observed
which may give cause for concern. The usual results of this operation are heavier than normal lubricating oil
consumption, and oil leaks from the air and exhaust manifolds. This condition is particularly evident on standby
generator set applications.
5.3.2.1 The soot of the generator is due to the fact that:
The cylinder temperatures are too low to ensure complete burning of all the fuel delivered.
A further result is that of abnormal carbon build -up on the valves, piston crowns and exhaust ports. Fuel dilution of
the lubricating oil will also occur.
5.3.2.2 To prevent the soot of the generator following steps should be observed:
Running on light load should be avoided or reduced to the minimum period.
In a period of 50 operation hours the engine or generator set should be run on full load for four hours, to burn off
accumulations of carbon in the engine and exhaust system. This may require the use of a 'dummy load'. The load
should be built up gradually from 30 % to 100 % within 3 hour s an d ho ld at 100 % for one hour.
5.3.3 Generator load for a longer period and overload
Ensure the generator is not overloaded. Overloading occurs when the electrical load is higher than the generator
can provide. If this occur for a longer period, the engine may be damaged. Overloading may cause rough running,
high oil and fuel consumption, increased emissions.
For a long engine life, the long therm load should not exceed 80 % of the nominal load. Long therm load is the load
over several hours. It is harmless for the generator to deliver full nominal power for 2-3 hours.
The hole conception of the Fischer Panda generator make sure, that the full power operation at extreme condition
will not increase the engine temperatures over. Please note that the emissions of the generator also increase at full
power operation.
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5.3.4 Protection conductor:
The standard Panda generator is grounded. The 3-phase connection (delta) centre point is bridged to earth in the
AC output terminal box (mounted on the generator). This is the initial earth safety point and is sufficient to ensure
safe operation however only as long as no other system is inst alled. This syste m is adapted to enab le test running of
the generator before delivery.
The bridge to ground (PEN) is only effective when all components in the electrical system share a common ground.
The bridge to ground can be removed and reconnected to another ground system if required for other safety standards.
Full voltage connections are mounted in the electrical cabinet. It must be ensured that the electrical cabinet is
secured and closed while the generator is running.
The starter battery cable should be disconnected when work is being done on either the generator or the electrical
system in order to prevent accidental starting of the generator.
5.3.5 Operating control system on the Fischer Panda generator
Fischer Panda generators are equipped with various sensors/temperatures switches. The combustion engine is further equipped with a oil pressure control switch, which switches the motor off, if the oil pressure sinks to a particular
level.
5.4 Instructions for capacitors - not present at all models
CAUTION! Danger to Life - High voltage
Do not touch the capacitor contact terminals!
The generator's electrical system requires two different groups of capacitors:
A) The booster capacitors
B) The operating capacitors
Both types are mounted in the electrical cabinet. (At some models direct on the generator)
Capacitors store an electrical charge. It is p ossible that even af ter they have been disconnecte d stored energy is still
held. Therefore it is essential that the connectors are not touched.
Should it be necessary to check or test the capacitors, they should be shorted out by using an insulated screw driver .
The operating capacitors are automatically discharged when the generator is stopped in the normal way. The
booster capacitors will be discharged through internal resistors.
For safety however, the capacitors have to be discharged (short circuited) prior to carrying out any work on the AC-
Control box.
5.5 Checks before start - see remote control panel data sheet
Note:The instructions and regulations of the remote control panel
data sheet must be respected.
Respect the safety instruction in front of this manual.
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Page 52
5.6 Starting the generator - see remote control panel data sheet
Note:The instructions and regulations of the remote control panel
data sheet must be respected.
Respect the safety instruction in front of this manual.
5.7 Stopping the generator - see remote control panel data sheet
Note:The instructions and regulations of the remote control panel
data sheet must be respected.
Respect the safety instruction in front of this manual.
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Page 53
Installation Instructions
6. Installation Instructions
Attention! All connections (hoses, wires etc) and installation
instructions are designed and suited for “standard”
installation situations.
In situations where Fischer Panda has no detailed
information concerning certain installation requirements
(such as vehicle specifications, maximum vehicle speed -and
all other conditions concerning special operating situations)
the installation instructions should be used as an example
guide only.
The installation must be undertaken and proved by a suitable qualified/trained person and may in accordance with
the law as required by the country and special situation.
Damages caused by faulty or incorrect installation are not covered by the warranty.
6.1 Personal requirements
The described installation must be done by a technical trained person or a Fischer Panda service point.
6.1.1 Hazard notes for the installation
Notice!:see “Safety first!” on Page 10.
Follow the general safety instruction at the front of this manual.
Warning!: Automatic startDanger for life! - The generator can be equipped with a
automatic start device. This means the generator can be
started by an external signal. To avoid an unexpected
starting of the generator, the starter battery must be
disconnected before start working at the generator.
Warning!: Risk of injuryWorking at a running generator can result in severe
personal injury. Therefore before starting work at the
generator:
Make sure that the generator is stopped and the starter
battery is disconnected to guarantee that the generator
cannot be inadvertently started.
Do not run the generator with removed sound isol at ion cover
Warning!: Risk of injuryImproper installation can result in severe personal
injuries or material damage.
• Always undertake installation work when the generator is
switched off.
• Ensure there is sufficient installation clearance before start
working.
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Page 54
• Ensure tidiness and cleanliness at the workplace. Loose
components and tools lying around or on top of each other
are sources of accidents.
• Only perform installation work using commercially available
tools and special tools. incorrect or damaged tools can
result injuries.
sources. Therefore:
• No open flames during work on the generator.
• Do not smoke.
• Remove oil and fuel residues from the generator and floor.
Installation Instructions
-Warning!: Danger of fire Oil and fuel vapours can ignite on contact with ignition
Contact with engine oil, antifreeze and fuel can result in
damage to health. Therefor:
• Avoid skin contact with engine oil, fuel and antifreeze.
• Remove oil and fuel splashes and antifreeze from the skin
immediately.
• Do not inhale oil and fuel vapours.
installation and maintenance can result in severe
personal injury and/or material damage.
Electrical voltages above 48 volts (battery chargers greater
than 36 volts) are always dangerous to life). The rules of the
respective regional authority must be adhered to. Only an
electrician may carry out installation of the electrical
connections for safety reasons.
operation. Risk of severe burns.
Danger!: Danger of poisoning
ATTENTION!: Danger to Life - High voltageDanger for Life. Improper handling, operation,
Warning!: Hot surface/materialGenerator, oil and antifreeze can be hot during/after
During Installation/maintenance personal protective
equipment is required to minimize the health hazards.
Instruction!: Personal protective equipment necessary.
• Protective clothing
• safety boots
• protective gloves
• Ear defender
• safety glasses
Attention!: disconnect all loadDisconnect all load during the work at the generator to
avoid damages at the load.
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Installation Instructions
6.2 Generator instructions
• It is important to pay attention to the fresh air intake.
• Sufficient space must be available below/next to the gene rator, in order to a llow flow of cooling air. (Undersid e and
side: Underneath is not sufficient!)
• The radia t or m ay no t be cove re d .
• Untrained personnel should never open the generator.
6.3 Preparing the base - Placement
Since Panda generators have extremely compact dimensions, they can be installed in tight locations. Attempts are
sometimes made to install them in almost inaccessible places. Please consider that even almost maintenance-free
machinery must still remain accessible at least at the front (drive belt, water pump) and the service-side (actuator,
dipstick). Please also note that in spite of the automatic oil-pressure sensor it is still essential that the oil level has to
be checked regularly.
The generator should not be placed in the proximity of light walls or floors, which can have resonance vibrations
because of airborne sounds. If this should be unavoidable, then it is recommended that this surface is lined with 1
mm lead foil, which will change the mass and the vibration behaviour.
You should avoid fixing the generator on a slippery surface with little mass (i.e.). This acts as an amplifier of airborne
sounds in the most unreasonable cas e. An impr ovem ent can be achieved by reinforcing these surfaces with ribs. In
addition, the breakthroughs, which interrupt these surfaces, should be sawed off. The lining of the surrounding walls
with a heavy layer (i.e lead) and foam additionally improve the conditions.
The generator sucks its air from the surrounding engine room . Therefore it must be ensured that suf ficient ventilation
openings are present, so that the generator cannot overheat.
High temperature of the intake air decline the power of the generator and increases the coolant temperature. Air
temperatures of more than 40 ° C reduce the power by 2 % per temperature rise of 5 ° C. In order to keep 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.
6.3.1 Advice for optimal sound insulation
The convenient base consist s of a stable framework, on which the generator is fastened by mean s of shockmounts. The combustion air can be sucked in unhindered.
Fischer Panda recommend captive shock mount!
Fig. 6.3.1-1: Shock mountShock mount
representative picture
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Page 56
representative picture
Installation Instructions
Fig. 6.3.1-2: Captive shock mountCaptive shock mount
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Installation Instructions
1 2 3 4
5
7
8
9
6
1. Connection fuel IN
2. Connection fuel OUT
3. Cable for fuel pump
4. Cable for iControl panel
5. Oil drain hose
6. Cable for fan
7. Cable for PMGi 6000 inverter
8. Passage for starter battery minus (-)
9. Passage for starter battery plus (+)
6.4 Connections
Sample for the connection at the Fischer Panda generator. See the description of the generator for the original
location.
Fig. 6.4.0-1: Connections - sample
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Page 58
Fig. 6.4.0-2: Connections - sample
1 2 3
4
1. Connection cooling water IN
2. Connection cooling water OUT
3. Connection exhaust OUT
4. Connection to external expansion tank
Installation Instructions
6.5 Fuel system installation
6.5.1 Fischer Panda installation kit - Fuel system
Note:The following additional component s will be required for
the specified installation. You can purchase them as an
installation kit or separately at Fischer Panda.
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Page 59
Installation Instructions
representative picture
Fig. 6.5.1-1: Fuel hoseFuel hose
No return valve
representative picture
Pre filter with water separator
representative picture
Fig. 6.5.1-2: No return valve
Fig. 6.5.1-3: Pre filter with water separator
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Page 60
Alternative Article
representative picture
Installation Instructions
Fig. 6.5.1-4: Pre filter with water separatorPre filter with water separator
Quick connector for fuel lines
representative picture
Hose clamps
representative picture
Fig. 6.5.1-5: Quick connector for fuel lines
Fig. 6.5.1-6: Hose clamps
6.5.2 The following items need to be installed:
• Fuel supply pump (DC)
• Pre-filter with water separator (not part of the delivery)
• Fine particle fuel filter
• Return fuel line to fuel tank (unpressurized)
The external Fuel pump should be installed near the tank
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Installation Instructions
With the Fischer Panda generator is usually supplied an
external, electrical fuel pump (DC). The fuel pump must be
installed close at the fuel tank. The electrical connections is
prepared at the generator.
Some generators (f.e. with Deutz diesel engine) has an engine driven
internal fuel pump. At these generators the electrical fuel pump is optional,.
Fig. 6.5.2-1: electrical fuel pumpElectrical fuel pump
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Installation Instructions
5
2
3
4
1
6
1. Fuel tank
2. external fuel pump
3. external fuel prefilter with water separator
4. Non return valve
5. Fuel fine filter
6. Generator
Fig. 6.5.2-2: Fuel system - schema
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Installation Instructions
At generators with Kubota EA 300 or Farymann engines, the
fine filter is delivered with the generator . This fine filte r should
be installed in the fuel feed line next to the generator.
representative picture
6.5.3 Connection of the fu el lines at the tank
tank at separate connection points.Lead the return fuel pipe
connected to the day tank to the floor
Fig. 6.5.2-3: externer FeinfilterExternal fine filter
Note:General fuel feed and return line must be connected to the
Connection of the return pipe to the ta nk
The return pipe connected to the tank must be dropped to the same depth as the suction pipe, if the generator is
mounted higher than the tank, in order to prevent fuel running back into the tank after the motor has been switched
off, which can lead to enormous problems, if the generator is switched off for a long period.
Non-return valve in the suction pipe
A non-return valve must be fitted to the suction pipe, which prevents the fuel flowing back after the generator has
been switched off, if it is not possible to use the return flow pipe as a submerge pipe placed in the tank. The instructions „Bleeding Air from the Fuel System“ must be read after initial operation or after it has stood still for a long
period, in order to preserve the starter battery.
ATTENTION! Non-return valve for the fuel return pipe
If the fuel tank should be installed over the level of the
generator (e.g. daily tank), then a non-return valve must
be installed into the fuel return pipe to guarantee that
through the return pipe no fuel is led into the injection
pump.
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6.5.4 Position of the pre-filter with water separator
separator must be installed outside of the sound insulation
capsule in the fuel system line (not included in the delivery).
representative picture
6.6 Generator DC system installation
Installation Instructions
Fig. 6.5.4-1: Pre-filter with water separatorAdditionally to the standard fine filter a pre-filter with water
The Panda generators from 6000 upwards have their own dynamo to charge a DC starter battery.
It is recommended to install an additional starter battery for the generator.
The generator is then independent from the remaining battery set. This enables you to start the genset at any time
with its own starter battery even if the other batteries are discharged. A further advantage of a separate starter
battery is that it isolates the generator's electric system from the rest of the boat's DC system, i.e. minus pole (-) is
not connected electrically to Earth/Ground.
The generator is then Earth/Ground free.
6.6.1 Connection of the starter battery block
IAn own separate starter battery must be installed for the generator.
The positive cable (+) of the battery is attached directly at the solenoid switch of the starter motor (position 1). The
negative cable (-) of the battery is attached underneath the starter motor at the engine mo un t (po sit ion 2).
NOTE:Panda Generators Panda 6000 and higher normally
provided with an alternator/dynamo to charge the starter
battery. At generators without alternator/dynamo it is
needed to charge the starter battery with an external
battery charger.
ATTENTION!Make sure that the voltage of the starter battery fits to
the start system voltage
f.e. 12 V starter battery for a 12 V start system
f.e. 24 V starter battery for a 24 V start system (2x12 V
batteries in a row)
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Installation Instructions
installed as near as possible to the generator. The
positive terminal of the battery is attached at the red
cable, the negative pole at the blue cable.
NOTE:To avoid large voltage drops the battery should be
It must be guaranteed that first the cables a re atta ched at the
generator and then at the battery.
Battery connection
Attention!: Consider correct connection
sequence
Attention!: Right connection of the battery.
Wrong connection of the battery bank can cause a shortcircuit and fire.
Install an appropriate fuse and a battery ci rcuit breaker in the plus p ole cable of the battery, but with a distance to the
battery of up to 300 mm (12 inch) at maximum.
The cable from the battery to the safety device must be secured with protective pipe/sle eve against chafing through.
For the connection use self-extinguishing and fir e-protected cables, which are appropriate for temperatures up to 90
°C, 195 °F.
The batteries must be installed in such a way that they do not chafe through or other mechanical load can be
stripped.
The battery poles must be secured against unintentional short-circuit.
The positive battery cable within the generator must be shifted in such a way that it is protected against heat and
vibrations by appropriate sleeve/protective pipe. It must be shifted in such a way that it doe s not affect rotary parts or
parts, that become hot in operation, e.g. wheel, exhaust elbow union, tail pipe and the engine. Do not lay the cable
too tautly, since otherwise it could be damaged.
Make a test run after the installation and check the laying of the batteries during the test run and afterwards. If
necessary, correct the laying.
Examine regularly the cable laying and the electrical connections.
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Page 66
The positive (+) battery cable is connected direc tly to th e
1
2
solenoid switch of the starter.
The negative (-) battery cable is connected to the engine
foot.
Installation Instructions
Fig. 6.6.1-1: Positive Battery Cable Positive battery cable
Fig. 6.6.1-2: Negative Battery CableNegative battery cable
Note! The battery negative pole may not be connected
with the boat ground or with the protective grounding of
the 12 V installation!
All Panda generators are equipped with an independent DC
starter motor.
1. Solenoid switch for starter motor
2. Starter motor
Fig. 6.6.1-3: DC Starter MotorDC Starter Motor
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Installation Instructions
1. Generator
2. Battery block
3. Fuse
4. Battery main switch
1. Generator
2. Battery block
3. Fuse
4. Battery main switch
Fig. 6.6.1-4: Connection starterbattery 12V - schema
Fig. 6.6.1-5: Connection starterbattery 24V - schema
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Page 68
6.6.2 How to connect two 12V batteries to a 24V battery bank
Fig. 6.6.2-1: Installation starter batteryThe starter batteries have to be connected in this order:
1. (+) cable of first battery
Fig. 6.6.2-2: Installation starter battery2. (-) cable of second battery
Installation Instructions
Fig. 6.6.2-3: Installation starter battery3. (+) cable of second battery
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Installation Instructions
Disconnect the batteries in in reverse procedure.
Fig. 6.6.2-4: Installation starter batterie4. (-) cable of first battery
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Installation Instructions
1
2
3
4
5
6
7
1. Generator
2. Fuel pump
3. iControl panel
4. Generator output
5. PMGi inverter
6. Starter battery
7. Radiator
6.6.3 Connection of the remote control panel - see separate control panel manual
6.7 Connection of electrical components
Fig. 6.7.0-1: Connection of electrical components - Scheme
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Installation Instructions
2
1
1. Generator 2. External radiator
6.7.1 Connection of the external radiator
Fig. 6.7.1-1: Connection of the external radiator
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Installation Instructions
6.7.2 Installation PMGi inverter - See separate PMGi 8000 inverter manual
6.8 Installation of the cooling system
6.8.1 General instructions
The PANDA vehicle generator is supplied as standard without a radiator. Various radiators are available according to
the customer’s requirements; these can be chosen according to the appropriate operating and installation situation.
The cooling system can also be assembled together with a normal commercial vehicle radiator.
Some series has an integrated Radiator (f.e. PVK-UK, PSC ect.), for these generators an external radiator is not
necessary.
At generators with attached radiator (f.e. PVK-UK series) skip
this chapter.
Note:
6.8.2 Fischer Panda installation kit - cooling system
Note:The following additional components will be required for the
specified installation. Y ou can purchase them as an installation
kit or separately at Fischer Panda.
representative picture
Fig. 6.8.2-1: Coolant hoseCoolant hose
Elbow pipe
representative picture
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Fig. 6.8.2-2: Elbow pipe
Page 73
Installation Instructions
f.e. for connection of the external expansion tank.
representative picture
Fig. 6.8.2-3: T-pieceT-piece
Sensor connection piece
representative picture
Roof passage
single or double passage
representative picture
Fig. 6.8.2-4: Sensor connection piece
Fig. 6.8.2-5: Roof passage
External expansion tank
representative picture
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Fig. 6.8.2-6: External expansion tank
Page 74
representative picture
Installation Instructions
Fig. 6.8.2-7: Hose clampsHose clamps
Radiator
Different models for roof mount, side mount or underfloor mount are
available.
The cooling capacity must be selected regarding the generator size and the
operation area (f.e. radiator with higher capacity for operation in warm areas)
representative picture
Fig. 6.8.2-8: Radiator
6.8.3 Determing the size of the radiator
Consideration must be paid to the total heat load when determining the size of the unit. This equates to the generator nominal performance without the water-cooled pre-silencer. The heat resistance is 1.8 times the generator nominal capacity, when the water-cooled pre-silencer is used (i.e. Panda 12000 PVMV-N has a total heat capacity of
approx. 18kW). The radiator can be serviced by any usual radiator servicing agency. It should, however, be pointed
out that the radiator possesses high safety levels. The radiator is often manufactured too small. Fischer Panda also
has various radiators available (for horizontal and vertical installation) as standard generator components.
6.8.4 Radiator position
The place and fitting position of the radiator must be carefully considered. It is especially important that the warm air
can escape. For this reason, the best place for the radiator is in a vertical position on the vehicle roof (if one take into
account that an obstruction could arise in narrow entrances).
The manufacturer is only too happy to give suggestions on how to install the radiator. It must, however, be expressively pointed out that all recommendations of this type are not bin ding. It continually occurs that special influencing
factors are not recognised from the start. The customer or the technician making the installation must always take
changes to the position or radiator’s place of installation into consideration. The manufacturer cannot accept liability
for the recommendations given to the best of his knowledge. As a precaution, attention should always be paid that
the air outlet for escaping warm is as large as possible. The vehicle paint sprayer is often not in agreement with
this, but the person making the installation must make the aim clear. The fitter must make his position clear.
Radiators which are installed vertically, and the warm air is blown downwards, must be twice the size of such radia-
tors, by which the warm air rises through its own thermal energy. It must also be considered that a build up of heat
results through the emission of warm air in the direction of the ground, whereby the warm air is once again forced to
rise to the area of the radiator. Freely escaping warm air cannot be guaranteed in this case. Additional ventilators
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Installation Instructions
may be necessary should the warm air need to be channelled through pipes.
It must be ensured that warm air is extracted out of the radiator.
6.8.5 Permitted coolant temperatures
The performance of the radiator must be so measured that the coolant temperature of the Panda generator does not
exceed more than 70°C. The coolant intake must be fitted direct to the coolant pump.
There must be a large amount of water circulating to ensure that the difference in temperature when compared to
the temperature of the water leaving the generator (full load) does not exceed 12°C. The difference may also
amount to 17K if a pre-silencer is installed.
The hoses must be so laid out that knots and other obstructions are avoided. If necessary, the amount of coolant
must be measured. As a minimum the following values are necessary:
6.8.6 Essential coolant amounts:
Panda 4500 ............................... min. ca. 10 l/min
Panda 8000 - 9000 ...................approx. 16 to 22 l/min
Panda 12000 - 14000 ..............approx. 24 to 28 l/min
Panda 18 - 24 ........................... approx. 32 to 38 l/min
Panda 30 - 32 ........................... approx. 40 to 45 l/min
Panda 42 - 65 ........................... approx. 50 to 60 l/min
The greater the amount of coolant circulating, the lower the difference in temperature. If the necessary cooling performance cannot be achieved, the amount circulating can be increased by adjusting the pulley on the pump and
thereby raising the performance.
ATTENTION! The coolant pressure may, however, not exceed 0.7 bar!
6.8.7 Construction and position of the radiator
The radiator can be assembled away from the generator in a well ventilated position. Attention must be paid th at the
radiator emission direction is completely free of obstruction. Turbulence is to be avoided. There is often a clash
between the streamline appearance of the chassis and the technical requirements.
The radiator can be installed (vertically) or (horizontally). Consideration must be given to the fact that air is drawn in
via a fan motor.
The best result is achieved if the radiator is fitted vertically on the vehicle roof.
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Page 76
Fig. 6.8.7-1: Possible positioning of the external radiator
2
1
3
1. Radiator on the roof
2. Radiator vertical
3. Radiator under the vehicle
Installation Instructions
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Installation Instructions
2
1
1. Plug for fan control 2. Bores (diameter 4mm)
6.8.8 Pay attention to the following item at the horizontal assembly of the radiator:
To avoid damages of the fan motor please bore some holes on the backside of the fan (diameter approx 4mm).
Because water can enter the fan (rainwater, condenswater, sweatwater etc.). The water can run out through these
holes. (see below 02) Generally a fan is a wearing part and should be changed one time a year.
Fig. 6.8.8-1: Preperation of the fan
6.8.9 Distance from the radiator to the unit
The coolant water pump mounted on the generator is so laid out that a maximum distance of up to 5 mtrs length
from the radiator is possible. The hose cross-section must be laid out accordingly. The minimal internal diameter
amounts to 18mm (Panda 4500). A hose must be used for both sides (forward and back flow) which is resilient to
pressure and high temperatures (at least 120°C).
6.8.10 Coolant expansion tank
It is absolutely essential, that a expansion tank, that can be aerated, is fitted adjacent to the radiator. The ventilation
pipe should, if possible, be fitted to the radiator’s highest position. For this, a pipe with a maximum diameter of
10mm suffices, which must be fed to the expansion tank. A further pipe, which must be fitted to the floor of the
expansion tank, can be fitted to the cooling system in any desired place (i.e. T-piece). Frequently a connection is
provided on the radiator itself. The coolant expansion tank is not normally supplied by Fischer Panda. For this a
standard vehicle expansion tank is the most suitable. Vehicle accessory range is the most suitable.
6.8.11 Antifreeze
The antifreeze concentration must be regularly checked in the interests of safety. The antifreeze solution supplied
from the factory provides protection to -15°C. If lower temperatures are occasioned during transportation o r storage,
then the coolant must be drained. The cooling system is, however, so arranged that the draining of the coolant is
only possible in the assembled state, when air under pressure is blown into the system. Air pressure of approx. 0.5b
suffices, in order to blow out the water.
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Installation Instructions
6.8.12 ATTENTION! Temperature restriction!
This pump may only be used if it is ensured that the temperature of the coolant entering the pump does not exceed
70°C during continual duty. 75°C is permissible for short periods. These may, however, in no case be for lon ger per iods. If the coolant temperature exceeds the permissible rate, this can lead to the impeller blades being torn off.The
advantage of this impeller pump is that this pump, as a "positive displacemen t pump", is self-suctioning and is therefore very sensitive to air bubbles etc.
Ventilating the cooling system with the aid of a self suction impeller pump is very simple. In some cases the pump is
additionally installed for this reason alone. Unfortunately the operating noise of these pumps is very loud.
In spite of this attention must be paid that a zone is available at a high point, where the air bubbles in the coolant are
able to escape to. As a rule, this is the expansion tank, as long as this is connected direct to the tank. If the coolant
expansion tank is, however, so integrated in the system that it cannot be reached by circulating water, then an air
release valve must be fitted in the circulation pipe at a place of your own choice, which can then also be connected
to the expansion tank (see next page).
In case of doubt, you should send a diagram of the required coolant system to Fischer Panda and let this be chekked there.
6.8.13 Installation with special air separator
An "air separator" must be fitted at all critical plac es in the circ ula tio n syst em , in cas e a pe rf ect au to m atic ventila tio n
on account of obstacles in the pipe passage cannot be achieved. A self-actuating ventilation valve must be fitted to
each air separator.
6.8.14 Monitoring the Temperature
You are expressively advised to measure the temperature of the circulating coolant after installation. Two remote
thermometers must be used for this. A connection must be fitted to the mo tor coolant inlet; the second on the co olant
outlet. After a short warming-up period, the generator must have a load of at least 75% of the nominal capacity
placed on it. The coolant circulating is to be checked. The values must lie within the following limits:
1. Coolant inlet, max 70°C during constant duty a t maximum
load
2. Coolant outlet, max 85°C during constant duty
3. Difference of both values: This point is especially impor-
tant and gives an indication of the coolant circulating . The
difference should amount to a maximum of 17°C for a
water-cooled system with an integrated water-cooled presilencer, as a rule it should, however, lie between 10 12°C.
The circulating coolant is not sufficient, if the difference amounts to more than 15°C, and the amount of water circulating must be increased. This can be solved, for example, if the pipe passage is improved or the pulley diameter is
reduced. It is absolutely essential to measure the performance of the cooling system after installation of the generator. The above named values should be considered as the maximum permissible values. They are also valid for
operation at high temperatures. During constant duty at normal temperatures (20°C), the values should be well
below the above named data.
6.8.15 Installing a Coolant Temperature Display
A remote display unit for coolant temperatures should be installed, when fitting sensitive systems (i.e. Television
broadcasting vehicles, ambulances or other vehicles) with sensitive measuring instruments. In this case a standard
coolant display device with remote thermometer can be used. It is absolutely essential that two display instruments
are installed:
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Installation Instructions
1. Cooling water inlet
2. Cooling water outlet
It does not matter at which place the measurement is made. T-pieces for hose elements can be obtained from Fis-
cher Panda into which the usual trade sensors can be installed.
6.8.16 Monitoring of temperature:
1. Temperature at the cylinder head
2. Temperature at the manifold
3. Temperature in the generator winding area (only Panda
8000 upwards)
The winding temperature monitor is no t fi tted w ith a sp ecial disp lay un it. Th e fuel so leno id valv e is switch ed on as a
circuit breaker for the motor stop solen oid or the fuel pu mp. If the ge nerator switc hes off because the win ding overheats, nothing is displayed. In this case a long period of waiting can, in circumstances, be necessary. This can be
bridged by using the switch. This must be carried ou t by an electrician who should use the circuit diagram for this. It
suffices in this case when the plug which leads to the guage wire is opened and both conducters in the plug are
bridged. This shut down should, however, be a last resort! It is only applicable, if th e gen erator temp er ature e x ceeds
the permissible value on accou nt of in acce ssible workin g c onditions. It must then be explained which measures are
necessary to restore normal operating conditions.
6.8.17 Recording the temperature values
Installation records are delivered with every handbook, which must be completed after installation and returned to
the manufacturer (Copy). The generator should be tested at 70% of its maximum performance. The temperature values must be checked at the maximum possible performance. The external tem perature m ust be t a ken into consid eration when doing this check. The values for T1 (see additional installation record for the vehicle version) may not
exceed 85°C, even at high external temperatures and maximum load . If necessary the maximu m permi ssible perfor mance must be reduced (i.e. by the use of fuses).
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Page 80
Fig. 6.8.17-1: Installation diagram for vertical radiator
01
06
02
05
04
03
08
10
07
09
11
11
01. Coolant expansion tank
02. Ventilation pipe
03. Ventilation screw
04. Fan for radiator
05. Radiator
06. Stop valve for coolant
07. Thermoswitch
08. Bucket with submerged pump
09. Water-cooled pre-silencer
10. Internal cooling water pump
11. T-piece
Installation Instructions
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Installation Instructions
03
04
06
05
01
08
09
11
12
02
10
13
07
05
01. Ventilation pipe
02. Water-cooled exhaust elbow
03. Coolant expansion tank
04. External fan control
05. Dry silencer
06. Exhaust outlet
07. T-piece with connection for Thermoswitch
08. External cooling water pump
09. Stop valve for coolant
10. T-piece
11. Radiator
12. Fan for radiator
13. Bucket with submerged pump
Fig. 6.8.17-2: Installation diagram for underneath the vehicle
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Page 82
Fig. 6.8.17-3: Installation diagram for radiator on the roof
2
6
3
5
4
1
1. Ventilation pipe
2. Radiator (horizontal)
3. Coolant expansion tank (integrated)
4. T-piece for Ventilation pipe
5. External cooling water pump
6. Bucket with submerged pump
Installation Instructions
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Installation Instructions
2
7
6
1
4
5
3
3
1. Ventilation pipe
2. Coolant expansion tank
3. T-piece for coolant expabsion tank
4. Water-cooled pre-silencer
5. Exhaust output
6. Special air separartor
7. Radiator
Fig. 6.8.17-4: Installation diagram with special air separator
6.9 Radiator fan control / electronic fan control
To control the radiator fan, various controls/electronic controls can be chosen from the Fischer Panda delivery
program.
Note!:In the following the basic functions of the fan controls
are described. The original manual/ data sheet with
further informations of the fan control must be
respected.
6.10 Standard fan control for 1-phase and 3-phase generators.
In the standard kit, the generators will be equipped with a one step fan control.
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Page 84
representative
6.11 Electronic fan control for DC fans RE 0201
Installation Instructions
Fig. 6.10.0-1: Fan control 230VFan control 230 V
For DC Fans the fan control RE 0201 can be used.
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Installation Instructions
Fig. 6.11-1:
6.12 Brief description
Temperature-dependent continuous speed controlling device for one or two DC-fans.
6.12.1 Function
The speed regulation of the fan is made by pulse tracing modulation ( PWM) of the o perat ing volt age. Pulse/no pulse
ratio becomes over an extern al temperature s ensor (NTC resistance to attach at clamp 7 and 8) dependent on the
coolant temperature. Between the lower limit temperature (starting temperature) and the upper limit temperature the
fan is controlled with 30 to 100% of the available operating voltage (PWM = 30% to 100%).
Potentiometer for adjustment concerning temperature and PWM behaviour
Poti Start: Adjusting the starting temperature (fan start-up). The start temperature is with left stop 60°C and with right stop 80°C. Ex
factory a starting temperature of 70°C is adjusted (potentiometer position: In the middle).
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Installation Instructions
Poti Window: Adjusting the temperature window: With the potentiometer „Window“ the size of the window between starting temperature
and temperature for full number of revolutions (upper limit temperature) can be adjusted. The temperature window can
be adjusted from 5°C to 20°C. Is the starting temperature adjusted to 70°C and the temperature window to 10°C thus the
fan start-up with 70°C and reaches the maximum speed with 80°C (upper limit temperature). Ex factory a temperature
window of 12,5°C is adjusted (potentiometer position: In the middle).
Poti Freq: Adjusting of the PWM frequency. Desired to many customers a potentiometer was added for changing the PWM
frequency. A selection of the frequency between approx. 1,7 and 3,5kHz is possible, which can serve for the avoidance
of unwanted oscillation/resonances. Ex factory a PWM frequency of 2 kHz is adjusted.
Function of the temperature sensors (NTC-resistance, extern und intern):
extern: Over this temperature sensor the coolant temperature is collected. The starting temperature (fan start-up) and the upper
limit temperature can be adjusted by means of potentiometer present at the plate. The PWM ratio starts with the
exceeding of the starting temperature with approx. 40% (for 2 seconds), so that the fan starts reliably. According to
expiration of the 2 seconds the PWM ratio is determined by coolant temperature and potentiometer adjust. Since the
coolant temperature will not continue to rise in the 2 seconds, the PWM ratio will jump back to the minimum value of 30%.
At, from here, far rising coolant temperature, the PWM ratio will then rise linear with the temperature. If the upper limit
temperature is nearly reached, the PWM ratio rose to 85%. By 85% to 100% PWM ratio with reaching the upper limit
temperature switching over is made by one step, in order to avoid very short turn-off times. Likewise switch-back is made
with falling coolant temperature of 100% to 85% PWM ratio. If the coolant temperature falls under the starting
temperature, the minimum PWM ratio is not fallen below of 30%, but remains constant. If the coolant temperature sinks
approx. 3°C under the starting temperature, then the fan is switched off completely. All data exclusively apply on use of
the temperature sensor type S891-100k of the manufacturer Epcos.
intern: Over this temperature sensor the temperature of the output stage is collected. If the temperature of the output stage rises
over 85°C, the PWM ratio, independently of the coolant temperature, is set to 100%, in order to avoid the switching losses
and cool the output stage down again. If the temperature of the output stage continues to rise nevertheless and beyond
90°C, the fan controller switches itself off. NOTE: The cooling of the generator is not ensured anymore. If the output
stage temperature sinks again under 85°C, the fan controller restarts itself. Such output stage temperatures cannot occur
however with intended use of the equipment.
Light emitting diodes: The 3 light emitting diodes (LED's) indicate the operating condition of the fan controller and have the following
meaning:
LED (green): Shines with normal operation. After the self check and successful recognizing of the sensors the fan controller jumps into
the normal operating condition, in which the fan regulates, if the temperature lies in the appropriate range.
LED (yellow): Shines if the fan controller is in slave-mode.
LED (red): Shines with the occurrence of the following errors:
Incorrect external temperature sensor. If the temperature sensor for the cooling water is defective or the feeder line to it
interrupted (cable break), then the fan is accessed with 100% PWM.
Incorrect internal temperature sensor. If the temperature sensor for the output stage is defective or the feeder line to it
interrupted (cable break), then this is indicated over the LED. The fan controller continues working normally.
Overheating of the output stage. If the output stage of the fan controller becomes too hot, then this switches itself off.
Please read in addition the description of the function of the internal temperature sensor.
6.12.2 Master - Slave - Operation
Two or three fan controllers can be connected with each other that over one temperature sensor for the cooling
water, all fan controllers cam be operated synchronous.
On the connection between master and slave the PWM signal of the masters will transfer. The slave takes over of it
the PWM ratio and the frequency. The slave spends its PWM impulse only then if that of the masters is terminated.
Thus even load of the current supply is reached. The second slave (if available) regards the first slave as its master
(see also drawing).
The slave operation is activated automatically, by the pres ence of a PWM si gnal at the slave control inlet. As soon
as such a signal is present, the slave follows the control signal and ignores its own adjusts and its own temperature
measuring input. If the ma ster does not spe nd a PWM signal, be cause th e coolant t emperat ure is un der its starting
temperature, the slave drops back into the master operation and uses its own adjusts and analyses its own
temperature measuring input. So that the slave behaves correctly now, a 100k fixed resistor must be attached at its
temperature measuring input, which corresponds to a coolant temperature below the starting temperature.
The plug-able plug-in for the master-slave-connection and the 100k fixed resistor belong not to the normal scope of
supply and must be ordered separately.
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Installation Instructions
Fig. 6.12.2-1:
6.12.3 Function of the clamps for the Master-Slave-Operation
Clamp 11+12: Control input for slave operation. Clamp 11 is the positive input. Clamp 12 is the negative input. The input is floating, so
Clamp 13+14: Output for the master-slave-operation. At clamp 13 is the signal and at clamp 14 is ground.
that via this input connected fan controllers of the same source can be supplied, without a ground loop develops.
6.12.4 Remote controlled switching on and off of the fan controller
he fan controller can be switched on and/or off over the connection „ON“ (clamp 9). If at connection „ON“ lies the
same voltage as at the connection „BAT +“, the fan controller is switched on. If at connection „ON“ lies no voltage,
the fan controller is switched off. If this op tion i s not need ed, the n the connection „ON“ can connected directly on the
printed circuit board, over the solder joint J101, with the connection „BAT +“.
• J101 closed: Fan control always on
• J101 open: Fan control only on if operation voltage at
connection „ON“
The solder joint J101 is seen from the direct line clamp directly behind the main safety device (main fuse) on the
printed circuit board.
6.12.5 12V / 24V - Operation
For 12V and/or 24V-operation the pre-resistor for the operating voltage of control electronics must be adapted. This
pre-resistor consists of two resistances, which are connected in series. For 12V-operation one of these resistances
is short circuit with the solder joint J102. For 24V-Betrieb the solder joint J102 must be opened. Additionally different
safety devices (fuses) must be installed depending upon operating voltage.
Main fuse (flat fuse on the printed circuit board):
12V-operation: 50A flat fuse
24V-operation: 30A flat fuse
Output fuse
(plug fuse on the terminal block, each two pieces):
12V-operation: 25A plug fuse
24V-operation: 20A plug fuse
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Installation Instructions
6.13 Technical Data
Characteristics
closed current (electronics off) 0,5mA
closed current (electronics on) 10 - 15mA
Benchmark figure of the temperature control:
fan start-up 60°C - 80°C
max. number of revolution 65°C - 100°C
tolerance of the temperatures ± 5%
Maximum ratings
maximum ambient temperature (for operation) 50°C
Maximum ratings: Battery operation 12V
nominal load operating voltage (continuity) 11 VDC - 14.4 VDC
load operating voltage (15min) - 16.0 VDC
maximum idle speed operating voltage (3 sec) 17 VDC
nominal load current (continuity) 40 A
maximum load current (3 sec) 44 A
nominal voltage fan 12 VDC
Maximum ratings: Battery operation 24V
nominal load operating voltage (continuity) 18 VDC - 28.0 VDC
load operating voltage (15min) - 28.8 VDC
maximum load operating voltage (3 sec) 30 VDC
idle speed voltage (continuity) 34 VDC
maximum idle speed operating voltage (3 sec) 36 A
nominal load current (continuity) 20 A
maximum load current (3 sec) 22 A
nominal voltage fan 24 VDC
Maximum ratings: Transformer operation 12V
sieving in the power supply 10000µF 63V (depending on the load current)
data for secondary winding after rectification/sieving
nominal load operating voltage (continuity) 11 VDC - 14.4 VDC
load operating voltage (15min) - 16.0 VDC
maximum load operating voltage (3 sec) 17 VDC
idle speed operating voltage (continuity) 28 VDC
maximum idle speed operating voltage (3 sec) 30 VDC
nominal load current (continuity) 40 A
maximum load current (3 sec) 44 A
nominal voltage fan 12 VDC
Maximum ratings: Transformer operation 24V
sieving in the power supply 10000µF 63V (depending on the load current)
data for secondary winding after rectification/sieving
full load operating voltage (15min) 18 VDC - 28.0 VDC
load operating voltage (15min) - 28.8 VDC
maximum full load operating voltage (3 sec) 30.0 VDC
maximum partial load operating voltage 36.0 VDC
idle speed operating voltage (continuity) 39.0 VDC
maximum idle speed operating voltage (3 sec) 40.0 VDC
maximum input peak voltage 44.0 VDC *1)
maximum output peak voltage 44.0 VDC *1)
nominal load current (continuity) 24 A
Seite/Page 88 Kapitel/Chapter 6: Installation Instructions 30.10.12
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Installation Instructions
maximum load current (3 sec) 28 A
nominal voltage fan 24 VDC
*1) The maximum input and/or output peak voltage is measured over the appropriate
clamps of the fan controller. It may be exceeded at no time. This applies independently
of whether a voltage increased height was possibly caused by the fan controller or an
external component. To this belong the switch off-transient of the fan (pulse width
modulation = fan will be 2000 times per second switched on and off), and by outside
switching operation caused glitches.
• solder joint J101 closed
• solder joint J102 open
Attention!: Configuration at delivery for 24V-
operation.
• main fuse 30A installed
• output fuse 20A installed
For 12V-operation the installed fuses must be replaced
against the provided fuses, as described abov e. The preresistors for the operating voltage of control electronics
must be configured like above described.
Assembly: Vertical on standard rail, pay attention to good ventilation.
At breach of specification can destroy one or more components of the system or shorten the life span
substantially.
Subject to change without prior notice.
30.10.12 Kapitel/Chapter 6: Installation Instructions Seite/Page 89
Page 90
Installation Instructions
6.14 Electronic fan control for single phase fans PKE-2.5V_Ziehl Abegg
The electronic fan control variety the fan rpm stepless.
6.14.1 Preset for the use with Fischer Panda generators
The Ziehl Abegg fan control is pr eset for the use with F ischer Panda gen erators. For the pr eset following data and
jumper settings are used.
Fig. 6.14-1: Preset
Seite/Page 90 Kapitel/Chapter 6: Installation Instructions 30.10.12
Page 91
Installation Instructions
line
230V 50Hz
T
temperature
sensor
1
2
-R
M
fan
PE
-M
4,2kOhm
2
1
-R
R1
A
B
J5
J4
R2 R3
n-max
Set
n-min Pband
PKE-2,5V(E)
Ziehl-Abegg
fan control
PE
PE
N
L1
U1
U2
GND
+24V
E
-A
6.14.2 Connection of the sensor (Ziehl Abegg KTY)
The sensor is connected to E/GND. A resistor 4,2kOhm must be connected parallel to the sensor.
Fig. 6.14.2-1: Connection plan
30.10.12 Kapitel/Chapter 6: Installation Instructions Seite/Page 91
Page 92
Installation Instructions
6.15 Electronic fan control for single phase fans PXET6Q_Ziehl Abegg
The electronic fan control variety the fan rpm stepless.
6.15.1 Preset for the use with Fischer Panda generators
The Ziehl Abegg fan control is pr eset for the use with F ischer Panda gen erators. For the pr eset following data and
jumper settings are used.
Fig. 6.15-1: Preset
Seite/Page 92 Kapitel/Chapter 6: Installation Instructions 30.10.12
Page 93
Installation Instructions
012
3
4 5 67 89
Datum
Bearb.
Gepr.
Norm
Urspr. Ers.dErs.f
Blatt 1
Bl.
=
+
von 1
Zust. Änderung Datum Name
Zeichnungsnummer:
D-33104 Paderborn
Otto-Hahn-Str. 32-34
www.fischerpanda.de
+49(0)5254/9202-0
Projektnummer:
Fischer Panda
Generatoren
Fischer Panda GmbH
Bröckling
070367_00_00---
---070367_00_00 ---
Schönberger
26.08.2010
connectionplan - fan control ZA PXET6Q / PXET6Q
M
fan
PE
-M
4,2kOhm
2
1
-R
T
temperature
sensor
1
2
-R
line
230V 50Hz
E1
110
on
Ziehl Abegg PXET6Q
PE
PE
N
N
L1
L1
U1
U1
U2
U2
11
12
14
TB
TB
D1
D1
A1
GND
E1
GND
24V
GND
-A
.
-F
6.15.2 Connection of the sensor (Ziehl Abegg KTY)
The input TB and D1 are bridget.
The sensor is connected to E1/GND. A resistor 4,2kOhm must be connected parallel to the sensor.
Fig. 6.15.2-1: Connection plan
30.10.12 Kapitel/Chapter 6: Installation Instructions Seite/Page 93
Page 94
Installation Instructions
6.16 Electronic fan control for 3 phase fans PKD T5 Ziehl Abegg
The electronic fan control variety the fan rpm stepless.
Fig. 6.16.0-1: Fan control PKD T5Fan control PKD T5
representative picture
Seite/Page 94 Kapitel/Chapter 6: Installation Instructions 30.10.12
Page 95
Installation Instructions
6.16.1 Configuration of the electronic fan control PKD T5 for Fischer Panda Generators
30.10.12 Kapitel/Chapter 6: Installation Instructions Seite/Page 95
Page 96
Fig. 6.16.1-1: Configuration of the fan control PKD T5 for Fischer Panda Generators
Installation Instructions
Seite/Page 96 Kapitel/Chapter 6: Installation Instructions 30.10.12
Page 97
Installation Instructions
3
2
1
4
5
6
7
8
1. Exhaust oulet
2. Generator
3. Dachdurchführung mit Winkel
4. Vibration damper
5. External pre-silencer
6. Exhaust pipe
7. External series silencer
1
2
3
4
5
6
7
8
1. Generator
2. Exhaust outlet
3. Compensator
4. External pre-silencer
5. Vibration damper
6. Exhaust pipe
7. External series silencer
8. End pipe
6.17 Exhaust installation
Fig. 6.17-1: Exhaust connection for roof outlet
Fig. 6.17-2: Exhaust connection for mounting below the vehicle
6.18 Isolation test
ACHTUNG!After installation, but before the generator is set into
normal operation and handed to the customer, an
isolation test must be performed as followed:
1. Disconnect all load.
2. Start the generator.
30.10.12 Kapitel/Chapter 6: Installation Instructions Seite/Page 97
Page 98
Installation Instructions
3. Measure with a voltmeter (AC) the voltage between:
a) Generator housing and PMGi housing.
b) Generator housing and ground of the vehicle.
The measured voltage must be lower than 50 mV.
4. Test the installed protective devices (like RCD). If a RCD is installed, a functional test must be done. Check all
terminals for right connections. Measure all phases against each other and against the neutral wire.
5. If the generator is Protected by PME, make sure that all components has the same ground at the housing.
The protective devices must match the national regulation.
6.19 Set into operation
After the installation the generator must be brought in service. For this the „Service reco rd and warr anty regis tratio n
must be worked through and filled out by the installing technical trained person.
This document must be handed out to the owner. The owner must be instructed for the operation, maintenance and
hazards of the generator. These include the in the manual mentioned hazards and further ones, which are the result
of the specific installation and the connected components.
Panda to get full warranty. Make a copy for your hands.
6.20
Note!:Send the original Serv ice and warranty record to Fischer
Seite/Page 98 Kapitel/Chapter 6: Installation Instructions 30.10.12
Page 99
Maintainence
7. Maintainence
7.1 Personal requirements
All maintenance, if not special marked, can be done by the trained persons.
Further maintenance must be done by technical personal or Fischer Panda service points.
7.2 Hazard notes for the maintenance
Notice!:Follow the general safety instruction at the front of this manual.
automatic start device. This means the generator can be
started by an external signal. To avoid an unexpected starting
of the generator, the starter battery must be disconnected
before start working at the generator.
injury. Therefore before starting work at the generator:
Make sure that the generator is stopped and the starter
battery is disconnected to guarantee that the generator
cannot be inadvertently started.
Do not run the generator with removed sound isol at ion cover
Improper installation/maintenance can result in severe
personal injuries or material damage.
• Always undertake installation/maintenance work when the
generator is switched off.
• Ensure there is sufficient installation clearance before start
working.
Warning!: Automatic startDanger for life! - The generator can be equipped with a
Warning!: Risk of injuryWorking at a running generator can result in severe personal
Warning!: Risk of injury
• Ensure tidiness and cleanliness at the workplace. Loose
components and tools lying around or on top of each other
are sources of accidents.
• Only perform installation work using commercially available
tools and special tools. incorrect or damaged tools can
result injuries.
Oil and fuel vapours can ignite on contact with ignition
sources. Therefore:
• No open flames during work on the generator.
• Do not smoke.
• Remove oil and fuel residues from the generator and floor.
30.10.12 Kapitel/Chapter 7: Maintainence - Seite/Page 99
Warning!: Danger of fire
Page 100
damage to health. Therefor:
• Avoid skin contact with engine oil, fuel and antifreeze.
• Remove oil and fuel splashes and antifreeze from the skin
immediately.
• Do not inhale oil and fuel vapours.
tion and maintenance can result in severe personal
injury and/or material damage.
Electrical voltages above 48 volts (battery chargers greater
than 36 volts) are always dangerous to life). The rules of the
respective regional authority must be adhered to. Only an
electrician may carry out installation of the electrical
connections for safety reasons.
Maintainence
Danger!: Danger of poisoningContact with engine oil, antifreeze and fuel can result in
ATTENTION!: Danger to Life - High voltageDanger for Life. Improper handling, operation, installa-
Generator, oil and antifreeze can be hot during/after operation.
Risk of severe burns.
During Installation/maintenance personal protective equipment
is required to minimize the health hazards.
• Protective clothing
• safety boots
• protective gloves
• Ear defender
• safety glasses
Disconnect all load during the work at the generator to avoid
damages at the load.
Warning!: Hot surface/material
Instruction!: Personal protective equipment
necessary.
Attention!: disconnect all load
Warning!:Batteries contains acid or alkalis.
Improper handling can result in battery explosion and
leakage. Acid or alkalis can run out. An explosion of the
battery is possible.
See the operation and safety instruction from your battery
manufacturer.
Seite/Page 100 - Kaptitel/Chapter 7: Maintainence 30.10.12
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