Fischer Panda 6500/7, 10000/9, 8000/8 User Manual

Page 1

Manual marine generator

Panda 6500/7 mini PMS 230/400 V - 50 Hz - 6 kVA 120/240 V - 60 Hz - 6 kVA Panda 8000/8 mini PMS 230/400 V - 50 Hz - 8 kVA 120/240 V - 60 Hz - 8 kVA

Panda 10000/9mini PMS 230/400 V - 50 Hz - 10,5 kVA 120/240 V - 60 Hz - 8,7 kVA

Super silent technology

Panda_6500-10000_PMS_eng.R04 9.12.14

Page 2

Current Revision Status

Document

Actual: Panda_6500-10000_PMS_eng.R04_9.12.14 Replaces: Panda_6500-10000_PMS_eng.R03

Revision Page

7 mini +8 mini eingefügt Jahresupdate 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

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.

FischerPandaGmbH

Otto‐Hahn‐Str.40

D‐33104Paderborn

Germany

Tel.

Fax.

Hotline

Web

+49(0)52549202‐0

+49(0)52549202‐550

+49(0)52549202‐767

[email protected]

www.fischerpanda.de

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Inhalt / Contens

Current Revision Status2 3 General Instructions and Regulations12

3.1 Safety first! 12

3.2 Tools 16

3.3 Manufacturer declaration in accordance with the Machinery Directive 2006/42/EC 18

3.4 Customer registration and guarantee 18

3.4.1 Technical support 18

3.4.2 Caution, important information for start-up! 18

3.5 Safety Instructions - Safety First! 19

3.5.1 Safe operation 19

3.5.2 Observe safety instructions! 19

3.5.3 Personal protective clothing (PPE) 19

3.5.4 Cleanliness ensures safety 19

3.5.5 Safe handling of fuels and lubricants 20

3.5.6 Exhaust fumes and fire protection 20

3.5.7 Safety precautions against burns and battery explosions 21

3.5.8 Protect your hands and body from rotating parts! 21

3.5.9 Anti-freeze and disposal of fluids 21

3.5.10 Implementation of safety inspections and maintenance 22

3.6 Warning and instruction signs 22

3.6.1 Special instructions and hazards of generators 22

3.6.1.1 Protective conductor and potential eq ualisa t ion:23

3.6.1.2 Protective conductor for Panda AC generators: 23

3.6.1.3 Switch off all loads while working on the generator 23

3.6.1.4 Potential equalisation for Panda AGT DC generators 23

3.6.1.5 Safety instructions concerning cables24

3.6.2 Recommended starter battery sizes 24

3.6.3 Important instructions for batteries - starter and/or traction batteries 24

3.6.4 General safety instructions for handling batteries 25

4 In case of Emergency First Aid / Im Notfall - Erste Hilfe27

4.1 WHEN AN ADULT STOPS BREATHING 28

5 Basics29

5.1 Intended use of the machine 29

5.1.1 Purpose of the manual and description of the definitions trained person/operator/ user 29

5.1.1.1 Trained persons 29

5.1.2 Operator 29

5.1.2.1 User 29

5.2 Panda Transport Box 30

5.2.1 Bolted Fischer Panda Transport Box 30

5.2.2 Fischer Panda Transport Box with metal tab closure 30

5.3 Transport and Loading/Unloading 30

5.3.1 Transporting the generator 30

5.3.2 Loading/unloading of the generator 30

5.4 Scope of delivery 31

5.4.1 Asynchronous Generator: 31

5.4.2 Opening the MPL sound insulation capsule 33

5.4.3 Opening the GFK sound insulation capsule 34

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Inhalt / Contens

5.5 Special maintenance notes and arrangements at long periods of stand still time or shutdown 34

5.5.1 Reference note for the starter battery at a long-term standstill 34

5.5.2 Arrangements at a short-term standstill 35

5.5.3 Arrangements at a medium-term standstill / winter storage 35

5.5.3.1 Arrangements for conservation : 35

5.5.3.2 Arrangements for deconservation after a medium-term standstill (3 to 6 months). 36

5.5.4 Arrangements at a long-term standstill / shutdown 36

5.5.4.1 Arrangements for conservation : 36

5.5.4.2 Arrangements after a long-term standstill (shutdown) / recommissioning (more than 6 months): 37

6 The Panda Generator39

6.1 Type plate at the Generator 39

6.2 Description of the Generator 40

6.2.1 Right Side View 40

6.2.2 Left Side View 41

6.2.3 Font View 42

6.2.4 Back View 43

6.2.5 View from above 44

6.3 Details of functional units 45

6.3.1 Components of the Cooling System (Raw Water) 45

6.3.2 Components of the Cooling System (Fresh Water) 46

6.3.3 Components of Fuel System 50

6.3.4 Components of Combustion Air 52

6.3.5 Components of the Electrical System 54

6.3.6 The Operation Surveillance System 58

6.3.7 Components of the Oil Circuit 60

6.4 Remote Control Panel - see separate Control Panel Manual 61

6.4.1 Starting the Generator - see separate Control Panel Manual 61

6.4.2 Stopping the Generator - see separate Control Panel Manual 61

7 Installation Instructions63

7.1 Personal requirements 63

7.1.1 Hazard notes for the installation 63

7.2 Preparing the base - Placement 64

7.2.1 Advice for optimal sound insulation 65

7.3 Generator Connections 65

7.4 Installation of the cooling system - raw water 65

7.4.1 General Information 65

7.4.2 Installation of the through hull fitting in Yac ht s 65

7.4.3 Quality of the Raw Water Sucking In Line 66

7.4.4 Generator Installation above Waterline 67

7.4.5 Generator Installation below Water-Line 68

7.4.6 Generator Housing cooled by Raw Water 69

7.4.7 Indirect Cooling of the Genset Housing (by the Heat Exchanger) 70

7.5 Installation of the cooling system - fresh water 70

7.5.1 Position of the external cooling water expansion tank 70

7.5.2 Ventilating at the first filling of the Internal Cooling Water Circuit 71

7.5.3 Pressure Test for Controlling the Cooling Water Circuit 72

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Inhalt / Contens

7.5.4 Scheme for Freshwater Circuit at Two Circuit Cooling System 73

7.6 Installation of the water cooled exhaust system 74

7.6.1 Installation of the standard exhaust system 74

7.7 .Installation of the waterlock 75

7.7.1 Possible cause for water in the exhaust hose 75

7.7.1.1 Possible cause: exhaust hose 75

7.7.1.2 Possible cause: cooling water hose 75

7.7.2 Installation area of the waterlock 76

7.7.3 The volume of the waterlock 76

7.7.3.1 Ideal position of the waterlock78

7.7.3.2 Example of the installation of the waterlock off-center and possible ef-

fects: 81

7.8 Exhaust / water separator 84

7.8.1 Installation exhaust water separator 86

7.9 Installation of the fuel system 88

7.9.1 General references 88

7.9.2 The Electrical Fuel Pump 89

7.9.3 Connection of the fuel lines at the tank 89

7.9.4 Position of the pre-filter with water separator 90

7.9.5 Ventilating air from the fuel system 90

7.10 Generator DC system installation 91

7.10.1 Connection of the starter battery block 91

7.10.2 Connection of the remote control panel - see separate control panel manual 94

7.11 Generato r AC System Installation 95

7.11.1 Installation with looped in AC-Control box 95

7.11.2 Installation AC-Box / distribution panel separate connected 96

7.11.3 AC-Control Box with VCS and ASB - not all models 98

7.11.4 VCS voltage control 99

7.11.4.1 Alternative Mini VCS100

7.11.5 Installation with mini VCS mounted at the generator 101

7.11.6 Jump start at high starting current (Booster) 101

7.11.7 Insulation test 102

8 Generator operation instruction103

8.1 Personal requirements 103

8.2 Hazard notes for the operation 103

8.3 General operating instruction 103

8.3.1 Operation at low temperatures 103

8.3.1.1 Pre-heating the diesel motor 104

8.3.1.2 Tips regarding starter battery 104

8.3.2 Light load operation and engine idle 104

8.3.2.1 The soot of the generator is due to the fact that: 104

8.3.2.2 To prevent the soot of the generator following steps should be observed: 104

8.3.3 Generator load for a longer period and overload 104

8.3.4 Protection conductor: 105

8.3.5 Operating control system on the Fischer Panda generator 105

8.4 Instructions for capacitors - not present at all models 105

8.5 Checks before start - see remote control panel data sheet 105

8.6 Starting the generator - see remote control panel data sheet 106

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8.7 Stopping the generator - see remote control panel data sheet 106

9 Maintenance Instructions107

9.1 Personal requirements 107

9.2 Hazard notes for the maintenance 107

9.3 Environmental protection 109

9.4 Maintenance interval 109

9.5 General maintenance instructions 109

9.5.1 Checks before each start 109

9.5.2 Check of Hoses and rubber parts in the sound insulated capsule 109

9.6 Oil Change Intervals 110

9.7 Checking oil-level 110

9.7.1 Refilling Oil 111

9.7.2 After the oil level check and refilling the oil 111

9.8 Replacement of engine oil and engine oil filter 112

9.8.1 After the oil change 114

9.9 Verifying the starter battery and (if necessary) the battery bank 115

9.9.1 Battery 115

9.9.1.1 Check battery and cable connections 115

9.9.1.2 Check electrolyte level 115

9.9.1.3 Check electrolyte density 116

9.10 Grease lubricated generator backend bearing 116

9.10.1 Exchange of grease lubricated bearing 117

9.10.1.1 Demounting the cooling disc (if existent) 118

9.10.1.2 Demounting the back en d be a rin g 11 8

9.10.1.3 Installing the new backend bearing 119

9.11 Checking the oil level of the generator end bearing at Fischer Panda generators 122

9.11.1 Oil level check 123

9.11.2 Refilling oil 123

9.11.3 Refiller-Set 124

9.11.4 Screw plug 124

9.12 Replacement of the oil-cooled backend bearing 125

9.12.1 Exchange oil-cooled bearing 125

9.12.2 Demounting the bearing 125

9.13 Ventilating the fuel system 137

9.13.1 Replacement of the fuel filter 138

9.13.1.1 Optional fuel filter with sight glass 139

9.14 Checking the water separator in the fuel supply 140

9.14.1 Replace the air filter mat 140

9.14.2 Alternative replacement of the air filter mat with pull out holder 141

9.14.3 Alternative replacement of the air filter at housing with snap fasteners 143

9.14.4 Ventilation of the coolant circuit / freshwater 144

9.14.5 V-belt replacement for the internal cooling water pump 146

9.15 The raw water circuit 147

9.15.1 Clean raw water filter 147

9.16 Causes with frequent impeller waste 148

9.16.1 Replacement of the impeller 149

9.17 Replacing the Actuator 151

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Inhalt / Contens

9.17.1 Check and discharge the capacitors 153

9.18 Replacing the Electric Starter 156

9.19 Replacing the DC/DC Converter 159

9.20 Replacing the DC Alternator 160

9.21 Replacing the Oil Pressure Switch 164

9.21.1 Replacing the oil pressure sensor (optional component) 165

9.22 Replacing the Operating Current Relays 166

9.23 Replacing the fuses 167

9.24 Replacing a Thermoswitch 168

9.25 Replacing the Injection Nozzles 170

9.26 Checking the Flame Glow Plug (optional unit) 173

9.26.1 Replacing the Flame Glow Plug 174

9.27 Replacing the Stop Solenoid (Energize to stop) 175

9.28 Replacing the Glow Plugs 179

10 Generator Faults181

10.1 Personal requirements 181

10.2 Hazard notes for the troubleshooting 181

10.3 Tools and Measuring Instruments 183

10.4 Troubleshooting Table and Flowchart 184

10.4.1 Generator output voltage too low 184

10.4.2 Generator voltage too high (more than 240 V - 50 Hz 184

10.4.3 Generator voltage fluctuates 184

10.4.4 Generator not able to start electric motor 184

10.4.5 Diesel motor fails to start 184

10.4.6 Starter is turning motor, but fails to start 184

10.4.7 Motor does not achieve enough speed during starting process 186

10.4.8 Motor runs unsteady 186

10.4.9 Motor speed drops 186

10.4.10 Motor runs in off position 186

10.4.11 Motor stops by itself 186

10.4.12 Sooty, black exhaust 187

10.4.13 Generator must be shut off immediately if: 187

10.4.14 Troubleshooting for the VCS-Voltage Control 187

10.4.15 Troubleshooting Flowcharts 188

10.4.15.1Details and explanations concerning the troubleshooting flowchart 190

10.5 Versions of the generator power terminal box 194

10.6 Overloa din g th e ge ne r ator 198

10.6.1 Monitoring the Generator Voltage 199

10.6.2 Automatic voltage monitoring and auto-shut down 199

10.7 Generator-Output Voltage is too low 200

10.7.1 Discharging the Capacitors 200

10.7.2 Checking the Capacitors 201

10.7.2.1 Checking the electrical connections to the capacitors 201

10.7.3 Check the Generator Voltage 201

10.7.4 Measuring the Ohm Resistance of the Generator Windings 202

10.7.5 Check the Windings for Short circuit 202

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Inhalt / Contens

10.7.6 Measuring the In ductive Resistance 203

10.8 Generator provides no voltage 203

10.8.1 Rotor Magnetism Loss and „Re-magnetising“ 203

10.9 Engine Starting Problems 204

10.9.1 Electric Fuel Solenoid Valve 204

10.9.2 Re-start with Failure Bypass Switch 204

10.9.3 Lifting solenoid for motor stop - optio nal 205

10.9.4 Troubleshooting Table 206

11 Tables207

11.1 Technical Data 207

11.2 Rated current 212

11.3 Cable cross section 212

11.4 Fuel 213

11.5 Engine oil 213

11.5.1 Engine oil classification 213

11.5.1.1 Operating range: 213

11.5.1.2 Quality of oil: 213

11.6 Coolant specifications 214

11.6.1 Coolant mixture ratio 214

11.7 Types of coil 215

11.7.1 HP1 - 230V / 50 Hz 215

11.7.2 HP2 - 120V / 60 Hz 215

11.7.3 HP2 - 120V / 60 Hz - Duo 216

11.7.4 HP3 - 400V / 50 Hz 216

11.7.5 HP2 - 120V / 60 Hz 216

11.7.6 DVS - 400V / 50 Hz 217

11.7.7 DVS - 120V 240V / 60 Hz 217

11.8 Resistor & inducta nce of the generator coil 217

11.9 Voltage values stator coil 218

11.10 Diameter of conduits 219

Generator Control Panel P6+ Manual221 Current revision status222 Hardware222 12 Safety Instructions Generator Control P6+223

12.1 Personal req uir em e nt s 223

12.2 Safety instructions 223

13 General operation225

13.1 Panel Generator Control 225

13.1 Rear view 12 V-version 226

13.2 Rear view 24 V-version 227

13.3 Installation of the remote control panel 228

13.3.1 Placement. 228

13.3.2 Terminal connections 228

13.3.3 Function of the jumpers 229

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13.3.4 Configuration and adjustment 230

13.3.4.1 Configuration and setting sheet KE01 230

13.3.4.2 Configuration and setting sheet KE02231

13.3.4.3 Configuration and setting sheet KE03 232

13.3.4.4 Configuration and setting sheet KE04233

13.4 Starting preparation / Checks (daily) 234

13.4.1 Marine version 234

13.4.2 Vehicle version 234

13.5 Starting and stopping the generators 235

13.5.1 Starting the generator 235

13.5.2 Stopping the generator 236

13.6 Automatic adapter - optional 237

13.6.1 Function: 237

13.6.2 The Automatic input: 238

13.6.3 Terminal connections 239

13.7 Master-Slave adapter - optional 239

13.7.1 Fischer Panda Art. No. 21.02.02.015P, 12 V-version 239

13.7.2 Fischer Panda Art. No. 21.02.02.01P, 24 V-version 240

13.7.3 Terminal Connections: 240

13.7.4 Fuse: 240

13.7.5 Terminal connections 241

13.7.5.1 Terminal X2 (IN/OUT from view Master-Operating-Panel) 241

13.7.5.2 Terminal X3 241

13.7.6 Configuration and adjustment 242

13.7.6.1 Configuration and setting sheet KE05 242

13.7.6.2 Configuration and setting sheet KE06243

14 Measurements245

14.1 Hole pattern 245

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Leere Seite / Intentionally blank

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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 attemp t to undertake any repair work yourself, as this may affect your generator warranty. Your dealer will also be able to assist in finding your nearest Fischer Panda service 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

9.12.14 Kapitel/Chapter 3: - Seite/Page 11

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General Instructions and Regulations

3. General Instructions and Regulations

3.1 Safety first!

These symbols are used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury of lethal danger during certain maintenance work or operations. Read these instructions carefully.

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

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General Instructions and Regulations

prohibited.

result in severe personal injury.

The generator can be equipped with a automatic st art device. This means, an external signal may trigger an automatic start-up. To avoid an unexpected starting of the generator, the starter battery must be disconnected before working at the generator.

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 co rr es po nd in g parts and systems is

DANGER: Automatic start-up Danger for life! Working at a running generator can

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.

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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 damageWarning of hearing damages.

WARNING: Magnetic fieldWarning of magnetic field.

WARNING: OverpressureWarning of 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.

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General Instructions and Regulations

3.2 Tools

These symbols are used throughout this manual to show which tool must be used for maintenance or installation.

Spanners W.A.F X = width across flats of X mm

Hook wrench for oil filter

Screw driver, for slotted head screws and for Phillips head screws

Multimeter, multimeter with capacitor measuring unit

Socket wrench set

Hexagon socket wrench set

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General Instructions and Regulations

Clamp-on ammeter (DC for synchronous generators; AC for asynchronous generators)

Torque wrench

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General Instructions and Regulations

3.3 Manufacturer declaration in accordance with the Machinery Directive

2006/42/EC

Manufacturer declaration in accordance with the Machinery Directive 2006/42/EC The generator was designed in such a way that all assemblies correspond with the CE guidelines. If Machinery

Directive 2006/42/EC is applied, then it is forbidden to start the generator until it has been ascertained that the system into which the generator is to be integrated also complies with the Machinery Directive 2006/42/EC. This includes the exhaust system, cooling system and electrical installations.

The evaluation of “protection 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.

3.4 Customer registration and guarantee

Use the advantages of registering your product:

• you will receive a Guarantee Certificate after approval of your installation data

• you will receive extended product information that may be relevant to safety.

• You will receive free upgrades as necessary. Additional advantages: Based on your complete data record, Fischer Panda technicians can provide you with fast assistance, since 90 % of

the disturbances result from defects in the periphery. Problems due to installation errors can be recognized in advance.

3.4.1 Technical support

Technical Suppor t via th e In ter n et: [email protected]

3.4.2 Caution, important information for start-up!

1. The commissioning log shall be filled in immediately after initial operation and shall be confirmed by signature.

2. The commissioning log must be received by Fischer Panda GmbH at Paderborn within 4 weeks of initial

operation.

3. After receiving the commissioning log, Fischer Panda will make out the of ficial 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

3.5 Safety Instructions - Safety First!

3.5.1 Safe operation

Careful handling of the equipment is the best insurance against an accident. Read the manual diligently, and make sure you understand it before starting up the equipment. All operators, regardless of their experience level, shall read this manual and additional pertinent manuals before commissioning the equipment or installing an attachment. The owner shall be responsible for ensuring that all operators receive this information and are instructed on safe handling practices.

3.5.2 Observe safety instructions!

Read and understand this manual and the safety instructions on the generator before trying to start up and operate the generator. Learn the operating practices and ensure work safety. Familiarise yourself with the equipment and its limits. Keep the generator in good condition.

3.5.3 Personal protective clothing (PPE)

For maintenance and repair work on the equipment, do not wear loose, torn, or ill-fitting clothing that may catch on protruding parts or come into contact with pulleys, cooling disks, or other rotating parts, which can cause severe injury.

Wear appropriate safety and protective clothing during work.

Do not operate the generator while under the influence of alcohol, medications, or drugs.

Do not wear head phones or ear buds while operating, servicing, or repairing the equipment.

3.5.4 Cleanliness ensures safety

Keep the generator and its environment clean. Before cleaning the generator, shut down the equipment and secure it against accidental start-up.

Keep the generator free from dirt, grease, and waste. Store flammable liquids in suitable containers only and ensure adequate distance to the generator. Check the lines regularly for leakage and eliminate leaks immediately as applicable.

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General Instructions and Regulations

3.5.5 Safe handling of fuels and lubricants

Keep fuels and lubricants away from naked fire. Before filling up the tank and/or applying lubricant, always shut down the generator and secure it

against accidental start-up. Do not smoke and avoid naked flame and sparking near fuels and the generator. Fuel is highly

flammable and may explode under certain conditions. Refuel in well-ventilated open spaces only. If fuel/lubricant was spilled, eliminate fluids

immediately. Do not mix diesel fuel with petrol or alcohol. Such a mixture can cause fire and will damage the

generator. Use only approved fuel containers and tank systems. Old bottles and canisters are not adequate.

3.5.6 Exhaust fumes and fire protection

Engine fumes can be hazardous to your health if they accumulate. Ensure that the generator exhaust fumes are vented appropriately (leak-proof system), and that an adequate fresh air supply is available for the generator and the operator (forced ventilation).

Check the system regularly for leakage and eliminate leaks as applicable. Exhaust gases and parts containing such fumes are very hot; they may cause burns und er ce rtain

circumstances. Always keep flammable parts away from the generator and the exhaust system. To prevent fire, ensure that electrical connections are not short-circuited. Check regularly that all

lines and cables are in good condition and that there is no chafing. Bare wires, open chafing spots, frayed insulation, and loose cable connec tio ns can cause da ngero us electr ic shoc ks, shor tcircuit, 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

3.5.7 Safety precautions against burns and battery explosions

The generator and its cooling agents and lubricants as well as the fuel can get hot while the generator is operated. Use caution around hot components such as parts containing exhaust fumes, radiator, hoses, and engine block during operation and after the generator was shut down.

The cooling system may be pressurised. Open the cooling system on ly af ter letting th e 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 ha za rd, th is app lies both to th e starter battery and the battery bank of the AGT generators. While batteries are being charged, a hydrogen-oxygen mixture is generated, which is highly explosive (electrolytic gas).

Do not use or charge batteries if the fluid level is below the MINIMUM marking. The life span of the battery is significantly reduced, and the risk of explosion increases. Refill to a fluid level between maximum and minimum level without delay.

Especially during charging, keep sparks and naked fire away from the batteries. Ensure that the battery terminals are tightly connected and not corroded to avoid sparking. Use an appropriate terminal grease.

Check the charge level with an adequate voltmeter or acid siphon. Contact of a metal object across the terminals will result in short-circuiting, battery damage, and high explosion risk.

Do not charge frozen batteries. Heat the batteries to +16 °C (61 °F) prior to charging.

3.5.8 Protect your hands and body from rotating parts!

Always keep the capsule closed while operating the generator. To check the V-belt tension, always shut down the generator. Keep your hands and body away from rotating parts such as V-belt, fans, pulleys, and flywheel.

Contact can cause severe injury. Do not run the engine without the safety devices in place. Prior to start-up, mount all safety

devices securely and check for proper attachment and function.

3.5.9 Anti-freeze and disposal of fluids

Anti-freeze contains toxic substances. To prevent injury, wear rubber gloves and wash off any antifreeze 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

3.5.10 Implementation of safety inspections and maintenance

Disconnect the battery from the engine before performing service work. Affix a sign to the control panel - both the main and the corresponding slave panel - with the instruction “DO NOT START UP

- MAINTENANCE IN PROGRESS“ to prevent unintentio n al start-up. To prevent sparking due to accidental short-circuiting, always remove the earthing ca ble (-) first an d

reconnect it last. Do not start work until the generator and all fluids and exhaust system parts have cooled down.

Use only suitable tooling and appliances and familiarise yourself with their functions to prevent secondary damage and/or injury.

Always keep a fire extinguisher and a first aid box handy while performing maintenance work.

3.6 Warning and instruction signs

Keep warning and instruction signs clean and legible. Clean the signs with water and soap and dry them with a soft cloth. Immediately replace damaged or missing warning and instruction signs. This also applies to the installation of spare

parts.

3.6.1 Special instructions and hazards of generators

The electrical installations may only be carried out by trained and qualified personnel!

The generator must not be operated with the cover removed.

If the generator is being installed without a sound insulation capsule, it must be ensured that all rotating parts (belt-pulley, belts etc.) are covered and protected so that there is no danger to life and body!

If a sound insulation covering will be produced at the place of installation, then easily visible signs must show that the generator must only be switched on while the capsule is closed.

All servicing, maintenance, or repair work may only be carried out when the motor is not running. Electrical voltages above 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 installatio n of the electrical connectio ns of the generator.

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General Instructions and Regulations

3.6.1.1 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.

3.6.1.2 Protective conductor for Panda AC generators:

The generator is earthed“ as a standard (centre and ground are interconnected in the generator terminal box by a shunt). This is a basic first-level safety measure, which offers protection as long as no other measures are installed. Above all, it is designed for delivery and a possible test run.

This „neutralisation“ (Protective Earthing Neutral - PEN) is only effective if all par t s 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 disconnec ted if work on the gener ator or ele ctrical sy stem is to be carried out, so that the generator cannot be started up unintentionally.

3.6.1.3 Switch off all loads while working on the generator

All loads must be disconnected prior to working on the generator to avoid damage to the devices. In addition, the semiconductor relays in the AC control box must be disconnected in order to avoid the booster capacitors being activated during set-up. The negative 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 automatically discharged via t he winding of the generator. The booster capacitors are discharged by means of internal discharge resistors.

For safety reasons, all capacitors must be discharged through short-circuiting before work is carried out on the AC control box.

3.6.1.4 Potential equalisation for Panda AGT DC generators

For further information specific to your generator, see the chapter installation.

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General Instructions and Regulations

3.6.1.5 Safety instructions concerning cables

Cable types

It is recommended to use cables that are in compliance with the standard UL 1426 (BC-5W2) with type 3 (ABYC section E-11).

Cable cross-section

The cable shall be selected taking into account the amperage, cable type, and conductor length (from the positive power source connection to the electrical device and back to the negative power source 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.

3.6.2 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)

3.6.3 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 starter battery. Install as close to the battery as possible but with a max. distance of 300 m m (1 2 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. 3.6-1: Sample diagram for starter battery installation

3.6.4 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 eye protection and protective clothing. Do not touch your 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 be checked fo r excessive heating under load. Check the battery near vibrating components regularly for chafing and insulation defects.

ATTENTION! For battery charger generators (Fischer Panda AGT-DC)! Prior to installation, verify that the voltage of the battery bank complies with the output

voltage of the generator.

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In case of Emergency First Aid / Im Notfall -

Erste Hilfe

4. In case of Emergency First Aid / Im Notfall - Erste Hilfe

First Aid in case of accidents by electrical shocks 5 Safety steps to follow if someone is the victim of electrical shock

Do not touch the injured person while the generator is running.

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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4.1 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?

Tap or gently shake victim. Shout, “Are you OK?“

Roll Person onto Back.

Roll victim towards you by pulling slowly.

Open Airway.

Tilt head back, and lift chin. Shout, “Are you OK?“

Give 2 Full Breaths.

Keep head tilted back. Pinch nose shut. Seal your lips tight around victim's mouth. Give 2 full breaths for 1 to 1½ seconds each.

Shout, “Help!“

Call people who can phone for help.

Check for Breathing.

Look, listen, and feel for breathing for 3 to 5 seconds.

Check for Pulse at side of Neck.

Feel for pulse for 5 to 10 seconds.

Begin Rescue Breathing.

Keep head tilted back. Lift chin. Pinch nose shut. Give 1 full breath every 5 seconds. Look, listen, and feel for breathing between breaths.

Phone EMS for Help.

Send someone to call an ambulance.

Recheck Pulse Every Minute.

Keep head tilted back. Feel for pulse for 5 to 10 seconds. If victim has pulse, not breathing, continue

rescue breathing. If no pulse, begin CPR.

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5. Basics

5.1 Intended use of the machine

The Fischer Panda generator is made to produce electrical energy out of diesel fuel. The diesel fuel is converted to mechanical energy by the diesel engine. This mechanical energy drives the

generator. In the genset, the mechanical energy is converted to electrical energy. This process is controlled by (sometimes external) components, the remote control panel and the voltage control system (VCS).

For the process is a sufficient amount of fuel and comb ustion air necessary. Arising exhaust and heat must be lead away.

If the electrical power should be applied to a local net, The regulation and installation instructions of the Net owner and the regional authorities must be respected. This includes lightening conductor, personal protection switch etc.

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. It is not allowed to modify the product in any case. Never open the sound cover during operation. The safety and hazard notes of the manual must be respected.

5.1.1 Purpose of the manual and description of the definitions trained person/operator/ user

This manual is work instruction and operation instruction for the owner and user of Fischer Panda generators. The manual is the base and the guidelin e for the cor rect in st allation and maintenance of Fischer Panda Gene rators. The manual does not substitute the technical evaluation and should be used as an example guide only. The installation must be undertaken and proved by a suitable qualified/trained person and may in accordance with

the law as required by the country and special situation.

5.1.1.1 Trained persons

Trained persons for the mechanical components are motor mechanics or persons with similar education and training.

Trained persons for the electrical components are electricians or persons with similar education and training.

After the Installation, the trained person must instruct the owner for operation and maintenance of the generator. This must include the hazards of the generator use.

5.1.2 Operator

The operator is the for the operation of the generator responsible person.

After the installation, the operator must be instructed for the operation ad maintenance of the generator. This must include the hazards during operation of th e ge nerator and a instruction for the maintenance.

The operator must read and follow the manual and must respect the hazard notes and safe ty instructions.

5.1.2.1 User

Users are persons, estab lished by the operator, to operate the generator.

The operator must assure that the user read and understand the manual and that all hazard notes and safety instructions are respected. The user must be instructed by the operator regarding his activity at the generator.

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5.2 Panda Transport Box

5.2.1 Bolted Fischer Panda Transport Box

1. Remove the bolts for cover / sidewalls

2. Remove the cover

3. Remove the loose accessories

4. Remove the bolts for sidewalls / floor pallet

5. Remove the sidewalls

6. Open the generator attachment

5.2.2 Fischer Panda Transport Box with metal tab closure

1. Bend up the metal tab closures on the transport box lid.

2. Remove the cover

3. Remove the loose

4. Bend open the metal tab closures on the transport box bottom.

5. Remove the sidewalls

6. Open the generator attachment

5.3 Transport and Loading/Unloading

5.3.1 Transporting the generator

• The generator must always be upright for transport.

• For transport, the Fischer Panda Transport Box shall be used for the generator. The generator shall be secure ly attached to the bottom of the box.

• For loading/unlo ading, an adequate industrial truck shall be used.

• Depending on the transport distance (e.g. air cargo), th e generator fluids (coolant, e ngine oil, fuel) may have to be drained. The corresponding instructions and warnings must be fitted to the transport packaging.

5.3.2 Loading/unloading of the generator

For loading/unloading the generator, appropriate ring eye bolts shall be installed in the holes in the support rails. The load bearing capacity of each ring eye bolt must at least equal the generator weight.

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5.4 Scope of delivery

The Fischer Panda PMS generator system contains following components:

5.4.1 Asynchronous Generator:

Fig. 5.3-1: Lifting yoke (example)An adequate lifting yoke shall be used for transport/

representative picture

Fig. 5.4-1: Fischer Panda GeneratorFischer Panda Generator

Fig. 5.4-2: Remote control panelRemote control panel

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The AC Control Box contains the capacitors and the control circuit board (VCS) for the generator.

At ND generators and generators with mini VCS the capacitors and the VCS may mounted at the generator. The AC Control Box is not required for this generators.

representative picture

The Fischer Panda Manual contains following components:

• Clear foil bag with general informations ect.

• Generator manual with added remote contr ol panel man ual

Fig. 5.4-3: AC Control BoxAC Control Box

Fig. 5.4.1-4: Fischer Panda ManualFischer Panda Manual

• Spare part catalogue „Installation & Service Guide“

• Engine manual fr om the engine manufacturer.

• Wiring diagram for the gene rator

representative picture

Optionales components f.e.:

• Fuel pump

• Installation kit

• Water lock

• ect.

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5.4.2 Opening the MPL sound insulation capsule

be rotated roughly 180° counter-clockwise. Use a flat head screwdriver. Pull the sidewalls out by gripping into the slots.

Fig. 5.4-1: Sound insulation capsule, side partT o open the soun d insulation cap sule, the closures must

Fig. 5.4.2-2: Closure lockedClosure locked

Fig. 5.4-3: Closure openClosure open

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5.4.3 Opening the GFK sound insulation capsule

direction and lift the lash of the closure pin. After lifting of the lashes, the sound isolation cover upper pars can be removed.

Fig. 5.4-1: Lash closuresGFK sound insulation capsule with lash closures

Fig. 5.4-2: Lash closuresTo open the lash closures pull the handle in arrow

5.5 Special maintenance notes and arrangements at long periods of stand

still time or shutdown

Stand still is divided into the following groups:

• Short-term standstill (1 to 3 months).

• Medium-term standstill / winter storage (3 to 6 months).

• Long-term standstill (storage) / shutdown (more than 6 months).

5.5.1 Reference note for the starter battery at a long-term standstill

Notice: Starter batteries

Self-discharge of batteries is a physical and chemical process and cannot even be avoid by disconnecting the battery.

• Disconnect the battery from the generator at a long-term standstill.

• Charge the battery on a re gular basis. Follow the notes of the battery manufacturer.

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Before charging the battery, check the acid level according to the type of battery and refill each cell with distilled water up to the marking if necessary.

Today’s starter batteries are norma lly ma in te na nc e- fr ee .

Deep discharge may damage the battery and may be useless afterwards.

Keep the battery clean and dry. Continuously clean the battery terminals (+ and -) and clamps and lubricate with an acid-free and acid-resistant grease. Make sure there is a good contact of the clamp conn ections when assembling. If voltage is approx. below 1,95 Volt, the cell should not decline the open-circuit voltage of the battery. This equates approx. 2,1V / cell open-circuit voltage when battery is fully charged.

For a 12 V battery applies 11,7 V lower open-circuit voltage (battery flat) - conservation charging 13,2 V. For a 24 V battery applies 23,4 V lower open-circuit voltage (battery flat) - conservation charging 26,4 V.

These data relate to a battery temperature of 20-25°C. Consider the specifications of the battery manufacturer.

Notice: Fischer Panda recommendation:

• Install a battery main switch and turn it to the off-position. (Disrupt the battery circuit)

• Install a sufficient fuse in the positive battery line close to the battery

• Check contacts for corrosion on a regular basis.

5.5.2 Arrangements at a short-term standstill

Short-term standstill (1 to 3 months)

• Measure the charge of battery via the open-circuit voltage

• At stand still >7 days - disconnect the battery (e.g. put battery main switch to 0)

• Within 2-3 months - let the engine run for at least 10 min

• Fill fuel tank to 100% (level to full).

5.5.3 Arrangements at a medium-term standstill / winter storage

Medium-term stand still (3 to 6 months)

5.5.3.1 Arrangements for conservation:

• Check the charge of battery and recharge approximately every 3 months if necessar y. Consider the specificatio ns of the battery manufacturer.

• Check anti-freeze protection of the cooling water and refill if applicable.

The anti-freeze protection should not be older than 2 years. The content of the anti-freeze protection should be between 40% and 60% to ensure corrosion protection in the cooling water circuit; Refill anti-freeze if necessary.

If cooling water will be drained, for example after a conservation of the engine, no water should remain within the engine during the stand still. At the control unit a correspondent note „NO COOLING WATER“ has to be placed.

• Drain engine oil as required. Refill engine with conservation oil up to maximum at the oil dip stick.

• Drain diesel fuel from tank and refill with conservation mixture (90% diesel and 10% conservation oil - up to max).

Let engine run for 10 min.

• Remove v-belt as required and store packed at a dry place. Protect from UV radiation.

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Attention!Cover alternator openings.

No cleaning fluids or preserving agents may enter the alternator. Danger to destroy the alternator.

• Clean engine according to the manufacturer.

• Inject engine parts and v-belt pulleys with a preserving agent.

• Clean air filter housing and inject with a preserving agent.

• Close suction hole and exhaust opening (e.g. with tape or end caps).

• Drain sea water circuit.

• Close sea cock.

• Clean sea water filter.

• Remove impeller and store.

Attention!Carry out a deconservation before recommissioning.

5.5.3.2 Arrangements for deconservation after a medium-term standstill (3 to 6 months).

• Check charge of batter y and recharge if necessary. Consider the specifications of the battery manufactur er .

• Check anti-freeze protection of the cooling water and refill if applicable.

• Drain engine oil. Renew oil filter and oil according to specification.

• Remove preserva tion agent of the engine with petroleum.

• Degrease the v-belt pulleys and install v-belt correctly. Check v-belt tension!

• Disconnect turbocharger oil pressure line if existent and refill clean motor oil in pipe.

• Keep engine shut-off lever in 0-position and turn engine several times by hand.

• Clean air filter housing with petroleum, check air filter and renew if necessary.

• Remove covers of the exhaust opening and the suction holes.

• Connect battery. Close battery main switch.

• Install impeller.

• Open sea cock.

• Check sea water filter.

• Keep shut-off lever at generator in 0-position and activate starter for approx. 10 sec. Make a break for 10 sec. and repeat procedure twice.

• Visual inspection of the generator according to initial operation and start generator.

5.5.4 Arrangements at a long-term standstill / shutdown

Standstill (more than 6 months)

5.5.4.1 Arrangements for conservation:

• Check the charge of battery and rech arge ap proximately ever y 3 months if necessary. Con sider the specifications of the battery manufacturer.

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• Check anti-freeze protection of the cooling water and refill if applicable. The anti-freeze protection should not be older than 2 years. The content of the anti-freeze protection should be

between 40% and 60% to ensure corrosion protection in the cooling water circuit; Refill anti-freeze if necessary. If cooling water will be drained, for example after a conservation of the engine, no water should remain within the

engine during the stand still. At the control unit a correspondent note „NO COOLING WATER“ has to be placed.

• Drain engine oil as required. Refill engine with conservation oil up to maximum at the oil dip stick.

• Drain diesel fuel from tank and refill with conservation mixture (90% diesel and 10% conservation oil - up to max).

Let engine run for 10 min.

• Remove v-belt as required and store packed at a dry place. Protect from UV radiation

• Disconnect battery.Sprinkle terminals with acid-free grease.

Attention!Cover alternator openings.

No cleaning fluids or preservative agents may enter the alternator. Danger to destroy the alternator.

• Clean engine according to the manufacturer.

• Inject engine parts and v-belt pulleys with a preserving agent.

• Clean air filter housing and inject with a preserving agent.

• Sprinkle exhaust turbo charger (if existe nt) with conservation agent at intake and exhaust and close lines again.

Sprinkle preserving agent to the intake and exhaust lines than attach again.

• Remove valve cover and sprinkle the inside of the cover, shafts, springs, rocker lever etc. with preserving agent.

• Remove injectors and sprinkle the cylinder area with preserving agent. Keep the shut-off lever on the 0-position and

turn the engine by hand for several times. Screw in the injectors with new gaskets. Consider the tors ional moments.

• Sprinkle slightly the radiator cap and tank lid and respectively the radiator cap at the expansion tank and reinstall.

• Close intake and exhaust openings (for examp le with tape or end caps).

• Drain sea water circuit.

• Close sea cock.

• Clean sea water filter.

• Dismount impeller and store.

Attention!Carry out a de-conservation before recommissioning.

5.5.4.2 Arrangements after a long-term standstill (shutdown) / recommissioning (more

than 6 months):

• Check the charge of battery and recharge if necessary. Consider the specifications of the battery manufacturer.

• Check anti-freeze protection and level of the cooling water and refill if applicable.

• Drain engine oil. Renew oil filter and oil according specification.

• Remove preservation agent of the engine with petroleum.

• Degrease the v-belt pulleys and install v-belt correctly. Check v-belt tension!

• Disconnect turbocharger oil pressure line if existent and refill clean motor oil in pipe.

• Keep engine shut-off lever in 0-position and turn engine several times by hand.

• Clean air filter housing with petroleum, check air filter and renew if necessary.

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• Remove covers of the exhaust opening and the suction holes.

• Connect battery. Close battery main switch.

• Install impeller.

• Open sea cock.

• Check sea water filter.

• Keep shut-off lever at generator in 0-position and activate starter for approx. 10 sec. Make a break for 10 sec. and repeat procedure twice.

• Visual inspection of the generator according to initial operation and start generator.

Notice: Fischer Panda recommendation:

After a long-term standstill a complete 150 h inspection according to inspection schedule should be carried out.

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The Panda Generator

6. The Panda Generator

6.1 Type plate at the Generator

Fig. 6.1-1: Type plate at the generator

Fig. 6.1-2: Description type plate

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6.2 Description of the Generator

01. Water-cooled exhaust manifold / Heat exchanger (inside)

02. DC-alternator

03. V-belt for DC-alternator and cooling water pump

04. Oil pressure switch

05. Magnetic switch for starter motor

06. Starter Motor

07. Engine oil filter

08. Generator power terminal box

09. Connection point external ventilation valve

10. Sound-cover base part

11. Exhaust connection

12. Connection for external cooling water expansion tank

13. Raw water injection point

14. Thermoswitch for cooling water injection

15. Generator housing with winding

16. Mini VCS

6.2.1 Right Side View

Fig. 6.2.1-1: Right Side View

The Panda Generator

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The Panda Generator

01) Charge control for DC-alternator

02) Air suction housing with air filter

03) Actuator for speed control

04) Generator housing with winding

05) Cooling water connection block

06) Failure bypass switch

07) Flat fuse

08) Starter Relay Ks

09) Pre-Glow Relay (Glow Plugs) K2

10) Starter Relay Fuel pump K3

11) Seawater inlet

12) Fuel fine filter

13) Oil dipstick

14) Seawater pump

15) Adjusting nut

16) Ventilation screw fuel pump

17) Internal cooling water pump

18) Ventilation screw internal cooling water pump

6.2.2 Left Side View

Fig. 6.2.2-1: Left Side View

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6.2.3 Font View

01) Ventilation screw thermostat housing

02) Ventilation screw internal cooling water pump

03) Internal cooling water pump

04) Alternator 12 V

05) V-belt for DC-alternator and internal cooling water pump

06) Engine oil filter

07) Seawater pump

08) Fuel fine filter

09) Seawater inlet

10) Fuel intake connection

11) Fuel backflow connection

12) Fuel pump cable (2x1,5mm²)

13) Oil drain hose

14) Remote control panel cable (12x1mm²)

15) Electronic Voltage Control cable VCS (5x1mm²)

16) AC-Control box cable

17) Electronic Voltage Control cable VCS (5x1mm²)

18) AC-Control box cable

19) Main power

20) Battery minus (-)

21) Battery plus (+)

The Panda Generator

Fig. 6.2.3-1: Front View

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The Panda Generator

01. Capacitor (boost) (at generators with boost option only

02) Air suction housing with air filter

03) Capacitor (excitation)

04) Generator front plate

05) Cooling plate

06) Cooling water connection block

07) Intake external cooling water expansion tank

08) Back flow external cooling water expansion tank

6.2.4 Back View

Fig. 6.2.4-1: Back View

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6.2.5 View from above

01) Ventilation screw fuel

02) Ventilation screw internal cooling water pump

03) Ventilation screw thermostat housing

04) Thermostat housing with thermostat set

05) 12 V DC-alternator

06) Oil filler neck

07) Water cooled exhaust manifold / Heat exchange (inside)

08) Injection nozzle

09) Cylinder head thermo-switch

10) Air suction housing with air filter

11) Charge control for DC-Alternator

The Panda Generator

Fig. 6.2.5-1: View from above

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The Panda Generator

6.3 Details of functional units

6.3.1 Components of the Cooling System (Raw Water)

The diagram shows the supply pipes for the generator. The connection neck for the raw water connection is shown on the right hand side. The cross-section of the intake pipe should be nominally larger than the generator connection.

Fig. 6.3.1-1: Raw water intake Raw water intake

The raw water pump is fitted with a rubber impeller. This pump is self-inductive. If, fo r example, you fo rget to open the sea valve, then you must expect the impeller to be destroyed after a short period of time. It is recommended to store several impellers on board as spare parts.

The heat exchanger separates the raw water system from the fresh water system, so that the generator co mponent s do not have contact with the raw water circulation system. The raw water is fed direct to the exhaust connection piece at the heat exchanger outlet.

Fig. 6.3.1-2: Raw water impeller pump Raw water impeller pump

Fig. 6.3.1-3: Heat ExchangerHeat exchanger (mounted inside)

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A siphon must be installed if the generator sinks below the water line because of the rooking of the boat, even if it is only for a short period of time. A hose pipe on the generator casing has been produced for this. Both connecting pieces are bridged by a formed piece of hose.

The Panda Generator

Fig. 6.3.1-4: Connection ventilation valveVentilation valve

Fig. 6.3.1-5: Raw Water InjectionRaw Water Injection

The injection point for the marine generator water-cooled exhaust system is situated at the exhaust connection pieces The exhaust connections must be regularly checke d for signs of corrosion.

6.3.2 Components of the Cooling System (Fresh Water)

If the generator is fitted with a dual cooling system, the fresh water circulation system is sealed. The warmest point of the fresh water circulation system is located at the point marked at the exhaust elbow (see arrow). The cooling water leads from this point to the heat exchanger.

Fig. 6.3.2-1: Freshwater backflowFreshwater backflow

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The Panda Generator

The ventilation pipe at the water-cooled exhaust manifold leads to the external expansion tank. This pipe only serves as a ventilation pipe, if both pipes are to be connected to the external expansion tank (ventilation pipe and intake pipe).

external expansion tank

Fig. 6.3.2-2: Ventilation pipeVentilation pipe

Fig. 6.3.2-3: External Expansion TankHose connection pieces for the

The external expansion tank is connected by two hose connections. The connecting pieces showed here serves as constant ventilation for the water-cooling system.

In case the external expansion tank is connected with two hoses, the system will ventilate itself. In this case, additional ventilation is only necessary when the generator is initially filled, or if the cooling water is not circulating.

The internal freshwater circulation system is separated from the Raw water circulation system by the heat exchanger. This means the Raw water circulation system does not come into contact with the generator components. The Raw water is fe d directly to the exhaust connection at the heat exchanger outlet.

Fig. 6.3.2-4: Heat ExchangerHeat exchanger

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The cooling water is fed to and from the double lined casing

of the generator. The cooling water terminal block seals must be regularly checked for leaks.

In order to protect the generator casing from corrosion and electrolyse, the terminal block assumes the function of a sacrificial anode.

The Panda Generator

Fig. 6.3.2-5: Cooling Water Connection Block Cooling Water Connection Block

Fig. 6.3.2-6: Internal Cooling Water PumpInternal Cooling Water Pump

The fresh water pump aids the circulation of the fresh water. The fresh water enters and leaves the engine at the fresh

water pump.

A.) To the thermostat housing B.) From the external expansion tank The intake pipe from the external cooling water expansion

tank is connected to the point shown with „B“.

Fig. 6.3.2-7: Cooling water intakeCooling water intake

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The Panda Generator

The ventilation screw above the cooling water pump casing may not be opened, whilst the generator is running. If this occurs by mistake, air will be drawn through the opening. Extensive ventilation of the whole system is then necessary.

Fig. 6.3.2-8: Ventilation Screw Cooling Water PumpVentilation screw cooling water pump

Fig. 6.3.2-9: Ventilation Screw Thermostat HousingVentilation screw thermostat housing

The ventilation screw on the thermostat housing should occasionally be opened for control purposes. Standing machinery should principally carry out ventilating.

The manifold is cooled by means of the internal cooling system (freshwater). The cooling water filler necks on the casing of the manifold may not be opened. These cooling water necks are only required to fill the motor with cooling water in cases of repair. The normal cooling water controls may only be carried out at the external expansion tank.

Fig. 6.3.2-10: Water Cooled Exhaust ManifoldWater cooled exhaust manifold

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6.3.3 Components of Fuel System

The Panda generator is always supplied with an external, electrical (12 V DC) fuel pump. The fuel pump must be always installed in the proximity of the tank. The electrical connections with the lead planned for it are before inst alled at the generator. Since the suction height and the supply pressure are limited, it can be sometimes possible that for reinforcement a second pump must be installed.

The Panda Generator

Fig. 6.3.3-1: External Electrical Fuel PumpExternal Electrical Fuel Pump

1. Fuel intake

2. Fuel backflow

A consequential filtering of fuel is especially important for all marine systems.

A fine filter, which is firmly att ached to th e inside of the sound insulation capsule for the marine version, is supplied on delivery, and loose for other makes. In all cases a furth er prefilter with water separator must be installed. See directions for fuel filter installation.

Fig. 6.3.3-2: Connection Pieces for the Fuel PipeConnecting Pieces for the Fuel Pipe

Fig. 6.3.3-3: Fuel FilterFuel Filter

Fig. 6.3.3-4: Fuel-stopsolonoid Fuel Ventilation Screw

All models that do not have a fuel solenoid valve are equipped with a fuel ventilation screw to ventilate the fuel system.

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The Panda Generator

If the engine does not start after the ventilation, the fuel injection lines must be ventilated individually.

Fig. 6.3.3-5: Injection nozzles Injection Nozzles

Fig. 6.3.3-6: Glow PlugsGlow plugs

The glow plugs serve the pre-chamber for the heating with cold start. The glow device must be operated, if the temperature of the generator is below 16 ° C. This is practically the case with each start. The glow device and starter button are set in a way that ne ither may be used at the same time.

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6.3.4 Components of Combustion Air

The sound cover for the marine generator is normally provided at the lower surface with drilling, through which the combustion air can inflow.

It must be consistently paid attention that the generator is installed in such a way that no water can enter from below in close proximity to these air openings. (Minimum distance 150 mm).

The Panda Generator

Fig. 6.3.4-1: Combustion air intakeAir Suction Openings at the Sound Insulated Capsule

capsule

Drilling at the lower surface of the sound cover serve the admission of fresh air for the entrance. It must be safe that no raw water or other water can come into this range of openings. If air is sucked in through these openin gs, water can penetrate also into the sound cover .

The air intake casing (1) in the diagram shows the 12-volt DC charge control (2). This control must be checked if the 12-volt DC voltage is no longer correct.

If the cover is removed, the inside of the air suction housing becomes visible. In these air suction housings is a filter element. The filter for the marine version is normally changed. It should be checked once in a while.

Fig. 6.3.4-2: Drilling for Combustion AirDrilling for combustion air at the sound insulated

Fig. 6.3.4-3: Air Suction HousingAir suction housing with 12 V DC charge control

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The Panda Generator

If the cover is removed, the inside of the air suction housing becomes visible. In these air suction housings is a filter element. At the marine version the filter is normally not changed. It should be checked once in a while.

Fig. 6.3.4-4: Air FilterAir Suction Housing with Air Filter Set

Fig. 6.3.4-5: Combustion Chamber Intake ElbowCombustion chamber intake elbow

The figure shows the induction elbow at the combustion engine. At the front of this induction elbow you can see the hose connection between air suction housings and induction elbow. The air filter must be checked, if this hose contracts during operation.

At the back side of the engine is the water-cooled exhaust elbow.

Underneath the exhaust elbow, the raw water is injected into the exhaust

On the top side, the pipe union for the internal raw water circuit is to be seen and the filler neck for the cooling water.

Fig. 6.3.4-6: Exhaust ElbowWater-cooled Exhaust Elbow

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Seawater from the external cooling circle is fed here.

The Panda Generator

Fig. 6.3.4-7: Exhaust ConnectionExhaust connection at the exhaust elbow

Fig. 6.3.4-8: Exhaust OutletExhaust outlet

Connect the exhaust pipe with the water lock.

6.3.5 Components of the Electrical System

1. Cable for starter battery (minus)

2. Cable for starter battery (plus)

Fig. 6.3.5-1: Cable for Starter BatteryConnection starter battery

During connection to the starter battery, it must be always ensured that the contact is guaranteed.

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The Panda Generator

31 2

At the front of the sound insulation cover is also the outlet for the main power cable. Here are also the cables for exte rn al condensers connections, depending upon type of generator (see Connection Diagram for the AC-Control box!)

All remaining cables are located at the front end of the generator for electrical connections, depending upon type. The connections are taken from the AC-Control Box Plan. See here:

Fig. 6.3.5-2: Main PowerMain Power

Fig. 6.3.5-3: Electrical ConnectionsElectrical connections for control

1. Fuel pump

2. Remote control panel

3. VCS

4. AC-Control-Box

1. Starter motor and

2. Solenoid switch The diesel engine is started electrically. The electrical starter

with the solenoid switch is located at the rear of the engine.

Fig. 6.3.5-4: Starter MotorStarter motor

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The generator voltage is determined by progressive speed control through „VCS“ in conjunction with the speed actuator. Speed increases with increasing load.

The Panda Generator

Fig. 6.3.5-5: ActuatorActuator for speed regulation

Fig. 6.3.5-6: Blind PlugBlind Plug for Speed Sensor

All Panda Generators can be fitted with an external automatic starter. A separate speed sensor is necessary for this automatic starting system. The speed sensor is fitted as series in the case of some models. In the case of other models, the opening for the speed sensor is closed off by means of a sealing plug.

All Panda generators from Panda 6.000 are provided with its own charge system for the 12V DC mains. This DC-alternator is powered over a v-belt together with the internal cooling water pump.

The 12 V charge system may be used only for the generatorown starter battery.

Fig. 6.3.5-7: DC AlternatorDC Alternator

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The Panda Generator

L Z

The voltage regulator for the 12 V DC-a ltern ator is lo ca ted at the back of the air suction housing. The housing is streamlined for cooling purposes. The voltage regu la to r may not be externally covered. The surface must be accessible for cooling.

Fig. 6.3.5-8: Charge ControlCharge control for DC alternator

Fig. 6.3.5-9: Generator Power Terminal Box 230V/50HzGenerator Power Terminal Box 230V/50Hz

To locate the Terminal box see Chapter A2. In these terminal box there are the electrical connection

points for the AC generator. Here is also the bridge for the protective grounding of the generator . The cover may on ly be removed, if it is guaranteed that the generator cannot be inadvertently started.

Sample Picture

To locate the Terminal box see Chapter A2. In these terminal box there are the electrical connection

Fig. 6.3.5-10: Generator Power Terminal Box 400V/50HGenerator Power Terminal Box 400V /50 H z

Sample Picture

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power relays

K2Ks

F1 F2

F1 fuse 15 A for DC wiring F2 fuse 25 A for starter relay Ks power relay for starter K2 power relay for glow plugs K3 power relay for fuel pump

6.3.6 The Operation Surveillance System

The Panda Generator

Fig. 6.3.5-11: Terminal BlockTerminal block for remote control cable with fuses and

The thermo-switch at the cylinder head serves to monitor the generator temperature. All thermo-switches for the generators from Panda 6.000 upward are two-pole (ear thed), so called „openers“. This means the contacts are open in normal cases and close only when the limits have been exceeded.

If the impeller pump stops and delivers no more seawater, the exhaust connection becomes extremely hot.

Fig. 6.3.6-1: Thermo-switch at Cylinder HeadThermo-switch at cylinder head

Fig. 6.3.6-2: Thermo-switch at exhaust connectionThermo-switch at exhaust connection

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The Panda Generator

winding

1. Generator winding

2. Thermo-switch

3. Housing Two thermo-switches inside the windings to protect the

generator winding, which for safety reasons are installed independently in parallel.

In order to be able to monitor the lubricating oil system, an oil pressure switch is built into the system. The oil pressure switch is at the rear of the engine (In front of the electrical starter).

Fig. 6.3.6-3: Thermo-switch in the generator windingThermo-switch in the generator

Fig. 6.3.6-4: Oil Pressure SwitchOil pressure switch

The failure bypass switch offers the possibility of starting the generator if the electrical control switches off due to overheating of the cooling system.

Fig. 6.3.6-5: Failure Bypass switchFailure bypass switch

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6.3.7 Components of the Oil Circuit

Normally the filler neck for the engine oil is on the top side of the valve cover. A second filler neck is additionally attached at the operating side for numerous generator types. Please ensure the filler necks are always well secured after filling with engine oil.

Consider also the references to the engine oil specification.

The Panda Generator

Fig. 6.3.7-1: Oil filter neck with capOil filter neck with cap

At the dipstick the permissible level is indicated by the markings „maximum“ and „minimum“. The engine oil should be never filled beyond the maximum.

The oil filter should also be replaced, when an oil change is carried out.

Fig. 6.3.7-2: Oil dipstickOil dipstick

Fig. 6.3.7-3: Oil filterOil filter

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The Panda Generator

Fig. 6.3.7-4: Oil Drain HoseOil Drain Hose

The Panda generator is equipped so that the engine oil can be drained by means of a hose. The generator should be installed in such a way, that a collecting basin can be placed deeply enough. If this is not possible, an electrical oil drain pump must be installed.

Note: Lubricating oil should be drained warm!

6.4 Remote Control Panel - see separate Control Panel Manual

6.4.1 Starting the Generator - see separate Control Panel Manual

6.4.2 Stopping the Generator - see separate Control Panel Manual

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Installation Instructions

7. Installation Instructions

All connections (hoses, wires etc) and installation instructions are designed and suited for “standard” installation situations.

In situations where Fischer Panda has no detailed information concerning certain installation requirements (such as vehicle specifications, maximum vehicle speed -and all other conditions concerning special operating situations) the installation instructions should be used as an example guide only.

The installation must be undertaken and proved by a suitable qualified/trained person and may in accordance with the law as required by the country and special situation.

Damages caused by faulty or incorrect installation are not covered by the warranty.

7.1 Personal requirements

The described installation must be done by a technical trained person or a Fischer Panda service point.

7.1.1 Hazard notes for the installation

Follow the general safety instruction at the front of this manual.

Working 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 decanted to guarantee that the genera tor cannot be inadvertently started.

Do not run the generator with removed sound isol at ion cover

Improper installation can result in severe personal injuries or material damage.

- Always undertake installation work when the gener ator is switched off.

- Ensure there is sufficient installation clearance before start working.

Notice!:see “Safety first!” on Page 12.

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.

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-Warning!: Danger of fire

Page 64

- Remove oil and fuel residues from the generator and floor.

Installation Instructions

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!: protective equipment necessary.

- Protective clothing

- safety boots

- protective gloves

- Ear defender

- safety glasses

Disconnect all load during the work at the generator to avoid damages at the load.

Attention!: disconnect all load

7.2 Preparing the base - Placement

Since Panda generators have extremely compact dimensions, they can be installed in tight locat ions. 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 airb orne sounds in the most unreasonable case. An improvement can be achieved by reinforcing these surfac es with ribs . In

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Installation Instructions

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.

7.2.1 Advice for optimal sound insulation

Fig. 7.2.1-1: Generator BaseThe convenient base consists of a stable framework, on

which the generator is fastened by means of shock-mounts. Since the aggregate is „free“ downward, the combustion air

can be sucked in unhindered. In addition are void the vibrations, which would arise with a

closed soil.

7.3 Generator Connections

Connect all electrical wires within the capsule tightly to the motor and the generator. This is also the case for fuel lines and cooling water lines.

The electrical connections MUST be carrie d out according to the respective valid regulations. This also concerns used cable materials. The cable supplied is meant for laying „ protected“ (i.e. in p ipe) at a temper ature up to a max of. 70 ° C (160 ° F). The on-board circuit must also be fitted with all essential fuses.

ATTENTION! Before working (installation) on the System read the

section „Safety Instructions“ in thi s Man ua l.

7.4 Installation of the cooling system - raw water

7.4.1 General Information

The genset should have its own raw water (coolant water) inlet and should not be connected to any other engine systems. Ensure that the following installation instructions are complied with:

For the avoidance of galvanic corrosion, refer to the chapter „Service instruction for marine generators (corrosion protection)“.

7.4.2 Installation of the through hull fitting in Yachts

It is good practice for yachts to use a through hull fitting with an integr ated strainer. The through hull fitting (raw water intake) is often mounted against the sailing direction to induce more water intake for cooling.

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point in the sailing direction! When sailing at higher speeds more water will be forced into the inlet than the pump can handle and your generator will flood!

7.4.3 Quality of the Raw Water Sucking In Line

Installation Instructions

Fig. 7.4.2-1: Position of the Through Hull FittingFor Panda generators, the through hull inlet should NOT

In order to keep the suction resistance in the line at a minimum, the raw wate r intake system (i.e. sea cock, throughhull fitting, inlet filter, etc.) must have an inn er diameter of at least 1" (25 mm).

This applies also to installation components such as through-hull fitting, sea cock, raw water filter etc. The intake suction line should be kept as short as possible. Install the raw water inlet in close proximity to the

genset.

After start-up the cooling water quantity must be measured (e.g. by catching at the exhaust). The flow rate, as well as the necessary cross section of the cooling water pipe see section 11.10, “Diameter of conduits,” on page 219

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Installation Instructions

7.4.4 Generator Installation above Waterline

The Panda is equipped with a direct drive water intake pump mounted directly on the motor. Since the intake pump is an impeller pump there are wearing parts which are likely to require replacement after a period of time. Ensure that the genset is installed so that the intake pump can be easily accessed. If this is not possible, an external intake pump could be installed in an easily accessible location.

If the generator is installed above the waterline, it is possible that the impeller will wear out faster, because after starting, the pump runs dry for some seconds.

The raw water hose should form a loop as near as possible to the raw water inlet of the generator (see picture below). This ensures the pump only sucks in air for a short time. The impeller pump will be lubricated by raw water and the impeller life span will be increased.

By the installation of a check valve in the raw water inlet line, which is under the waterline, this problem can be restricted.

The impeller pump will remain intact longer, if an electrical booster pump is installed, and is strongly recommended in order to preserve the impeller pump.

exchanging the old pump. If the seal in g ring is def ec ti ve within the pump, raw water runs into the sound cover of the genset. A repair is then very expensive.

Replacement impeller and also a spare pump should always be on board. The old pump can be sent back to Fischer Panda.

1. Raw water filter

2. Water cock

3. Through hull Make certain that the raw water filter lies above the water

level, otherwise when cleaning, water can penetrate by the through hull. An external pre-pump can relieve the impelle r.

NOTE:Never change the impeller for many years, without

Fig. 7.4.4-1: Installing the generator above the water levelInstallation above water level

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Installation Instructions

7.4.5 Generator Installation below Water-Line

If the generator cannot be attached at least 600 mm above the waterline, a vent valve must be installed at the raw water line.

Fig. 7.4.5-1: Vent ValvePossible heeling must be taken into consideration if installed

at the „mid-ship line“! The water hose for the external vent valve is located at the

back of the sound insulated cover. This hose is split in the middle and extended respectively at each end by an additional hose and a connecting nipple. Both hose ends must be led outside of the sound cover to one point, if possible 600 mm over the waterline in the mid-ship line. The valve is connected at the highest place to the two hose ends.

water pump.

If the water pump ceases, the valve spring ensures that air can enter and therefore, a syphon effect is avoided.

The de-aeration valve must be regularly controlled. If t he water pump stops, the valve spring ensures that air enters. It must be opened, cleaned and greased.

Fig. 7.4.5-2: Connection Vent Valve

Cut the hose for the external vent valve....

Note: The vent valve must be installed directly behind the

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Installation Instructions

1. Vent valve

2. Coolant connection block

3. Raw water pump

4. Exhaust manifold

5. Raw water filter ø 1"

6. Water cock ø1“

7. Through hull

Both hose ends must be led out outs ide of the sound cover to one point, if possible 600 mm over the waterline at the mid ships line. The valve is connected at the highest place with the two hose ends.

7.4.6 Generator Housing cooled by Raw Water

Fig. 7.4.5-3: Connection Vent Valve... an d be n d it upw ar ds .

Fig. 7.4.6-1: Installation Scheme for Direct Cooling

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7.4.7 Indirect Cooling of the Genset Housing (by the Heat Exchanger)

1. Vent valve

2. Exhaust manifold

3. Raw water pump (Raw water impeller pump)

4. Heat exchanger

5. Raw water filter

6. Water cock

7. Hull inlet

Fig. 7.4.7-1: Installation Scheme Indirect Cooling of the Genset Housing

Installation Instructions

7.5 Installation of the cooling system - fresh water

7.5.1 Position of the external cooling water expansion tank

Position of the external cooling water expansion tank

The Panda generator is normally supplied with an additional, external cooling water expansion tank. This tank must be installed in such a way that its lower edge is at least 500 mm more highly arranged than the upper edge of the sound cover.

If this 500 mm should be fallen below, i.e. the cooling water expansion tank is lower installed, very large problems can occur with filling and ventilating. Extend and displace the hose lines to the outside or possibly even up to the deck.

Fig. 7.5.1-1: Position of the External Cooling Water Expansion

Tank

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Installation Instructions

ATTENTION! The external cooling water expansion tank may be filled only up to the lower edge of the lower tension tape (see note „max“) in the maximum filling level in cold condition.

7.5.2 Ventilating at the first filling of the Internal Cooling Water Circuit

1. Fill up the external cooling water expansion tank with coolant.

ATTENTION: maximum fill level = „max.“- mark. The cover of the external expansion tank temporar ily must be

opened (all other closures are now closed!).

Fig. 7.5.2-1: Expansion tankExpansion Tank

2. Open venting screw on the pipe socket of the internal cooling water pump. Close the vent screw when air free water comes out

• Check the water level in the expansion tank during the

venting. Fill up if necessary.

Never open the vent screw while the generator is running.

Sample picture

screw when air free water comes out

• Check the water level in the expansion tank during the

venting. Fill up if necessary.

Never open the vent screw while the generator is running

Fig. 7.5.2-2: Venting screw - Internal Cooling Water PumpVenting Screws

Fig. 7.5.2-3: Venting screw - Thermostat housing3.Open vent screw on the thermostat housing. Close the vent

Sample picture

4. Start the Generator After filling the generator it must be started. During this first

phase of start-up, the generator may not be loaded. Switch the generator off after about 10 sek. of operation!

5. Repeat the steps 1-4 till no air comes out of the vent screw at thermostat housing.

6. Close the vent screws.

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7. Fill up the expansion tank.

8. Close the expansion tank.

9. Re-ventilating process 10 Operating hours after the first start-up (and if necessary)

Also after the first implementing a small amount of air can be reside in the cooling circuit. To ensure an immaculate and actual operating of the cooling system the ventilating process must be repeated casual in the next few days (weeks, if necessary). Small amount of air will still exit out of the ventilating openings, especially if the generator stood still for a long time.

ATTENTION! During the ventilating process repeated checks must be made to check the cooling water is indeed circulating. If there are air bubbles in the internal cooling water pump, it could be that the cooling water is not circulating. The generator will heat up very quickly and switch off, because of overheating.

Anti-freeze

In the interest of safety, the freezing point of the closed circuit coolant should be checked on a regular basis. Be sure that the coolant/antifreeze mixture is good for at least -15°C (5 ° F) and if it is possible that your genset experiences lower temperatures, for example during storage or transportation, then the entire cooling system should be drained and purged

7.5.3 Pressure Test for Controlling the Cooling Water Circuit

Check if a temperature difference exists between cooling water in-flow and cooling water return flow by use of the hand.

Feel the cooling water in-flow line at the internal cooling water pump. Feel the cooling water return pipe either at the outlet of the water-cooled exhaust elbow union or at the side, where

this pipe exits at the heat exchanger. The temperature difference between in-flow and return should be approximately 10 degrees.

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1. Expansion Tank

2. Exhaust Manifold

3. Thermostat Housing

4. Freshwater pump

5. Heat Exchanger

6. Cooling Water Connection Block

7.5.4 Scheme for Freshwater Circuit at Two Circuit Cooling System

Fig. 7.5.4-1: Scheme for Freshwater Circuit at Two Circuit Cooling System

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7.6 Installation of the water cooled exhaust system

7.6.1 Installation of the standard exhaust system

The generator exhaust system must remain completely independent and separate from the exhaust system of any other unit(s) on board. The water lock must be installed at the lowest point of the exhaust sy ste m . An op tion al n o ise insulated water lock can also be installed. The exhaust hose descends from the capsule to the water lock. Then the hose rises via the „goose neck“ to the silencer (see drawing). The goose neck must be vertical and sit preferably along the ship's keel centre line. In order that the back pressure inside the exhaust is not to high, the total length of the exhaust system should not exceed 6 m (20 ft.)

By injecting the outlet raw water into the exhaust manifold, the exhaust gases are cooled and the noise emissions from the exhaust system are reduced.

Exhaust diameter see section 11.10, “Diameter of conduits,” on page 219

Fig. 7.6.1-1: Installation Scheme Standard Exhaust System

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7.7 .Installation of the waterlock

Note!:Pay attention to the right flow direction throught the

waterlock.

Unfortunately , it can occasionally occu r that, because of an disa dvant ageous mountin g position of the waterlo ck, sea water gets into the diesel engines’ combustion chamber. This disables the diesel engine by irreversible damages. Quite frequently, this leads to discussions during which the parties involved in the yachts’ construction or the installation of the generator have to explain themselves.

One point in this situation can be clarified definitely:

If sea water gets into the inner section of the engine, this is not possible due to constructional defects of the generator or to malfunctions on the engine itself. It can only reach the combustion chamber via the exhaust hose and thus get into the engine.

Thereby, the position of the generator and the waterlock, as well as the arrangement of the cooling water and exhaust hoses play the decisive role.

If the waterlock is arranged in an unfavourable position, the cooling water flowing back in the exhaust hose can rise so high, that it reaches the exhaust stack. Since at least one discharge valve is always op en when the engine is shut off, the sea water has free access to the combustion chamber. By capillary action, this sea water then flows past the cocks and even reaches the engine oil in that way. (In fact, a surprisingly high oil level is a first indication of an upcoming catastrophe).

If an usual high oil level can be detected and/or the oil is of a greyish colour, the engine must not be used anymore. This is a certain sign for cooling wat er that got int o the oil pan. If the engine is started under thes e conditions, the water and the oil are mixed into an emulsion. The oil will quickly become so viscous that one will have to call it a paste. In this phase the fine oil hoses are blocked and a few moments later the machine gets destroyed because of insufficient lubrication. Before this happens, an immediate oil change should be made. Since the water can only reach the engine via the combustion chamber, it can be assumed that the compression rings will start to corrode. These effects have to be discussed with an engine expert. It will certainly be reasonable to immediately inje ct plenty penetrating oil through the intake stack and to slowly turn the engine with the starter motor.

The cooling water can reach the exhaust area via the exhaust hose as well as via the cooling water feed.

7.7.1 Possible cause for water in the exhaust hose

7.7.1.1 Possible cause: exhaust hose

If the cause is the exhaust hose itself, the following points are to be checked at the hose: a) Position of the waterlock is too high. The water reaches the exhaust hose. b) Position of the waterlock is too far away from the middle of the generator. The water reaches the exhaust hose in

tilted position. c) The waterlock is too small relating to the length of the exhaust hose.

7.7.1.2 Possible cause: cooling water hose

If the generator is not clearly installed 600 mm over the water line, the cooling water feed must be equipped with a „venting valve“ which is at least led out 600 mm over the water line. (This position must also be assured in every tilted position. Therefore, the venting valve should be located in the ships’ center line, so that it cannot move in tilte d position).

a) Position of the venting valve is too low. The water flows into the exhaust area when the ship is tilted.

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b) Position of the venting valve is too far from the ships’ center line. The water reaches the exhaust area when the ship is tilted.

c) The venting valve does not work, because it jams or it is clotted. (The venting valve’s function needs to be checked regularly.)

As it consistently happens that functioning risks are not realised during the laying of the exhaust hose, the following explanations refer explicitly to the exhaust hose. Here, the location, the size and the position of the „wat erlock “ play a very decisive role:

7.7.2 Installation area of the waterlock

Concerning a water-cooled exhaust system, it must be regarded that - under no circumstances - cooling water from the exhaust hose can get into the exhaust elbow area at the engine. If this happens, the cooling water can get into the combustion chamber via an open discharge valve. This would lead to irreparable damage at the engine.

In addition to that, one has to reckon with poss ible tilted positions of sailing yachts, which makes the position of the waterlock even more important. In general one could say that:

The deeper the waterlock is located underneath the generator, the better the pr otec tio n from entering water into the combustion chamber.

The picture below shows that the distance between the critical point at the exhaust elbow and the maximum permissible water level in the exhaust hose is stated with 600 mm. This distance should be understood as a minimum distance.

Fig. 7.7.2-1: Installation area of the waterlock

7.7.3 The volume of the waterlock

The waterlock must be measured so large, that it can take the entire amount of water flowing back from the exhaust

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hose. The amount of water depends on the hoses’ length (L) and its cross section. While the diesel engine is running, cooling water is continuously injected into the exhaust system and is carted outside with the emissions by the exhaust gas pressure. When the engine is turned off, the number of revolutions sinks quite fast. By doing so, the point is reached where the exhaust gas pressure does not suffice anymore to cart the cooling water out. All cooling water remaining in the hose at that point flows back into the waterlock. At the same time, the diesel engine itself continues to cart cooling water through the cooling water pump, as long as it keeps on rotating.

The waterlock must necessarily be measured large enough that it can take the entire amount of cooling water and, at the same time, does not exceed the prescribed vertical height of 600 mm up to the critical point at the exhaust elbow.

Fig. 7.7.3.0-1: Volume of the waterlock

If there are any doubts, a verification can easily be made by temporarily using a clear-sighted hose (1) as exhaust hose. In that way, the cooling water level can be checked very easily.

Fig. 7.7.3.0-2: Testing the cooling water level

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7.7.3.1 Ideal position of the waterlock

Important Note! The ideal position of the waterlock would be in center underneath the generator. Only in this position it is

assured that the water level cannot change drastically in tilted position by the waterlock moving out of the center line. See the following pictures:

Fig. 7.7.3.1-1: Ideal position of the waterlock

In Fig. 7.7.3.1-1, the waterlock is mounted in center underneath the g enerator. When the ship tilts, the position of the waterlock related to the critical point at the exhaust hose, changes only slightly.

Fig. 7.7.3.1-2: Tilted position 15 degrees

Tilted position 15 degrees - Fig. 7.7.3.1-2

The distance from the exhaust elbow to the hydrostatic head has derated to 540 mm.

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Fig. 7.7.3.1-3: Tilted position 30 degrees

Tilted position 30 degrees - Fig. 7.7.3.1-3

The distance of the water level, even in ideal position, changes that only 458 mm distance remain. So the critical distance is under-run already.

Fig. 7.7.3.1-4: Tilted position 45 degrees

Tilted position 45 degrees - Fig. 7.7.3.1-4

In this case the water level rise so high, that the distance constitutes only 325 mm. Even when the water lock is mounted in the ideal spot, at an extremely tilted position of 45 degrees there is still the

risk that water can get straight into the discharge stack area through strong rocking motions („sloshing“). This shows that the distance of 600 mm rep resents a minimum size at which, even when installed ideally, the water can slosh into the exhaust elbow when the ship is very tilted or rocks very hard.

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Summary:

The preset minimum height of 600 mm must be regarded unconditionally and is only valid if the waterlock is mounted in its ideal position in center underneath the generator. A higher position is highly recommended if it has to be reckoned with tilted positions of 45 degrees.

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7.7.3.2 Example of the installation of the waterlock off-center and possible effects:

The following pictures are primarily relevant for an installation of the generator with the waterlock on sailing yachts. A change in the mounting position caused by tilted position does not have to be reckoned concerning motor yachts. Here it is only necessary to regard that the volume of the waterlock is measured so large that it can take the entire amount of water flowing back, and at the same time, maintains the minimum distance of 600 mm.

A) Installation of the waterlock 500 mm next to the generator’s center line:

Fig. 7.7.3.2-1: waterlock, 500 mm next to the center line

Fig. 7.7.3.2-2: Tilted position, 15 degrees

Tilted position 15 degrees - Fig. 7.7.3.2-2

The distance is only 404 mm instead of the original 600 mm. So this is very close to the critical point.

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Fig. 7.7.3.2-3: Tilted position 30 degrees

Installation Instructions

Tilted position 30 degrees - Fig. 7.7.3.2-3

The distance between the hydrostatic head and the critical point at the exhaust elbow is only 216 mm. This means that in a tilted position of 30 degrees you already face the highest risk of sea water sloshing into the combustion chamber.

Fig. 7.7.3.2-4: Tilted position 45 degrees

Tilted position 45 degrees - Fig. 7.7.3.2-4

The water level is now at the same height as the critical point at the exhaust elbow. If the ship is sailed in a tilted position of 45 degrees with an installation like this, the ingress of cooling water into the combustion chamber is inevitable. Irreparable damages are pre-programmed.

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B) Installation distance between waterlock and the generator’s center line 1000 mm

Fig. 7.7.3.2-5: waterlock, 1000 mm next to center line

Fig. 7.7.3.2-6: Tilted position 15 degrees

Tilted position 15 degrees - Fig. 7.7.3.2-6

The distance is, contrary to the original 600 mm, only 327 mm. This is very close to the critical point already.

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Fig. 7.7.3.2-7: Tilted position 30 degrees

Installation Instructions

Tilted position 30 degrees - Fig. 7.7.3.2-7

The water level and the critical point at the exhaust elbow are at the same level now. If the ship is sailed in a tilted position of 30 degrees with an installation like that, the infiltration of cooling water into the combustion chamber is inevitable. Irreparable damages are pre-programmed.

Summary:

Concerning sailing yachts it must be regarded, that the waterlock is mounted in center underneath the generator, at least in reference to the ships’ center line. Thus the waterlock is prevented from „leaking“ very strongly when the ship is tilted.

The „leaking“ of the waterlock leads to a rise of the water level which then gets too close to the exhaust elbow’s critical point.

7.8 Exhaust / water separator

In order to reduce the noise level of the gener ator unit to a minimum, an optional exhaust outlet muffler can be mounted next to the through-hull fitting. Additionally there is a component at Fischer Panda, which acts as both an „exhaust goose neck“, and water separator. With this „exhaust/water separator“ the cooling water is derived over a separate pipe. The exhaust noises emana ting from the exter ior of the yacht are strongly decreased. Particularly the „water splash“.

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(1) Raw water outlet

Fig. 7.8.0-1: Water Flow Exhaust Water SeparatorWater flow exhaust water Separator

Fig. 7.8.0-2: Exhaust Water SeparatorWater flow exhaust water Separator

(2) Hose connector (3) Reducer (if required) (4) Hose (5) Hose connector (6) Sea cock (7) Hull outlet (8) Hose Clips

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7.8.1 Installation exhaust water separator

1. Generator

2. Silencer / Water lock

3. Exhaust-Water-Separator

4. Silencer

5. Sea cock

6. Hull outlet

Fig. 7.8.1-1: Installation Exhaust Water Separator

Installation Instructions

If the exhaust water separator was sufficiently highly ins talled, a goose neck is no longer necess ary. The exhaust/ water separator fulfils the same function. If the „Super silent“ exhaust system were installed correctly, the generator will not disturb your boat neighbour. The exhaust noise should be nearly inaudible. The best result is reached, if the hose line, which derive the cooling water, is relocate on a short way „falling“ directly to the outlet and this outlet is under the waterline.

If the through-hull exhaust outlet has to be mounted far from the generator, an exhaust-water separator must definitely be installed. The raw water from the separator must then run along the shortest possible path in the through-hull outlet. For such long exhaust routes, the exhaust hose diameter should also be increased, f.e. from NW40mm to NW50mm in order to reduce the back-pressure. The exhaust may have a length of over 10m (32 ft.) if the exhaust hose diameter is increased. An additional outlet exhaust muffler close to the hull outlet will help further to reduce noise emissions.

The generator will not disturb your boat neighbours, if the „Super silent Exhaust System has been correctly installed. The exhaust noise should be almost inaudi ble .

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Example of an unfavourable installation:

- Water lock not far enough below the lowest level of the generator

- Distance water lock to exhaust/water separator too large

Fig. 7.8.1-2: Example for an unfavourable Installation

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1. Generator

2. Fuel stopcock

3. Fuel filter

4. Fuel return

5. Condensation water suction pump (optional)

6. Fuel tank

7. Fuel supply

8. Electrical fuel pump (DC)

7.9 Installation of the fuel system

7.9.1 General references

Inside the generator capsule itself, there is the fuel filter installed (exception: Panda 4200 and 4500). Additional fuel filters (with water separator) must be mounted outside the capsule in easily accessible places in the fuel lines between the tank intake fuel pump and the diesel motor's fuel pump.

Generally forward and return fuel flow pipes must be mounted to the diesel tanks. Do not connect the generator fuel supply lines with any other fuel lines of other diesel systems.

• The following items need to be installed:

• Fuel supply pump (DC)

• Pre-filter with water separator (not part of the delivery)

• Fine particle fuel filter

• Return fuel line to fuel tank (unpressurized) The fuel supply pump should be mounted as close to the fuel tank as possible. The electric cable for the fuel pump

is already installed on the generator (length 5 m).

Fig. 7.9.1-1: Installation Scheme Fuel System

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7.9.2 The Electrical Fuel Pump

With the Panda generator is usually supplied an external, electrical fuel pump (DC). The fuel pump must be installed close at the fuel tank. The electrical connections are preloaded at the generator with the lead planned.

Suction height of the pump: max. 1,2 m at 02, bar

Diameter of fuel lines: section 11.10, “Diameter of conduits,” on page 219.

Fig. 7.9.2-1: Electrical Fuel PumpElectrical fuel pump

7.9.3 Connection of the fuel lines at the tank

Lead the return fuel pipe connected to the day tank to the floor

The return pipe connected to the tank must be dropped to the same depth as the suction pipe, if the generator is mounted higher than the tank, in order to prevent fuel running back into the tank after the motor has been switched off, which can lead to enormous problems, if the generator is switched off for a long period.

Non-return valve in the suction pipe

A non-return valve must be fitted to the suction pipe, which prevents the fuel flowing back after the generator has been switched off, if it is not possible to use the return flow pipe as a submerge pipe placed in the tank. The 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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7.9.4 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).

Installation Instructions

Fig. 7.9.4-1: Pre-filter with water separatorAdditionally to the standard fine filter a pre-filter with water

7.9.5 Ventilating air from the fuel system

Normally, the fuel system is designed to vent air itself i.e. as soon as the electric starter motor starts; the fuel pump starts working and the fuel system will be air-vent automatically after some time. It is, nevertheless essential, to vent the system as follows prior to the first operation (as all hoses are empty):

1. Switch main power switch on control panel „ON“.

2. Push failure bypass switch and hold tight. The electric fuel pump has to be run audibly. By moving the failure bypass switch you can hear the solenoid valve of

the generator starting and stopping (when the sound insulation cover is taken off).

3. After the fuel pump has been running 3 to 4 minutes, because the failure bypass switch has been pressed down, the bleeding screw of the solenoid valve has to be unscrewed. The switch has to be continuously depressed, when opening the screw . A piece of clo th or absorb ent p ape r should be put under the co nnection to avoid fuel entering the sound insulation cover.

4. The air vent screw can be screwed in again, as soon as fuel runs out without bubbles. Then release the depressing the failure bypass switch.

5. Starting the generator Now the generator can be started by pushing the „START“-button. The generator should start after a short while.

One of the pipe union nuts of an injection hose has to be unscrewed, should the unit not start; then try to restart the generator. After the generator has started, the pipe union nut has to be tightened again.

Main power switch „OFF“

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Not installed at all models!

7.10 Generator DC system installation

Fig. 7.9.5-1: Vent Screw at the Fuel Stop Solenoid ValveVent Screw at the fuel stop solenoid valve

The Panda generators from 6.500 NE 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 an y 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 elec tric system from the rest of the boat's DC s ystem, i.e. minu s pole (-) is not connected electrically to Earth/Ground.

The generator is then Earth/Ground free.

7.10.1 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 underne ath the starter motor at the engine mount (position 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)

NOTE:To avoid large voltage dro ps the battery should be installed as near as possible to the generator. The positive terminal of the battery is attached at the red cable, the negative pole at the blue cable.

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It must be guaranteed that first the cables are att ached 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 circuit breaker in the plus pole ca ble of the batter y, but with a distance to the battery of up to 300 mm (12 inch) at maximum.

The cable from the battery to the safety device must be secured with protective pipe/sleeve against chafing through. For the connection use self-extinguishing and fire-protected cables, which are appropriate for temperatures up to 90

°C, 195 °F. The batteries must be installed in such a way that they do not chafe through or other mechanical load can be

stripped. The battery poles must be secured against unintentional short-circuit. The positive battery cable within the generator must be shifted in such a way that it is protected against heat and

vibrations by appropriate sleeve/prote ctive pip e. It must be shif ted in such a way that it does not af fect rot ary p art s 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 ch eck 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.

Fig. 7.10.1-1: Positive Battery Cable Positive battery cable

The positive (+) battery cable is connected direc tly to th e solenoid switch of the starter.

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1 2 3

The negative (-) battery cable is connected to the engine foot.

Note! The battery negative pole may not be connected with the boat ground or with the protective grounding of the 120 V installation!

Fig. 7.10.1-2: Negative Battery CableNegative battery cable

Fig. 7.10.1-3: DC-RelayDC-Relay

The Panda generators 8000 to 30 are equipped with various DC-relays, which can be found under the terminal strip. The various relays have the following tasks (also see the DC circuit diagram)

1. Starter motor relay

2. Pre-glow relay (glow plugs)

3. Fuel pump relay

Sample Picture - See wiring diagram

All Panda generators are equipped with an independent DC starter motor.

1. Solenoid switch for starter motor

2. Starter motor

Fig. 7.10.1-4: DC Starter Motor DC Starter Motor

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Fig. 7.10.1-5: Battery installation - Scheme

1. Generator

2. Battery block

3. Fuse

4. Battery main switch

Installation Instructions

7.10.2 Connection of the remote control panel - see separate control panel manual

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Installation Instructions

1. Generator

2. AC-Control Box

3. Distribution panel

7.11 Generator AC System Installation

SAFETY INSTRUCTIONS of this manual FIRST! Be sure that all electrical installations (including all safety systems) comply with all required regulations of the regional authorities. This includes lightening conductor, personal protection switch etc.

7.11.1 Installation with looped in AC-Control box

Fig. 7.11.1-1: Installation with looped in AC-Control box

ATTENTION! Before the electrical system is installed, READ the

All electrical safety installations have to be made on board.

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7.11.2 Installation AC-Box / distribution panel separate connected

1. Generator

2. AC-Control Box

3. Distribution panel

Fig. 7.11.2-1: Installation AC-Box / distribution panel separate connected

Installation Instructions

A power source selector switch must be installed between the generator (or if applicable, AC-Control box) and the ship's electrical supply system. This switch must used to ensure that all AC consumers can be switched off at once. This switch should also be installed to keep the generator and shore (grid) power systems separate.

Fig. 7.11.2-2: 3-Way Cam Switch3-Way Cam Switch

A 3-way cam switch should be used. This switch basic positions: „Shore power“ - „OFF“ - „Generator“. If an (DC- AC) inverter is used, a fourth position will be required.

0. OFF I. Generator II. Shore power connection III. Inverter

The cam-type switch must have 2 poles, so that „MP“ and „phase“ can be switched off. If a 3-phase current system is also installed with the option of supplying fr om eithe r the gener ator or shor e power, an

additional switch must be installed to keep these systems separate. An alternative to a manual rotating switch is an automatic power relay. When th e gener ator is not runn ing, th e relay

remains in the shore power positio n. As soon as th e ge ner ator is running, the power relay switches automatically to the generator position.

Note: If the system has both single and 3-phase AC, it is CRITICAL that the two systems remain SEPARATE! Protection conductor

The generator is provided with a PEN safety system, as standard, which connects the 3-phase delta centre point „N“ to the safety ground strap.

If a separate ground protection cable is necessary (i.e. due to national safety regulations), the bridge between the

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generator housing and ground (in the AC-Control box) must be disconnected. Once such a ground protection cable is installed, it must be connected to the ground straps of all on board electrical devices.

In order to monitor the electrical system, it is recommended to install a voltmeter (and, if possible, a current mete r) down line from the power source selector s witch so that all respective power sources can be monitored. A separate voltmeter for the generator, itself, is therefore not required.

Electrical fuses

It is absolutely essential that the electrical system installation is inspected by a qualified electrical technician. The generator should have it s own AC inpu t el ectrical fu ses. T he fu se s sh ould b e sized such that the rated current of the generator on each of the individual phases is not exceeded by more than 25%.

Data for gensets with power output greater than 30 kW on request! The fuses must be of the slow type. A 3-way motor protection switch must be installed to pr otect the ele ctr ical motor.

Required fuses see rated current on the type plate

Required cable cross-sections

The following recommended electrical cable dimensions (cross sections) are the minimum required sizes for a safe installation. (see “Cable cross section” on page 212.)

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Installation Instructions

7.11.3 AC-Control Box with VCS and ASB - not all models

The required capacitors for the excitation of the generator are located in the AC-Control box, as well as the electronic control for voltage/speed regulation (VCS) and the starting current re-enforcement (ASB). The AC-Control box must be connected by electrical wires (high voltage and low-voltage) to the generator.

The front panel must always be closed, since the AC-Control box produces 400 V during operation.

The AC-Control box must be electrically connected to the generator (high and low voltage).

Danger - High voltageATTENTION! Before working on the System read the

„Section Safety Instructions in this Manual“.

Fig. 7.11.3-1: Opened AC Control BoxAC-Control Box

Inlet VCS-connection (X1) Inlet measuring voltage (X3) Excitation cable to generator (X4)

Fig. 7.11.3-2: Opened AC Control Box from Panda 30 upwardsAC-Control Box - from Panda 30 upwards

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Installation Instructions

1. Connection measuring voltage

2. Adjusting booster voltage (do not adjust!)

3. Adjustment VCS-voltage

4. Connection VCS inlet

5. Electrical fuse (1.6 A, slow to blow)

6. Potentiometer for booster time

7. Connection for PC

7.11.4 VCS voltage control

All Panda generators from Panda 8000 upwards are fitted with the electronic voltage control „VCS“ as standard. The VCS controls the generator voltage and motor speed . A actuator on th e injection pump ca n i ncrease the engin e

speed by up to 8%. If the generator is run without load, the voltage should be 231V with a frequency of ap proximate l y 48.5 to 49Hz. The

frequency (equates to the speed) can be increased by up to 8%. This ensures that the engine speed is increased when there is an extra load. The maximum speed is achieved when 80% load is reached.

The speed gauge is governed by an adjusting screw, above and below. Adjustment of this screw may not occur without the expressive approval of the manufacturer.

All signals pass through the circuit board in the AC-Control box. The signal impulse for the actuator is passed to the electric motor by means of the 5 core wire.

The generator maintains its full capability if the VCS has a defect. In this case the base current must be raised to at least 240 V by adjusting the minimum setting on the speed gauge,

in order to ensure that the generator output voltage at 70% nominal load does not drop below 21 5 V.

Fig. 7.11.4-1: VCS Control

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7.11.4.1 Alternative Mini VCS

Alternative for generators without AC control box the Mini VCS. The Mini VCS and the capacitors are is mounted at the generator.

Installation Instructions

Fig. 7.11.4.1-1: Mini VCS at the Panda 6000 ND PMSMini VCS at the Panda 6500 NE PMS

Note:

The Mini VCS has no internal fuse.

Fig. 7.11.4.1-2: Capacitors at the Panda 6000 ND PMSCapacitors at the Panda 6500 NE PMS

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