How it Works
Fischer Panda
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6500 PMS
User Manual
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Fischer Panda 6500 PMS, 7mini PMS User Manual

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Page 1
Power - wherever you are
Manual
Marine Generator
Panda 6500 PMS / Panda 7mini PMS
Super silent technology
120 / 240 V - 60 Hz / 6 kW
Fischer Panda GmbH
Panda_6500_7mini_PMS_eng.R01 22.3.11
Page 2

Current revision status

Document
Actual: Panda_6500_7mini_PMS_eng.R01_22.3.11 Replace:
Revision Page
Erstellt durch / created by
Fischer Panda GmbH - Leiter Technische Dokumentation Otto-Hahn-Str. 32-34 33104 Paderborn - Germany Tel.: +49 (0) 5254-9202-0 email: [email protected] web: www.fischerpanda.de
Copyright Duplication and change of the manual is permitted only in consultation with the manufacturer!
Fischer Panda GmbH, 33104 Paderborn, reserves all rights regarding text and graphics. Details are given to the best of our knowledge. No liability is accepted for correctness. Technical modifications for improving the product wit­hout previous notice may be undertaken without notice. Before installation, it must be ensured that the pictures, dia­grams and related material are applicable to the genset supplied. Enquiries must be made in case of doubt.
Page 3
Current revision status.......................................................................................................... 2
1 General References and Regulations ..........................................................................9
1.1 Safety first symbols ....................................................................................................... 10
1.2 Tools ................................................................................................................................ 15
1.3 Manufacturer declaration in accordance with the machine guideline 98/37/EG ...... 17
1.4 Customer registration and guarantee .......................................................................... 17
1.4.1 Technical Support ............................................................................................................. 17
1.4.2 Attention, important directions regarding operation! .......................................................... 17
1.5 Safety instructions - Safety first! .................................................................................. 18
1.5.1 Safe operation ................................................................................................................... 18
1.5.2 Observe safety instructions ............................................................................................... 18
1.5.3 Wear personal protective equipment (PPE) ...................................................................... 18
1.5.4 Cleanness protect ............................................................................................................. 18
1.5.5 Safe handling of fuel and lubricants - Keep away from fire ............................................... 19
1.5.6 Exhaust gases and fire prevention .................................................................................... 19
1.5.7 Cautions against burns and battery explosion ................................................................ . 20
1.5.8 Keep hands away from rotating parts ................................................................................ 20
1.5.9 Anti-Freeze and disposal of fluids ..................................................................................... 20
1.5.10 Implementation of security and maintenance .................................................................. . 21
1.6 Warning and caution labels ........................................................................................... 21
1.6.1 Safety instructions concerning operating the generator .................................................... 21
1.6.1.1 Protective grounding and potential equalisation.........................................................................22
1.6.1.2 Ground wire............................................................................................................................... 22
1.6.1.3 Switch off all load when working on the generator.................................................................... 22
1.6.1.4 Safety instructions concerning the cables..................................................................................23
1.6.2 Recommended starter battery size ................................................................................... 23
1.6.3 Important Advice for Batteries - Starting batteries and Traction batteries ......................... 23
1.6.4 Safety Instructions for the Handling with Batteries ............................................................ 24
2 In case of Emergency First Aid / Im Notfall - Erste Hilfe......................................... 27
2.7 WHEN AN ADULT STOPS BREATHING ....................................................................... 28
3 Basics ........................................................................................................................... 29
3.0.1 Intended use of the machine ............................................................................................. 29
3.0.2 Purpose of the manual und description of the definitions trained person/operator/user ... 29
3.0.2.1 Trained persons ........................................................................................................................ 29
3.0.3 Operator ............................................................................................................................ 29
3.0.3.1 User........................................................................................................................................... 29
3.1 Panda Transport Box ..................................................................................................... 30
3.1.1 Bolted Fischer Panda Transport Box ................................................................................ 30
3.1.2 Fischer Panda Transport Box with metal tab closure ........................................................ 30
3.2 Transport and Loading/Unloading ................................................................................ 30
3.2.1 Transporting the generator ................................................................................................ 30
3.2.2 Loading/unloading of the generator ................................................................................... 30
3.3 Scope of delivery ............................................................................................................ 31
3.3.1 Asyncron Genertoren: ....................................................................................................... 31
3.3.2 Opening the MPL sound insulation capsule . .................................................................. . 33
3.3.3 Opening the GFK sound insulation capsule ...................................................................... 33
3.4 Special maintenance notes and arrangements at long periods of stand still time or shut-
down 34
3.4.1 Reference note for the starter battery at a long-term standstill ......................................... 34
3.4.2 Arrangements at a short-term standstill ............................................................................ 35
3.4.3 Arrangements at a medium-term standstill / winter storage .............................................. 35
3.4.3.1 Arrangements for conservation:................................................................................................ 35
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Page 4
3.4.3.2 Arrangements for deconservation after a medium-term standstill (3 to 6 months)................... 36
3.4.4 Arrangements at a long-term standstill / shutdown ........................................................... 36
3.4.4.1 Arrangements for conservation: ............................................................................................... 36
3.4.4.2 Arrangements after a long-term standstill (shutdown) / recommissioning (more than 6 months): 37
4 The Panda Generator...................................................................................................39
4.1 Type plate at the Generator ........................................................................................... 39
4.2 Description of the Generator ......................................................................................... 40
4.2.1 Right Side View ................................................................................................................. 40
4.2.2 Left Side View .................................................................................................................... 41
4.2.3 Front View ......................................................................................................................... 42
4.2.4 Back View .......................................................................................................................... 43
4.2.5 View from above ................................................................................................................ 44
4.3 Details of Functional Units ............................................................................................ 45
4.3.1 Remote control panel ........................................................................................................ 45
4.3.2 Components of the Cooling System (Raw Water) ............................................................. 45
4.3.3 Components of the Cooling System (Fresh water) ............................................................ 47
4.3.4 Components of Fuel System ............................................................................................. 49
4.3.5 Components of combustion air .......................................................................................... 50
4.3.6 Components of Electrical System ...................................................................................... 52
4.3.7 Sensors and Switches for Operation Surveillance ............................................................ 54
4.3.8 Components of Oil Circuit .................................................................................................. 55
4.4 Operation of the generator - see separate remote control panel manual ................. 57
4.4.1 Daily routine checks before starting - see separate remote control panel manual. ........... 57
4.4.2 Starting Generator - see separate remote control panel manual. ..................................... 57
4.4.3 Stopping Generator - see separate remote control panel manual. .................................... 57
5 Installation Instructions...............................................................................................59
5.1 Personal requirements ................................................................................................... 59
5.1.1 Hazard notes for the installation ........................................................................................ 59
5.2 Preparing the base - Placement ................................................................................... 61
5.2.1 Advice for optimal sound insulation ...................................................................................61
5.3 Generator Connections .................................................................................................. 61
5.4 Installation of the cooling system - raw water ............................................................. 62
5.4.1 General Information ........................................................................................................... 62
5.4.2 Installation of the thru hull fitting in Yachts ........................................................................ 62
5.4.3 Quality of the Raw Water Sucking In Line .........................................................................62
5.4.4 Generator Installation above Waterline ........................................................................... . 63
5.4.5 Generator Installation below Water-Line ......................................................................... . 64
5.4.6 Generator Housing cooled by Raw Water ......................................................................... 65
5.4.7 Indirect Cooling of the Genset Housing (by the Heat Exchanger) ................................... . 66
5.5 Installation of the cooling system - fresh water .......................................................... 66
5.5.1 Position of the external cooling water expansion tank ....................................................... 66
5.5.2 Ventilating at the first filling of the Internal Cooling Water Circuit ...................................... 67
5.5.3 Pressure Test for Controlling the Cooling Water Circuit .................................................... 68
5.5.4 Scheme for Freshwater Circuit at Two Circuit Cooling System ....................................... . 69
5.6 Installation of the water cooled exhaust system ......................................................... 70
5.6.1 Installation of the standard exhaust system ...................................................................... 70
5.6.2 .Installation of the water collector ...................................................................................... 70
5.6.3 Possible cause: Exhaust duct ............................................................................................ 71
5.6.4 Possible cause: Coolant duct ............................................................................................ 71
5.6.5 Installation area of exhaust water collector ....................................................................... 71
5.6.5.1 The volume of the exhaust water collector............................................................................... 72
5.6.5.2 Position of the water collector.................................................................................................... 74
5.6.5.3 Example of the installation of the water collector off-center and possible effects: .................... 76
5.6.6 Exhaust / water separator .................................................................................................. 78
5.6.7 Installation exhaust water separator ................................................................................ . 80
5.7 Installation of the fuel system ....................................................................................... 82
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5.7.1 General references ............................................................................................................ 82
5.7.2 The Electrical Fuel Pump .................................................................................................. 83
5.7.3 Connection of the fuel lines at the tank ............................................................................. 83
5.7.4 Position of the pre-filter with water separator .................................................................... 84
5.7.5 Ventilating air from the fuel system ................................................................................... 84
5.8 Generator DC system installation ................................................................................. 85
5.8.1 Connection of the starter battery block .............................................................................. 85
5.8.2 Connection of the remote control panel - see separate control panel manual .................. 88
5.9 Generator AC System Installation ................................................................................ 89
5.9.1 Installation with looped in AC-Control box ......................................................................... 89
5.9.2 Installation AC-Box / distribution panel separate connected ........................................... . 90
5.9.3 AC-Control Box with VCS and ASB - not all models ...................................................... . 92
5.9.4 VCS voltage control ......................................................................................................... . 93
5.9.4.1 Alternative Mini VCS ..................................................................................................................94
5.9.5 Installation with mini VCS mounted at the generator ........................................................ 95
5.9.6 Jump start at high starting current (Booster) ..................................................................... 95
5.9.7 Insulation test .................................................................................................................. . 96
6 Maintenance Instructions............................................................................................ 97
6.1 Personal requirements .................................................................................................. 97
6.2 Hazard notes for this chapter ........................................................................................ 97
6.3 Environmental protection .............................................................................................. 99
6.4 General maintenance instructions ............................................................................... 99
6.4.1 Checks before each start .................................................................................................. 99
6.4.2 Check of Hoses and Rubber Parts in the sound insulated capsule .................................. 99
6.5 Oil Change Intervals ....................................................................................................... 99
6.5.1 Checking oil-level .............................................................................................................. 99
6.5.2 Refilling Oil ...................................................................................................................... 101
6.5.3 After the oil level check and refilling the oil ..................................................................... 101
6.6 Replacement of engine oil and engine oil filter ......................................................... 102
6.6.1 After the oil change ......................................................................................................... 104
6.7 Verifying the starter batterie and (if necessary) the battery bank ........................... 105
6.7.1 Battery ............................................................................................................................. 105
6.7.1.1 Check battery and cable connections ..................................................................................... 105
6.7.1.2 Check electrolyt level .............................................................................................................. 105
6.7.1.3 Check electrolyt density .......................................................................................................... 105
6.8 Grease lubricated generator backend bearing .......................................................... 106
6.8.1 Exchange of grease lubricated bearing ........................................................................... 107
6.8.1.1 Demounting the cooling disc (if existent)................................................................................. 107
6.8.1.2 Demounting the backend bearing ........................................................................................... 107
6.8.1.3 Installing the new backend bearing......................................................................................... 108
6.9 Checking the oil level of the generator end bearing at Fischer Panda generators 112
6.9.1 Oil level check ................................................................................................................. 112
6.9.2 Refilling oil ....................................................................................................................... 113
6.9.3 Refiller-Set ....................................................................................................................... 113
6.9.4 Screw plug ....................................................................................................................... 113
6.10 Replacement of the oil-cooled backend bearing ....................................................... 114
6.10.1 Exchange oil-cooled bearing ........................................................................................... 114
6.10.2 Demounting the bearing .................................................................................................. 114
6.11 Checking the water separator in the fuel supply ...................................................... 127
6.11.1 Ventilating the fuel system .............................................................................................. 127
6.11.2 Exchange of the Fuel Filter ............................................................................................. 128
6.11.2.1 Optional fuel filter with sight glass........................................................................................... 129
6.11.3 Replacement of the air filter mat ................................................................................... . 130
6.11.3.1 Alternative replacement of the air filter mat with pull out holder.............................................. 131
6.12 Ventilation of the coolant circuit / freshwater ........................................................... 132
6.12.1 Replacement of the V-Belt for the internal cooling water pump ...................................... 134
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6.13 The seawater circuit ..................................................................................................... 136
6.13.1 Cleaning the seawater filter ............................................................................................. 136
6.14 Reasons for frequent impeller wear ........................................................................... 136
6.14.1 Replacement of the impeller ......................................................................................... . 137
7 Generator Faults.........................................................................................................139
7.1 Personal requirements ................................................................................................. 139
7.2 Hazard notes for this chapter ...................................................................................... 139
7.3 Tools and Measuring Instruments .............................................................................. 140
7.4 Troubleshooting Table and Flowchart .......................................................................141
7.4.1 Generator output voltage too low .................................................................................... 141
7.4.2 Generator voltage too high (more than 240 V - 50 Hz .................................................... 141
7.4.3 Generator voltage fluctuates ........................................................................................... 141
7.4.4 Generator not able to start electric motor ........................................................................ 141
7.4.5 Diesel motor fails to start ................................................................................................. 141
7.4.6 Starter is turning motor, but fails to start .......................................................................... 141
7.4.7 Motor does not achieve enough speed during starting process ...................................... 142
7.4.8 Motor runs unsteady ........................................................................................................ 142
7.4.9 Motor speed drops ........................................................................................................... 142
7.4.10 Motor runs in off position ................................................................................................. 142
7.4.11 Motor stops by itself ......................................................................................................... 143
7.4.12 Sooty, black exhaust ....................................................................................................... 143
7.4.13 Generator must be shut off immediately if: ...................................................................... 143
7.4.14 Troubleshooting for the VCS-Voltage Control ................................................................. 143
7.4.15 Troubleshooting Flowcharts .......................................................................................... . 144
7.4.15.1 Details and explanations concerning the troubleshooting flowchart....................................... 146
7.5 Versions of the generator power terminal box .......................................................... 150
7.6 Overloading the generator ........................................................................................... 154
7.6.1 Monitoring the Generator Voltage ................................................................................. . 155
7.6.2 Automatic voltage monitoring and auto-shut down .......................................................... 155
7.7 Setting the speed governor of the actuator ............................................................... 156
7.7.1 Setting the maximum upper speed setting ...................................................................... 156
7.7.2 Setting the normal speed settings ................................................................................... 157
7.7.3 Greasing the trapezoidal thread spindle on the speed actuator .................................... . 158
7.7.4 Consequences of a continual overloading of the Actuator ............................................ . 159
7.7.5 Possible faults concerning the speed control „VCS“ ....................................................... 159
7.7.6 Steps to check the voltage control in case of a failure: .................................................. 159
7.7.6.1 ..........................................The following measures are necessary if the actuator is jammed: 160
7.7.6.2 Checking the generator voltage limitation .............................................................................. 160
7.8 Generator-Output Voltage is too low .......................................................................... 161
7.8.1 Discharging the Capacitors ............................................................................................. 161
7.8.2 Checking the Capacitors ............................................................................................... . 162
7.8.2.1 Checking the electrical connections to the capacitors............................................................ 162
7.8.3 Check the Generator Voltage ..........................................................................................162
7.8.4 Measuring the Ohm Resistance of the Generator Windings ...........................................163
7.8.5 Check the Windings for Short Circuiting .......................................................................... 163
7.8.6 Measuring the Inductive Resistance .............................................................................. . 164
7.9 Generator provides no voltage ................................................................................... 164
7.9.1 Rotor Magnetism Loss and "Re-magnetising" ................................................................. 164
7.10 Engine Starting Problems ............................................................................................ 165
7.10.1 Electric Fuel Solenoid Valve ........................................................................................... 165
7.10.2 Re-start with Failure Bypass Switch ................................................................................ 165
7.10.3 Lifting solenoid for motor stop - optional .......................................................................... 166
7.10.4 Troubleshooting Table ..................................................................................................... 167
8 Tables..........................................................................................................................169
8.1 Technical Data .............................................................................................................. 169
8.2 Rated current ................................................................................................................171
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8.3 Cable cross section ..................................................................................................... 171
8.4 Fuel ................................................................................................................................ 171
8.5 Engine oil ...................................................................................................................... 172
8.5.1 Engine oil classification ................................................................................................... 172
8.5.1.1 Operating range: ..................................................................................................................... 172
8.5.1.2 Quality of oil:............................................................................................................................ 172
8.6 Coolant specifications ................................................................................................. 173
8.6.1 Coolant mixture ratio ....................................................................................................... 173
8.7 Types of coil ................................................................................................................. 173
8.7.1 HP1 - 230V / 50 Hz ........................................................................................................ 173
8.7.2 HP1 - 120V / 60 Hz ........................................................................................................ 174
8.7.3 HP3 - 400V / 50 Hz ......................................................................................................... 174
8.7.4 HP3 - 120V / 60 Hz ......................................................................................................... 174
8.7.5 DVS - 400V / 50 Hz ......................................................................................................... 175
8.7.6 DVS - 120V 240V / 60 Hz ............................................................................................. . 176
8.8 Resistor & inductance of the generator coil .............................................................. 176
8.9 Voltage values stator coil ............................................................................................ 177
8.10 Diameter of conduits .................................................................................................... 177
9 Impellerfilter ............................................................................................................... 179
9.1 General .......................................................................................................................... 180
9.2 How it works ................................................................................................................. 180
9.3 Cleaning and replacement of the impellerfilter ......................................................... 180
9.4 Spare part kit ................................................................................................................ 184
9.5 Dimensions ................................................................................................................... 185
Generator Control Panel P6+ ............................................................................................ 187
Current revision status P6+ manual................................................................................. 188
10 Safety Instructions Generator Control P6+............................................................. 189
10.1 Personal requirements ................................................................................................ 189
10.2 Safety instructions for this chapter ............................................................................ 189
11 General operation ...................................................................................................... 191
11.1 Panel Generator Control .............................................................................................. 191
11.2 Rear view 12V-version ................................................................................................. 192
11.3 Rear view 24V-version ................................................................................................. 193
11.4 Installation of the remote control panel ..................................................................... 194
11.4.1 Placement. ...................................................................................................................... 194
11.4.2 Terminal connections ...................................................................................................... 194
11.4.3 Function of the jumpers ................................................................................................... 195
11.4.4 Configuration and adjustment ......................................................................................... 197
11.4.4.1 Configuration and setting sheet KE01..................................................................................... 197
11.4.4.2 Configuration and setting sheet KE02..................................................................................... 198
11.4.4.3 Configuration and setting sheet KE03..................................................................................... 199
11.4.4.4 Configuration and setting sheet KE04..................................................................................... 200
11.5 Starting preparation / Checks (daily) .......................................................................... 201
11.5.1 Marine version ................................................................................................................. 201
22.3.11 Panda_6500_7mini_PMS_eng.R01 - Kapitel/Chapter A: Seite/Page 7
Page 8
11.5.2 Vehicle version ................................................................................................................ 201
11.6 Starting and stopping the generators ........................................................................202
11.6.1 Starting the generator ...................................................................................................... 202
11.6.2 Stopping the generator ....................................................................................................203
11.7 Automatic adapter - optional ....................................................................................... 204
11.7.1 Function: .......................................................................................................................... 204
11.7.2 The mechanism entrance: ...............................................................................................204
11.7.3 Terminal connections ...................................................................................................... 206
11.8 Master-Slave adapter - optional .................................................................................. 207
11.8.1 Fischer Panda Art. No. 21.02.02.015H 12V-version .............................................. 207
11.8.2 Fischer Panda Art. No. 21.02.02.01H 24V-version ................................................ 207
11.8.3 Terminal Connections: ..................................................................................................... 208
11.8.4 Fuse: ................................................................................................................................ 208
11.8.5 Terminal connections ...................................................................................................... 208
11.8.5.1 Terminal X2 ( IN/OUT from view Master-Opearating-Panel).................................................. 208
11.8.5.2 Terminal X3............................................................................................................................ 209
11.8.6 Configuration and adjustment .......................................................................................... 210
11.8.6.1 Configuration and setting sheet KE05.................................................................................... 210
11.8.6.2 Configuration and setting sheet KE06.................................................................................... 211
12 Measurements ............................................................................................................213
12.1 Hole pattern ................................................................................................................... 213
Page 9
General References and Regulations
since
1977
since
1978
since
1988
since
1988
since
1988

1. General References and Regulations

Icemaster GmbH Fischer Marine
Generators
Conclusion Fischer -
Icemaster GmbH
100 % water cooled
Panda generators
Panda Vehicle
Generators
Fischer Panda
FISCHER GENERATORS have been manufactured since 1978 and are a well-known brand for first class diesel generators with especially effective sound-insulation. Fischer has been one of the leading manufacturers for marine generators in respect of quality and know-how during this period. FISCHER, as the worldwide manufacturer of modern marine diesel generators, developed the Sailor-Silent series for example and produced a GFK sound-insu­lated capsule as early as 1979 and the basis for new generator technology.
The companies Fischer and Icemaster amalgamated under the direction of Icemaster in 1988, in order to concen­trate on the development of new products. Production was moved to Paderborn.The amalgamation of the two quali­fied companies led to the development of a complete new programme within a short space of time. The generators developed at that time set new technological standards worldwide.
The generators became more efficient and powerful than other generators in the same nominal performance range, because of the improved cooling. Panda generator demonstrated its superiority in several tests by renowned institu­tes and magazines during the past years. The patented VCS (voltage Control System) means it can meet all demands including motor speed. The start-booster (ASB) means Panda generators meet the highest demands in respect of voltage stability and starting values.
A water-cooled Fischer Panda generator, with the same drive motor, produces 15 % more effective output than the majority of conventional generators. This superiority in efficiency also ensures a fuel saving to the same extent.
The Fischer Panda generators are currently manufactured in the performance range from 2 to 200 kW in various versions. Fast running motors are preferred for performances up to approx. 30 kW (nominal speed 3000 resp. 3600 rpm). The heavier slow runners are preferred for the higher range. The fast running generators have proved them­selves many times for many uses, that they meet the demands in quality of yachts and vehicles, and offer space and weight saving of 50 % compared to slow running generators.
In addition to the Panda series, Fischer Panda also supply the super compact high-tech sound-insulated battery charging generators from the DC/AC Panda AGT series, which is a very interesting solution for the production of mobile power.
The HTG-alternators ensure that a charging rate of 280 amps is achieved that was scarcely thought possible for this compact construction. This alternator replaces a separate shipboard generators (constant 230 volts AC with up to
3.500 W from the main machine)
22.3.11 General.R01.1 - Kapitel/Chapter 1: General References and Regulations Seite/Page 9
Page 10
General References and Regulations

1.1 Safety first symbols

These symbols are used throughout this manual and on labels on the machine itself to warn of the possibility of per­sonal injury. Read these instructions carefully. It is essential that you read the instructions and safety regulations before you attempt to assemble or use unit.
Warning!: Toxic elementsThis danger symbol refers to toxic danger and draws atten­tion to special warnings, instructions or procedures which, if not strictly observed, may result in severe personal injury or loss of life.
Attention!: Important AdviceThis warning symbol draws attention to special warnings, instructions or procedures which, if not strictly observed, may result in damage or destruction of equipment
instructions or procedures which, if not strictly observed, may result in damage or destruction of equipment
bes works
ided.
generator and/or electrical system
Warning!: Danger of fireThis warning symbol draws attention to special warnings,
Prohibitation!: No SmokingDo not smoke in that area / do not smoke during the descri-
Prohibitation: Fire and open flames prohibitedFires and open light are ignition sources, which must be avo-
Prohibitation: Turn on / start operation prohibitedDo not turn on or start operation. People are working at the
Seite/Page 10 General.R01.1 - Kapitel/Chapter 1: General References and Regulations 22.3.11
Page 11
General References and Regulations
Proscription!: Do not touch Berühren der entsprechenden Teile und Anlagen verboten
Warning!: Automatic start. Generator can be started by an external signal
These symbols refer to electrical danger and points to special warnings, instructions and advices, which must be noticed. Otherwise an electrical shock with personal injury or death can be the consequence.
or swallowed
Warning!: High voltage / danger by electricity ­Danger for life
Warning!: Danger for life and/or equipment General Warning
Warning!: Harmful if accumulateSubstances can be harmful or lead to death, if accumulated
Warning!: Electric shockWarning of live parts, which can cause electrical impacts
during contact. Special danger for persons with heart pro­blems and/or pace makers.
Warning!: Rotating partsDanger of injury by drawing into the machine. Injury by crus­hes and eventually the separation of extremities. Danger of drawing during contact with extremities, loose clothes, scarf, ties etc.
22.3.11 General.R01.1 - Kapitel/Chapter 1: General References and Regulations Seite/Page 11
Page 12
certain conditions - e.g. heat or ignition sources
ding
General References and Regulations
Warning!: Risk of explosionWarning of materials, which can lead to explosions under
Warning!: Hot surfaceSurfaces and substances may be hot. Danger of burn / scal-
Warning of materials, which cause corrosive damage during contact. These materials can work contaminating when entering into the body.
and drag along liquids. Danger of injury by parts flying around, danger of burn by liquids and gases.
Warning!: Danger carrosive material - contermi­nation of persons possible
Warning!: System can be under pressure!When opening the system the pressure can suddenly escape
Seite/Page 12 General.R01.1 - Kapitel/Chapter 1: General References and Regulations 22.3.11
Page 13
General References and Regulations
Warning!: Hearing damage
Warning!: Magnetic field
Warning!: High pressure
Protective clothing is close fitting, with low resistance to tea­ring, with narrow sleeves and without protruding parts. It mainly provides protection against being entangled by moving machine parts.
Wear ear defenders to protect the ears against hearing damage.
Wear safety glasses to protect the eyes against parts flying around or squirts of fluids. Optical eyeglasses are not repla­cement for appropriate eye protectors.
Instruction!: Wear personal protective equip-
ment (PPE)
Instruction!: Wear personal protective equip-
ment (PPE)
Instruction!: Wear personal protective equip-
ment (PPE)
Wearing protective gloves protects the hands against friction, graze, punctures or deep cuts as well as contact with hot sur-
Instruction!: Wear personal protective equip-
ment (PPE)
faces.
22.3.11 General.R01.1 - Kapitel/Chapter 1: General References and Regulations Seite/Page 13
Page 14
installation guidelines of manual, in order to avoid dangers and accidents. You protect yourself and the generator.
you and your children
General References and Regulations
Instruction!: Read the manual instructionsRead and consider the regulations, safety instructions and
Instruction!: Environmental protectionEnvironmental protection is the protection of our habitat. For
Seite/Page 14 General.R01.1 - Kapitel/Chapter 1: General References and Regulations 22.3.11
Page 15
General References and Regulations
X

1.2 Tools

This symbols are used throughout this manual to show which tool must be used at maintenance or installation.
Spanners SW X = required size X mm
Hook wrench for oil filter
Screw driver, for slotted head screws and for recessed head screws
Multimeter, multimeter with capacitor measuring
Socket wrench set
Hexagon wrench keys
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Page 16
General References and Regulations
Current clamp (DC for synchron generators; AC for asynchron generators)
Torque wrench
Seite/Page 16 General.R01.1 - Kapitel/Chapter 1: General References and Regulations 22.3.11
Page 17
General References and Regulations
1.3 Manufacturer declaration in accordance with the machine guideline 98/
37/EG
Manufacturer declaration in accordance with the machine guideline 98/37/EG The generator has been developed in such a way, that all assembly groups correspond to the CE guidelines. If
machine guideline 98/37/EG is applied, then it is forbidden to start the generator, until it has been ascertained that the system into which the generator is to be integrated, also corresponds to the machine guideline regulation 98/37/ EG. This includes the exhaust system, cooling system and electrical installation.
The evaluation of "protection against contact" must be carried out when installed, in conjunction with the respective system. This includes correct electrical connections, a safe ground wire connection, foreign body and humidity pro­tection, protection against humidity due to excessive condensation, as well as overheating through appropriate and inappropriate use in its installed state. The responsibility lies with those who undertake installation of the generator in the final system.

1.4 Customer registration and guarantee

Use the advantages of the customer registration:
• Thus you receive to extended product informations, which are sometimes safety-relevant
• you receive, if necessarily free Upgrades Far advantages: By your full information Fischer Panda technicians can give you fast assistance, since 90% of the disturbances
result from errors in the periphery. Problems due to errors in the installation can be recognized in the apron.

1.4.1 Technical Support

Technical Support per Internet: [email protected]

1.4.2 Attention, important directions regarding operation!

1. The installation certificate must be completed when taken into use, and certified by a signature.
2. The installation certificate must be despatched within two weeks of use to Fischer Panda.
3. The official guaranty confirmation will be completed by Fischer Panda after receipt and sent to the customer.
4. A guaranty must be shown to make any claims. Claims against the guaranty will not be accepted of the above said instructions are not, or only partially, carried out.
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General References and Regulations

1.5 Safety instructions - Safety first!

1.5.1 Safe operation

Careful operation is your best assurance against an accident. Read and understand this manual carefully before operating the engine. All operators, no matter how much experience they may have, should read this and other related manuals befor operating the generator or any equipment attached to it. It is the owner´s obnligation to provide all operators with this information and instruct them on safe operation.

1.5.2 Observe safety instructions

Read and understand carefully this manual and „Labels at the engine“ before attempting to start and operate the generator. Learn how to operate and work safely. Know how your equipment and its limitations. Always keep the generator in good condition.

1.5.3 Wear personal protective equipment (PPE)

Do not wear loose, torn or bulky clothing around the maschine that may catch on working controls and prejections or into fans, pulleys ond other moving parts causing personal injury.
Use additional safety items-PPE, e.g. safety protection, safety googles, gloves , etc. Do not operate the generator or any equipment attached to it while under the influence of alcohol,
medication, or other drugs, or while fatigued.
Do not wear radio or music headphones while operating the generator.

1.5.4 Cleanness protect

Keep the engine and the surrounding clean. Ensure that the generator is stopped before cleaning. Keep the generator clean and free of accu-
mulated dirt, grease and trash to avoid fire. Store flammable liquids in proper containers and cabi­nets away from sparks and heat. Check for leak immidiately and repair if necessary.
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General References and Regulations

1.5.5 Safe handling of fuel and lubricants - Keep away from fire

Keep away open fire from fuels and lubricants. Always stop the generator before refueling and/or lubrivating and protect against unintentional
starting. Do not smoke or allow flames or sparks in your work area. Fuel is extremely flammable and explo-
sive under certain conditions.
Refuel at a well ventilated and open place. When fuel and/or lubrication are spilled, refuel after letting the generator cool down.
Do not mix gasoline or alkohol with diesel fuel. The mixture can couse a fire or severe generator damage.
Do not use unapproved containers e.g. buckets, bottles, jars. Use approved fuel starrage contai­ners and dispensers.

1.5.6 Exhaust gases and fire prevention

Generator exhaust fumes can be very harmful af allowed to accumulated. Be sure to run the engine in a well ventilated location and where there are no people or livestock near the engine.
Check the Generator and all pipes and hoses regularly of leaks and repair immediately if neces­sary.
The exhaust gas and the engine can be very hot during operation and afterwards. To prevent a fire, do not expose dry gras, moved gras, or any other combustible material to exhaust gas or the hot generator surface.
To prevent a fire, do not short electrical cables. Check regularly all electrical cables and wires. Uncoated wires and loose connections can cause electrical shock, electrical short circuit and fire.
The generator should be integrated in the local fire protecting system.
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 of diesel engines and some components are carcinogen and can cause deformati­ons and other gene effects.
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General References and Regulations

1.5.7 Cautions against burns and battery explosion

To avoid burns, be cautious of hot components, e.g. muffler, muffler cover, radiator, hoses, engine body, coolants, engine oil, ect. during operation and after the engine has been shut down.
The Coolant system can be under pressure, Open the coolant system only, when the generator is colled down. Wear „Personal Protective Equipment„.
Be shure that the coolant system is closed and all hose clamps are tightend before operating the generator.
The battery (Starter battery and AGT battery bank) presents an explosive hazard. When the bat­tery is being charged, hydrogen and oxigen gasses are extremly explosive.
Do not use or charge a battery if its fluid level is below the lower mark. Otherwise, the component parts may deteriorate earlier than expected, which may shorten the the service life or cause an explosion. Immediatly, add distilled water until the fluid level is between the lower and the upper marks.
Keep sparks and open flames away from the battery, especially during charging. Do not strike a match near the battery.
Do not check the battery charge by placing a metal object across the terminals (danger of short circuit, battery damage and high danger of explosion). Use a Voltmeter or a hydrometer.
Do not charge a frozen battery. There is a riosk of explosion. When frozen, warm the battery up to at least 16°C.(61°F).

1.5.8 Keep hands away from rotating parts

Operate the generator with closed sound cover capsul only. Be shure to stop the generator befor checking or adjusting the belt tension. Keep your hands and body away from rotating parts, such as the cooing fan, V-Belt, fan drive
belt, ra´w water pump drive belt, pulley or Flywheel. Do not operate the generator without safety guards. Install safety guards securly before opera-
tion.

1.5.9 Anti-Freeze and disposal of fluids

Anti-freeze contains poison. Wear rubber gloves to avoid personal injury. In case of contact with skin, whash it off immideately. Do not mix different types of Anti-freeze. The mixture can produce chemical reactioncausing harmful substances. Use approved or genuine Fischer Panda Anti­freeze.
Protect the environment. When draining fluids from the generator, place a siutable container underneath the generator body. Consider the relevant enviromental protection regulations when disposing of oil, fuel, coolant, breakfluid, filters and batteries. Do not poor waste onto the ground, down a drain, or into any water source. Conducting safety checks and maintenance
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General References and Regulations

1.5.10 Implementation of security and maintenance

Disconnect the battery from the generator before conducting service. Put a „DO NOT OPERATE“ tag on the remote control panel to avoid accidental starting. Disconnect any automatic starter device, e.g. battery monitor to prevent automatic starting.
To avoid sparks from an accidental short circuit always disconnect the battery´s ground cable (-) first and connect it last. be shure that the generator is stopped and cooleed down when conducting daily and periodic maintaenance, service and cleaning.
Always use the apprppirate tools and fixtures. Verify that they are in good conditions before per­forming any service work. Make shure you understand how to use them before service.
Keep first aid kit and fire extinguisher handy at all times.

1.6 Warning and caution labels

Keep warning and caution labels clean and free from obstructing material. Clean warning and caution labels with soap and water, dry with a soft cloth. Replace damaged or missing warning and caution labels with new labels.

1.6.1 Safety instructions concerning operating the generator

The electrical installations may only be carried out by trained and qualified personnel!
The generator must not be taken into use with the cover removed.
If the generator is being installed without a sound insulation capsule, make sure that all rotating parts (belt-pulley, belts etc) are covered and protected so that there is no danger to life and body!
If a sound insulation covering will be produced at the place of installation, then well-placed signs must show that the generator can only be switched on with a closed capsule.
All servicing-, maintenance or repair work may only carried out, when the motor is not running. Electrical voltages above 48 volts (battery chargers greater than 36 volts) are always dangerous
to life). The rules of the respective regional authority must be adhered to. Only an electrician may carry out installation of the electrical connections for safety reasons.
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General References and Regulations
1.6.1.1 Protective grounding and potential equalisation
In the low voltage board for power supply of the consumers therefore a protective conductor is grounded and connected with electrically conductive objects. The connection with an outer conductor with these object then leads to the earth fault. This earth fault leads to the release of an over-current protection mecha­nism and thus to the disconnection of the voltage.
1.6.1.2 Ground wire
The generator, is "earthed" as series (centre and ground are connected together in the generator terminal box by a bridge). This is an initial ground fuse, which offers protection, as long as no other measures are installed. Above all, it is conceived for the delivery and possible test run.
This "neutralisation" (Protective Earthing Neutral - PEN) is only effective, if all parts of the electrical system are commonly "earthed" to a common potential. The bridges can be removed, if this is necessary for technical reasons and another protective system has been setup.
There is full current in the AC control box when the generator is running. It must therefore be ensured that the control box is closed and cannot be touched when the generator is running.
The battery must always be disconnected, if work on the generator or electrical system is to be carried out, so that the generator cannot be unintentionally started.
1.6.1.3 Switch off all load when working on the generator
All load must be disconnected, in order to avoid damages to the devices. In addition the semi conductors in the AC control box must be disconnected in order to avoid the boat capacitors being activated. The minus pole of the battery ought to be removed.
Capacitors are required to run the generator. These have two varying functions: A) The working capacitors B) The (Booster) capacitors Both Groups are located in a separate AC-Control box. Capacitors are electrical stores. There could be a residual of high electrical current at the contacts
for a period disconnection from the circuit. The contacts may not be touched for safety reasons, If the capacitors are to be exchanged or checked, and then a short circuit between the contacts should be made so that the stored energy is discharged.
If the generator is switched off in the normal manner, the working capacitors are automatically discharged by means of the windings. The booster capacitors are discharged by means of internal discharge resistors.
All capacitors must be short-circuited before work is carried out on the AC-Control box for safety reasons. Potential equalisation at Panda AGT DC generators. Further information for your generator see capture installation.
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Page 23
General References and Regulations
1.6.1.4 Safety instructions concerning the cables
Cable Type
It is recommended is that the cable used be UL 1426 (BC-5W2) compliant, with Type 3 stranding (ABYC Section E-
11)
Cable Size
The cable size must be selected taking into account the amperage, voltage and conductor length (from the positive power source connection to the electrical device and back to the negative power source connection.
Cable Installation
It is recommended that a self draining wire loom classified as V-2 or better in accordance with UL 94 be installed in the section of the cable routed in the interior of the sound capsule. Care should be taken to avoid hot surfaces such as the exhaust manifold or engine oil drain bolt and routed clear of any possible sources of chafing.

1.6.2 Recommended starter battery size

Only use batteries which are certified as starter battery by the manufacturer. Only use batteries with capacity recommended by the engine manufacturer.
Attention !! Check before installation if the starter battery voltage correspond with the genera­tor start system.
f.e. 12V starter battery for 12V start system
f.e. 24V starter battery for 24V start system

1.6.3 Important Advice for Batteries - Starting batteries and Traction batteries

ATTENTION!!! Initial operation:
Installation of battery lines. Consider the regulations and installation instructions of the battery manufacturer.
Consider ABYC regulation E11 AC and DC electrical systems on boats and/or EN ISO 10133:2000 small watercrafts, electrical systems, low voltage (DC) systems !
Ensure a professional battery installation.
The battery separation can be made mechanically or by an appropriate power relay. Consider the appropriate notes of the battery manufacturer concerning fire and explosion pre-
vention. Install a right sized fuse in the positive battery line as close as possible to the battery, but max.
12 inch, 300mm from the battery. The length of the cable to the fuse, the cable must be protected by a sheath or conduit against damage of the insu-
lation.
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General References and Regulations
Use only cable with self retardant and self extinguishing insulation suitable for high temperatures up to 195°F, 90°C. Install battery lines in a safe way that the cable insulation will not be shaved or damaged. Battery poles must be protected against short circuits by error. Inside the capsule of the Fischer Panda Generator the battery positive line must be protected
against heat and vibration by a suitable conduit or sheath and must be routed that way it is not touching any area that will get hot under normal operation like entire engine itself, exhaust elbow and exhaust manifold or exhaust lines or the V-belt and pulleys. The cable shall not be to tight otherwise damage will happen.
Run the generator carefully after installation and double check, if there is any possibility for damage of the battery cable. Correct if necessary.
Fig. 1.6-1: Sample scheme for starter battery installation

1.6.4 Safety Instructions for the Handling with Batteries

These instructions must be noticed additionally to the instructions of the battery manufac­turer:
• If the batteries are working, someone should be in your near area to help you in a case of emer­gency.
• Water and soap must be hold ready if battery acid corrode your skin.
• Wear eye protection and protective clothing. During working with the batteries don´t touch the eyes.
• If you got a acid splash on your skin or clothing grow it with much water and soap out.
• If you got acid in your eyes rinse them immediately with clear water until no cauterization is no­ticeable. Visit immediate a doctor.
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Page 25
General References and Regulations
• Never smoke in the near of the batteries. Avoid naked flames or open fires. In the area of batte­ries exists danger of explosions.
• Pay attention that no tools fall on the battery poles, if necessary cover them.
• During the installation don´t wear a wrist watch or arm jewels, you can create under these cir­cumstances a battery short-circuit. Burning of the skin could be the result.
• Protect every battery contact against unintentional touch.
• For battery banks: Use only cyclical profoundly dischargeable batteries. Starter batteries are not appropriate. Lead-gel batteries are commended. They are maintenance-free, profoundly dischar­geable and not produce gas.
• Do not charge a frozen battery.
• Avoid a batterie short-curcuit.
• Take care of a good ventilation of the battery to drain off developing gas.
• The battery connection terminals must be checked of a tight contact at least before operating.
• The battery connection cable must be carefully mounted and checked about incorrect heating at operation with load. The vibrating devices must be regulary checked about scour points and flaw in the isolation.
Attention !! For battery charge generators (Fischer Panda AGT-DC)!
Check before installation if the battery bank voltage correspond with the generator output voltage
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Page 26
General References and Regulations
Leere Seite / Intentionally blank
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Page 27
In case of Emergency First Aid / Im Notfall -
1 1
1
2
1
3
1
4
1
5
Erste Hilfe

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

First Aid in case of accidends by electrical shocks 5 Safety steps to follow if someone is the victim of electrical shock
Do not touch the injured person while the generator is running.
Switch off the generator immediately.
if you cannot switch off the generator, pull, push, or lift the person to safety using a wooden pole, rope, or some nonconductive material.
Call an emergency doctor as soon as possible.
Immediately start necessary first aid procedures.
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Page 28

2.7 WHEN AN ADULT STOPS BREATHING

Warning:DO NOT attempt to perform the rescue breathing techniques
provided on this page, unless certified. Performance of these techniques by uncertified personnel could result in further injury or death to the victim.
1
Does the Person Respond?
In case of Emergency First Aid / Im Notfall -
Erste Hilfe
2
Shout, "Help!"
Tap or gently shake victim. Shout, "Are you OK?"
3
Roll Person onto Back.
Roll victim toward you by pulling slowly.
4
Open Airway.
Tilt head back, and lift chin. Shout, "Are you OK?"
6
Give 2 Full Breaths.
Keep head tilted back. Pinch nose shut. Seal your lips tight around victim's
mouth.
Call people who can phone for help.
5
Check for Breathing.
Look, listen, and feel for breathing for 3 to 5 seconds.
Give 2 full breaths for 1 to 1½ seconds each.
7
Check for Pulse at side of Neck.
Feel for pulse for 5 to 10 seconds. Send someone to call an ambulance.
9
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.
8
Phone EMS for Help.
10
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.
Page 29

3. Basics

3.0.1 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 mechenical energy by the diesel engine. This mechanical energy drives the genera-
tor. In the genset, the mechanical energy is converted to electrical energy. This process is controlled by (sometims external) components, the remote control panel and the voltage control system (VCS).
For the process is a sufficent amount of fuel and combustion air necessary. Arising exhaust and heat must be lead away.
If the electrical power should be applyed to a local net, The regulation and installation instruktions of the Net owner and the regional authorities must be respected. This includes lightening conductor, personal protection switch etc.
Misaplication of the Product can damage and destroy the product and the electrical net inclusive all load which is attached to the net, and contain hazards like short circiut. It is not allowed to modify the product in any case. Never open the sound cover during operation. The safety and hazard notes of the manual must be respected.
3.0.2 Purpose of the manual und description of the definitions trained person/operator/
user
This manual is work instruction and operation instruction for the owner and user of Fischer Panda generators. The manual is the base and the guideline for the correct installation and maintenance of Fischer Panda Generators. The manual does not substitute the technical evaluation and should be used as an example guide only. The installation must be undertaken and proved by a suitable qualified/trained person and may in accordance with
the law as required by the country and special situation.

3.0.2.1 Trained persons

Trained persons for the mechanical components are motor mechanics or persons with similar education and training.
Trained persons for the electrical components are electricions or persons with similar education and trai­ning.
After the Installation, the trained person must instruct the owner for operation and maintenance of the gene­rator. This must include the hazards of the generator use.

3.0.3 Operator

The operator is the for the operation of the generator responceble person.
After the installation, the operator must be instructed for the operation ad maintenance of the generator. This must include the hazards during operation of the generator and a instruction for the maintenance.
The operator must read and follow the manual and must respect the hazard notes and safety instructions.

3.0.3.1 User

Users are persons, established by the operator, to operate the generator.
The operator must assure that the user read and understand the manual and that all hazard notes and safety instructions are respected. The user must be instructed by the opertor regarding his activity at the generator.
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Page 30

3.1 Panda Transport Box

3.1.1 Bolted Fischer Panda Transport Box

1. Remove the bolts for cover / sidewalls
2. Remove the cover
3. Remove the loose accessories
4. Remove the bolts for sidewalls / floor pallet
5. Remove the sidewalls
6. Open the generator attachment

3.1.2 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

3.2 Transport and Loading/Unloading

3.2.1 Transporting the generator

- The generator must always be upright for transport.
- For transport, the Fischer Panda Transport Box shall be used for the generator. The generator shall be securely attached to the bottom of the box.
- For loading/unloading, an adequate industrial truck shall be used.
- Depending on the transport distance (e.g. air cargo), the generator fluids (coolant, engine oil, fuel) may have to be drained. The corresponding instructions and warnings must be fitted to the transport packaging.

3.2.2 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.
Page 31
An adequate lifting yoke shall be used for transport/ loading

3.3 Scope of delivery

The Fischer Panda PMS generator system contains following components:

3.3.1 Asyncron Genertoren:

Fig. 3.2-1: Lifting yoke (example)
Fischer Panda Generator
representative picture
Remote control panel
representative picture
Fig. 3.3-1: Fischer Panda Generator
Fig. 3.3-2: Remote control panel
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Page 32
AC Control Box
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
Fig. 3.3-3: AC Control Box
Fischer Panda Manual
The Fischer Panda Manual contains following compon­ents:
- Clear foil bag with general informations ect.
- Generator manualwith added remote control panel manual
- Spare part catalog „Installation & Service Guide“
- Engine manual from the engine manufacturer.
- Wiring diagram for the generator
representative picture
Optionales components f.e.:
- Fuel pump
- Installation kit
- Water lock
Fig. 3.3.1-4: Fischer Panda Manual
- ect.
Page 33

3.3.2 Opening the MPL sound insulation capsule .

To open the sound insulation capsule, the closures must be rotated roughly 180° counter-clockwise. Use a fl at head screwdriver. Pull the sidewalls out by gripping into the slots.
Closure locked
Fig. 3.3-1: Sound insulation capsule, side part
Fig. 3.3.2-2: Closure locked
Closure open

3.3.3 Opening the GFK sound insulation capsule

Fig. 3.3-3: Closure open
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Page 34
GFK sound insulation capsule with lash closures
Fig. 3.3-1: Lash closures
To open the lash closures pull the handle in arrow direc­tion and lift the lash of the closure pin. After lifting of the lashes, the sound isolation cover upper pars can be removed.
Fig. 3.3-2: Lash closures

3.4 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).

3.4.1 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 regular basis. Follow the notes of the battery manufacturer.
Before charging the battery, check the acid level according to the type of battery and refill each cell with distilled
Page 35
water up to the marking if necessary. Today’s starter batteries are normally maintenance-free.
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 acidfree and acid-resistant grease. Make sure there is a good contact of the clamp connections 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 manu facturer.
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.

3.4.2 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

3.4.3 Arrangements at a medium-term standstill / winter storage

Medium-term stand still (3 to 6 months)
3.4.3.1 Arrangements for conservation:
• Check the charge of battery and recharge approximately every 3 months if necessary. Consider the specifications 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.
Attention!Cover alternator openings.
No cleaning fluids or preserving agents may enter the alter­nator. Danger to destroy the alternator.
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Page 36
• 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.
3.4.3.2 Arrangements for deconservation after a medium-term standstill (3 to 6 months).
• Check charge of battery and recharge if necessary. Consider the specifications of the battery manufacturer.
• Check anti-freeze protection of the cooling water and refill if applicable.
• Drain engine oil. Renew oil filter and oil according to 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 oilpressure 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.

3.4.4 Arrangements at a long-term standstill / shutdown

Standstill (more than 6 months)
3.4.4.1 Arrangements for conservation:
• Check the charge of battery and recharge approximately every 3 months if necessary. Consider the specifications 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
Page 37
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 existent) 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 torsional 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 example with tape or end caps).
• Drain sea water circuit.
• Close sea cock.
• Clean sea water filter.
• Dismount impeller and store.
Attention!Carry out a deconservation before recommissioning.
3.4.4.2 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 oilpressure 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.
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Page 38
• 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

4. The Panda Generator

4.1 Type plate at the Generator

Fig. 4.1-1: Type plate
Fig. 4.1-2: Discription type plate
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4.2 Description of the Generator

02
03
04
06
08 09
01
05
11
12
14
13
07 10
01) Thermostat housing
02) Alternator 12 V
03) Oil Pressure switch
04) Oil Filter
05) Pulley with tooth belt
06) Sound isolation capsule base part
07) Starter Motor with solenoid
08) Generator power terminal box
09) Thermo switch water injection elbow
10) Exhaust out
11) Generator housing with stator winding
12) Mini VCS
13) Thermo switch exhaust elbow
14) Water cooled exhaust elbow

4.2.1 Right Side View

Fig. 4.2-1: Right side view
The Panda Generator
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The Panda Generator
01
02
19
03
06
18
14
13
17
04
05
07
08
09
10
11
12
16
15
01) Capacitors
02) Regulator for dc alternator
03) Air suction housing with air filter mat
04) Generator housing with stator winding
05) Cooling water connection block
06) Connection external raw water venting valve
07) Type plate
08) Fuses
DC
09) Relays
10) Oil dipstick
11) Failure bypass switch
12) Raw water in
13) Fuel filter
14) Raw water pump
15) Actuator
15) Fuel solenoid valve
16) Thermostat housing with ventilation screw
17) Oil filler cap
18) Thermo switch cylinder head

4.2.2 Left Side View

Fig. 4.2-1: Left side view
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4.2.3 Front View

1509 10 11
01 02
03
05 06
07
08
14
17
19
13
18
04
12 16
01) Thermostat housing with venting screw
02) Ventilation screw fresh water pump
03) Fresh water pump with pulley
04) Tooth belt
05) Oil dipstick
06) Raw water impeller pump
07) Fuel filter
08) Raw water in
09) Fuel in
10) Fuel out
11) Cable for fuel pump
12) Oil drain hose
13) Cable for remote control panel
14) Cable for main power out
15) Passage for battery (-) cable
16) Passage for battery (+) cable
17) Oil filter
18) Connection point battery (+)
19) DC alternator
The Panda Generator
Fig. 4.2-1: Front view
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The Panda Generator
01
02
06
03
04
05
07
10
11
12
08
09
01) Mini VCS
02) Thermo switch at exhaust elbow
03) Water cooled exhaust elbow
04) Raw water injection nozzle
05) Generator front cover
06) Oil cooled ball bearing
07) Connection from external expansion tank fresh water (lower connection)
08) Connection to external expansion tank fresh water (upper Con­nection)
09) Connection to external venting valve raw water
10) Coolant connection block
11) Capacitors
12) Air filter housing with air filter mat

4.2.4 Back View

Fig. 4.2-1: Back view
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4.2.5 View from above

14
06
01
03
04
05
07
08
09 10
11
12
13
02
01) Thermo switch at exhaust elbow
02) Mini VCS
03) Air filter housing with air filter mat
04) Lifting eye
05) Capacitors
06) Thermo switch at cylinder head
07) Cylinder head
08) Fuel solenoid valve
09) Oil filler cap
10) Raw water impeller pump
11) Venting screw at fresh water pump
12) Venting screw at thermostat housing
13) DC alternator
14) Water cooled exhaust elbow
The Panda Generator
Fig. 4.2-1: View from above
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The Panda Generator

4.3 Details of Functional Units

4.3.1 Remote control panel

With the remote control panel the generator ist startet and stopped. It also display the warning and fault allerts. It is not allowed to run the generator without the Fischer Panda remote control panel. See the Remote control panel
manual for details.(At the end of this manual)

4.3.2 Components of the Cooling System (Raw Water)

Raw water intake
Raw water impeller pump
The raw water pump is fitted with a rubber impeller.
Fig. 4.3.2-1: Raw water intake
Fig. 4.3.2-2: Raw water impeller pump
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The Panda Generator
Impeller filter
If the impeller breaks, the parts will be caught by the impeller filter.
Ventilation valve
A siphon must be installed if the generator sinks below the water line because of the rocking of the boat, even if it is only for a short period of time.
Fig. 4.3.2-3: Impeller Filter
Fig. 4.3.2-4: Connection external ventilation valve
Heat exchanger
The heat exchanger separates the raw water system from the fresh water system, so that the generator components do not have contact with the raw water circulation system.
Fig. 4.3.2-5: Heat exchanger
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The Panda Generator
Raw Water Injection
Raw water output
The raw water discharges together with the exhaust.
Fig. 4.3.2-6: Injection raw water
Fig. 4.3.2-7: [Raw water output

4.3.3 Components of the Cooling System (Fresh water)

Filler neck (not all models)
The cooling water filler necks situated at the water-cooled manifold are only used, when the generator is initially started.
Fig. 4.3.3-1: Exhaust elbow
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The Panda Generator
Heat exchanger
The heat exchanger separates the raw water system from the fresh water system, so that the generator components do not have contact with the raw water circulation system.
Cooling Water Connection Block
Fig. 4.3.3-2: Heat exchanger
Fig. 4.3.3-3: Cooling Water Connection Block
Internal Fresh Water Cooling pump
The fresh water pump aids the ciculation of the fresh water.
The fresh water enters and leaves the engine at the fresh water pump.
Fig. 4.3.3-4: Internal Fresh Water Cooling Pump
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The Panda Generator
Ventilation Screw Fresh Water Cooling Pump
Ventilation Screw Thermostat Housing
Fig. 4.3.3-5: Ventilation Screw Fresh Water Cooling Pump
Fig. 4.3.3-6: Ventilation Screw Thermostat Housing

4.3.4 Components of Fuel System

External Electrical Fuel Pump
The Panda generator is always supplied with an external, electrical (DC) fuel pump.
Fig. 4.3.4-1: External Electrical Fuel Pump
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The Panda Generator
1
2
Connecting point for the fuel pipes
1. Fuel intake
2. Fuel backflow
Fuel solenoid valve
Fig. 4.3.4-2: Fuel Connections
Fig. 4.3.4-3: Fuel Solenoid Valve
Injection nozzles

4.3.5 Components of combustion air

Fig. 4.3.4-4: Injection Nozzle
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The Panda Generator
Air suction openings at the sound insulated capsule
The sound cover for the marine generator is normally provi­ded at the lower surface with drillings, through which the combustion air can inflow.
Air suction housing with air filter set
Fig. 4.3.5-1: Combustion air intake
Fig. 4.3.5-2: Air suction housing
Water-cooled Exhaust Elbow
Fig. 4.3-3: Water colled exhaust elbow
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The Panda Generator
1
1
Exhaust outlet

4.3.6 Components of Electrical System

Connection starter battery
1. Cable for starter battery (plus)
Fig. 4.3.5-4: Exhaust Output
Fig. 4.3.6-1: Battery cable (+)
Connect the battery (+) directly to the starter solonoid
Connection starter battery
1. Cable for starter battery (minus) Connect the battery (-) to the generator foot connnection
point.
Fig. 4.3.6-2: Connections for starter battery
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The Panda Generator
1
1
2
1
2
Main power
At the front of the sound insulation cover is also the outlet for the main power cable.
Electrical connections for control / fuel pump
1. Remote control panel
2. Fuel pump
Fig. 4.3.6-3: Load
Fig. 4.3.6-4: Electrical connections
Starter motor
1. Starter motor and
2. Solenoid switch The diesel engine is started electrically. The electrical starter with the solenoid switch is located on
the right side of the generator, in front of the engine.
Fig. 4.3.6-5: Starter motor
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The Panda Generator
K3K1
K2F
Generator power terminal box
Located in this box are the electrical connection points for the AC generator.
Terminal block for remote control cable with fuses and power relays
see wiring diagram
Fig. 4.3.6-6: Generator power terminal box
Fig. 4.3.6-7: Terminal block
Excitation capacitors

4.3.7 Sensors and Switches for Operation Surveillance

Fig. 4.3.6-8: Excitation capacitors
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The Panda Generator
Thermo-switch at cylinder head
The thermo-switch at the cylinder head serves to monitor the generator temperature.
83 / 78 ° C
Thermo-switch at water-cooled exhaust elbow
This thermo-switch is located at the water-cooled exhaust elbow and serves to monitor the freshwater circulation system. It takes a measurement at the warmest spot, since the combustion gases are guided from the cylinder head to the exhaust elbow.
Fig. 4.3.7-1: Thermo-switch at cylinder head
Fig. 4.3.7-2: Thermo-switch at exhaust elbow
83 / 78 ° C
Thermo-switch in the stator winding
Thermo-switch 2 x 165 / 175 ° C Two thermos-switches and one NTC inside the winding protect the stator winding, which for safety reasons are
installed independently in parallel.
Oil pressure switch
Fig. 4.3.7-3: Oil pressure switch
In order to be able to monitor the lubricating oil system, an oil pressure switch is built into the system.

4.3.8 Components of Oil Circuit

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The Panda Generator
Oil filler neck with cap
Normally the filler neck for the engine oil is on the top side of the valve cover.
Oil dipstick
At the dipstick the permissible level is indicated by the mar­kings "maximum" and "minimum".
Fig. 4.3.8-1: Engine oil filler neck
Fig. 4.3.8-2: Engine oil dipstick
Engine oil filter
This oil filter should also be replaed, when an oil change is carried out.
Fig. 4.3.8-3: Engine oil filter
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The Panda Generator
Oil drain hose
The Panda generator is so equipped that the engine oil can be drained over a drain hose.
Fig. 4.3.8-4: Engine oil drain hose

4.4 Operation of the generator - see separate remote control panel manual

4.4.1 Daily routine checks before starting - see separate remote control panel manual.

4.4.2 Starting Generator - see separate remote control panel manual.

4.4.3 Stopping Generator - see separate remote control panel manual.

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The Panda Generator
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Installation Instructions

5. Installation Instructions

All connections (hoses, wires etc) and installation instructions are designed and suited for “standard” installation situations.
In situations where Fischer Panda has no detailed information concerning certain installation requirements (such as vehicle specifications, maximum vehicle speed -and all other conditions concerning special operating situations) the installation instructions should be used as an example guide only.
The installation must be undertaken and proved by a suitable qualified/trained person and may in accordance with the law as required by the country and special situation.
Damages caused by faulty or incorrect installation are not covered by the warranty.

5.1 Personal requirements

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

5.1.1 Hazard notes for the installation

Follow the general safety instruction at the front of this manual.
Working at a running generator can result in severe personal injury. Therfore befor starting work at the generator:
Make shure that the generator ist stopped and the starter battery is diconnected to guarantee that the generator cannot be inadvertently started.
Do not run the generator with removed sound isolation cover
Impropper installation can result in servere personal injuries or material damage.
- Always undertake installation work when the generator is switched off.
Notice!:see “Safety instructions - Safety first!” on Page 18.
Warning!: Risk of injuryr
Warning!: Risk of injuryr
- Ensure there is sufficient installation clearance before start working.
- Ensure tidiness and cleanliness at the workplace. Loose components and tools lying around or on top of each other are sources of accidents.
- Only perform installation work using commercially avalilable tools and special tools. incorrect or damaged tools can result injuries.
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Installation Instructions
Oil and fuel vapours can ignite on contact with ignition sources. Therfore:
- No open flames during work on the generator.
- Do not smoke.
- Remove oil and fuel residues from the generator and floor.
Contact with engine oil, antifreeze and fuel can result in damage to health
. Therefor :
- Avoid skin contact with engine oil, fuel and antifreeze.
- Remove oil and fuel splashes and antifreeze from the skin immediatlly.
- Do not inhale oil and fuel vapours.
tion and maintenance can result in sévere persoanl injury and/or material damage.
Electrical voltages above 48 volts (battery chargers greater than 36 volts) are always dangerous to life). The rules of the respective regional authority must be adhered to. Only an electrician may carry out installation of the electrical connec­tions for safety reasons.
-Warning!: Danger of fire
Danger!: Danger of poisoning
ATTENTION!: Danger to Life - High voltageDanger for Life. Improper handling, operation, installa-
ration. Risk of severe burns.
During Installation/mainenance personal protective equipment is required to minimize the helth hazards.
- Protective clothing
- safety boots
- protective gloves
- Ear defender
- safety glasses
Disconnet all load during the work atthe generator to avoid damages at the load.
Warning!: Hot surface/materialGenerator, oil and antifreeze can be hot during/after ope-
Instructiont!: Personal protective equipment necessary.
Attention!: disconnect all load
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Installation Instructions

5.2 Preparing the base - Placement

Since Panda generators have extremely compact dimensions, they can be installed in tight locations. Attempts are sometimes made to install them in almost inaccessible places. Please consider that even almost maintenance-free machinery must still remain accessible at least at the front (drive belt, water pump) and the service-side (actuator, dipstick). Please also note that in spite of the automatic oil-pressure sensor it is still essential that the oil level has to be checked regularly.
The generator should not be placed in the proximity of light walls or floors, which can have resonance vibrations because of airborne sounds. If this should be unavoidable, then it is recommended that this surface is lined with 1 mm lead foil, which will change the mass and the vibration behaviour.
You should avoid fixing the generator on a slippery surface with little mass (i.e.). This acts as an amplifier of airborne sounds in the most unreasonable case. An improvement can be achieved by reinforcing these surfaces with ribs. In addition, the breakthroughs, which interrupt these surfaces, should be sawed off. The lining of the surrounding walls with a heavy layer (i.e lead) and foam additionally improve the conditions.
The generator sucks its air from the surrounding engine room. Therefore it must be ensured that sufficient ventilation openings are present, so that the generator cannot overheat.
High temperature of the intake air decline the power of the generator and increases the coolant temperature. Air temperatures of more than 40 °C reduce the power by 2 % per temperature rise of 5 °C. In order to keep th ese effects as small as possible, the temperature in the engine room should not be higher than 15 °C in rel ation to the outside temperature.

5.2.1 Advice for optimal sound insulation

The convenient base consists of a stable framework, on which the generator is fastened by means of shock-mounts.
Since the aggregate is "free" downward, the combustion air can be sucked in unhindered.
In addition are void the vibrations, which would arise with a closed soil.
Fig. 5.2.1-1: Generator Base

5.3 Generator Connections

Connect all electrical wires within the capsule tightly to the motor and the generator. This is also the case for fuel lines and cooling water lines.
The electrical connections MUST be carried out according to the respective valid regulations. This also concerns used cable materials. The cable supplied is meant for laying "protected" (i.e. in pipe) at a temperature up to a max of. 70 °C (160 °F). The on-board circuit must also be fitted with all essential fuses.
Before working (installation) on the System read the section „Safety Instructions“ in this Manual.
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ATTENTION!
Page 62
Installation Instructions

5.4 Installation of the cooling system - raw water

5.4.1 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)".

5.4.2 Installation of the thru hull fitting in Yachts

It is good practice for yachts to use a thru hull fitting with an integrated strainer. The thru hull fitting (raw water intake) is often mounted against the sailing direction to induce more water intake for cooling.
For Panda generators, the thru hull inlet should NOT 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!
Fig. 5.4.2-1: Position of the Thru Hull Fitting

5.4.3 Quality of the Raw Water Sucking In Line

In order to keep the suction resistance in the line at a minimum, the raw water intake system (i.e. sea cock, thru-hull fitting, inlet filter, etc.) must have an inner diameter of at least 1" (25 mm).
This applies also to installation components such as thru-hull fitting, sea cock, raw water filter etc. The intake suction line should be kept as short as possible. Install the raw water inlet in close proximity to the gen-
set.
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 8.10, “Diameter of conduits,” on page 177
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Installation Instructions
1
2
3

5.4.4 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.
Never change the impeller for many years, without exchanging the old pump. If the sealing ring is defective within the pump, raw water runs into the sound cover of the 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.
Installation above water level
1. Raw water filter
2. Water cock
3. Thru hull Make certain that the raw water filter lies above the water
level, otherwise when cleaning, water can penetrate by the thru hull. An external pre-pump can relieve the impeller.
NOTE:
Fig. 5.4.4-1: Installing the generator above the water level
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Installation Instructions

5.4.5 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.
Possible 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.
Note:
The vent valve must be installed directly behind the water pump.
Fig. 5.4.5-1: Vent Valve
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 the water pump stops, the valve spring ensures that air enters. It must be opened, cleaned and greased.
Fig. 5.4.5-2: Connection Vent Valve
Cut the hose for the external vent valve....
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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. Thru hull
...and bend it upwards. Both hose ends must be led out outside of the sound cover to
one point, if possible 600 mm over the waterline at the mid­ships line. The valve is connected at the highest place with the two hose ends.

5.4.6 Generator Housing cooled by Raw Water

Fig. 5.4.6-1: Installaton Scheme for Direct Cooling
Fig. 5.4.5-3: Connection Vent Valve
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Page 66

5.4.7 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. 5.4.7-1: Installation Scheme Indirect Cooling of teh Genset Housing
Installation Instructions

5.5 Installation of the cooling system - fresh water

5.5.1 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. 5.5.1-1: Position of the External Cooling Water Expansion
Tank
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Installation Instructions
10
10
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.
ATTENTION!

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

Expansion Tank
1. Fill up the external cooling water expansion tank with coo­lant.
ATTENTION: maximum fill level = „max.“- mark. The cover of the external expansion tank temporarily must be
opend (all other closures are now closed!).
Fig. 5.5.2-1: Expansion ttank
Venting Screws
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 van­ting. Fill up if necessary.
Never open the vent screw while the generator is running.
Sample picture
3.Open vent screw on the thermostat housing. Close the vent
screw when air free water comes out
• Check the water level in the expansion tank during the van­ting. Fill up if necessary.
Never open the vent screw while the generator is running
Sample picture
Fig. 5.5.2-2: Venting screw - Internal Cooling Water Pump
Fig. 5.5.2-3: Venting screw - Thermostat housing
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 tthermostat housing.
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Installation Instructions
6. Close the vent screws.
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 ima­culate und 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.
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.
ATTENTION!
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

5.5.3 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 approx 10 degrees.
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Installation Instructions
1. Expansion Tank
2. Exhaust Manifold
3. Thermostat Housing
4. Freshwater pump
5. Heat Exchanger
6. Cooling Water Connection Block

5.5.4 Scheme for Freshwater Circuit at Two Circuit Cooling System

Fig. 5.5.4-1: Scheme for Freshwater Circuit at Two Circuit Cooling System
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Installation Instructions
1. Generator
2. Water lock
3. Goose neck
4. Silencer
5. Hull outlet

5.6 Installation of the water cooled exhaust system

5.6.1 Installation of the standard exhaust system

The generator exhaust system must remain completely independent and separate from the exhaust system of any other unit(s) on board. The exhaust hose has an inner diameter of 30 mm. The water lock must be installed at the lowest point of the exhaust system. An optional noise insulated water lock can also be installed. The exhaust hose descends from the capsule to the water lock. Then the hose rises via the "goose neck" to the silencer (see drawing). The goose neck must be vertical and sit preferably along the ship's keel centre line. 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 8.10, “Diameter of conduits,” on page 177
Fig. 5.6.1-1: Installation Scheme Standard Exhaust System

5.6.2 .Installation of the water collector

Unfortunately, it can occasionally occur that, because of an disadvantageous mounting position of the water collec­tor, sea water gets into the diesel engines’ combustion chamber. This disables the diesel engine by irreversible damages. Quite frequently, this leads to discussions during which the parties involved in the yachts’ construction or the installation of the generator have to explain themselves.
One point in this situation can be clarified definitely:
If sea water gets into the inner section of the engine, this is not possible due to constructional defects of the genera­tor or to malfunctions on the engine itself. It can only reach the combustion chamber via the exhaust duct and thus
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Installation Instructions
get into the engine. Thereby, the position of the generator and the water collector, as well as the arrangement of the coolant and exhaust
ducts plays the decisive role. If the water collector is arranged in an unfavourable position, the coolant flowing back in the exhaust duct can rise so
high, that it reaches the exhaust stack. Since at least one discharge valve is always open when the engine is shut off, the sea water has free access to the combustion chamber. By capillary action, this sea water then flows past the cocks and even reaches the engine oil in that way. (In fact, a surprisingly high oil level is a first indication of an upco­ming catastrophe.)
If an usual high oil level can be detected and/or the oil is of a greyish colour, the engine must not be used anymore. This is a certain sign for coolant that got into the oil pan. If the engine isstarted under these con­ditions, the water and the oil are mixed into an emulsion. The the oil will quickly become so viscous that one will have to call it a paste. In this phase the fine oil ducts are blocked and a few moments later the machine gets destroyed because of insufficient lubrication. Before this happens, an immediate oil should be made. (Since the water can only reach the engine via the combustion chamber, it can be assumed that the com­pression rings will start to corrode. These effects have to be discussed with an engine expert. It will cer­tainly be reasonable to immediately inject plenty penetrating oil through the intake stack and to slowly turn the engine with the starter motor.)
The coolant can reach the exhaust area via the exhaust duct as well as via the coolant feed.

5.6.3 Possible cause: Exhaust duct

If the cause is the exhaust duct itself, the following points are to be checked at the duct: a) Position of the water collector is too high. The water reaches the exhaust duct. b) Position of the water collector is too far away from the middle of the generator. The water reaches the exhaust
duct in tilted position. c) The water collector is too small relating to the length of the exhaust duct.

5.6.4 Possible cause: Coolant duct

If the generator is not clearly installed 600 mm over the water line, the coolant feed must be equipped with a ’venting valve’, which is at least lead out 600 mm over the water line. (This position must also be assured in every tilted posi­tion. Therefore the venting valve should be located in the ships’ center line, so that it can not move in tilted position.)
a) Position of the venting valve is too low. The water flows into the exhaust area when the ship is tilted. b) Position of the venting valve is too far from the ships’ center line. The water reaches the exhaust area when the
ship is tilted.
c) The venting valve does not work, because it jams or it is clotted. (The venting valves’ function needs to be chek­ked regularly.)
As it consistently happens that funtioning risks are not realised during the laying of the exhaust duct, the following explanations refer explicitly to the exhaust duct. Here, the location, the size and the position of the ’exhaust water collector’ play a very decisive part:

5.6.5 Installation area of exhaust water collector

Concerning a water-cooled exhaust system, it must be regarded that - under no circumstances - coolant from the exhaust duct can get into the exhaust elbow area at the engine. If this happens, the coolant can get into the combu­stions chamber via an open discharge valve. This would lead to irreparable damage at the engine.
In addition to that, one has to reckon with possible tilted positions of sailing yachts, which makes the position of the water collector even more important. In general one could say that:
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Installation Instructions
The deeper the water collector is located underneath the generator, the better the protection from entering water into the combustion chamber.
The pictures below, the distance between the critical point at the exhaust elbow and the maximum permissible water level in the exhaust duct is stated with 600 mm. This distance should be understood as a minimum distance.
Fig. 5.6.5-1: Installation area of the exhaust water collector
5.6.5.1 The volume of the exhaust water collector
The exhaust water collector must be measured so large, that it can take the entire amount of water flowing back from the exhaust duct. The amount of water depends on the ducts’ length (L) and its cross section. While the diesel engine is running, coolant is continuously injected into the exhaust system and is carted outside with the emissions by the exhaust gas pressure. When the engine is turned off, the number of revolutions sinks quite fast. By doing so, the point is reached where the exhaust gas pressure does not suffice anymore to cart the coolant out. All coolant remaining in the duct at that point flows back into the water collector. At the same time, the diesel engine itself conti­nues to cart coolant through the coolant pump, as long as it keeps on rotating.
The water collector must necessarily be measured so large, that it can take the entire amount of coolant and, and the same time, does not exceed the prescribed vertical height of 600 mm up to the critical point at the exhaust elbow.
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Installation Instructions
1
Fig. 5.6.5.1-1: Volume of the exhaust water collector
If there are any doubts, a verifiction can easily be made by temporarily using a clear-sighted hose as exhaust hose. In that way, the coolant level can be checked very easily.
Fig. 5.6.5.1-2: Testing the coolant level
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Installation Instructions
5.6.5.2 Position of the water collector
Important Note! The ideal position of the water collector would be in center underneath the generator. Only in this position it
is assured that the water level can not change drastically in tilted position by the water collector moving out of the center line. See the following pictures:
In this picture, the water collector is mounted in center under­neath the generator. When the ship tilts, the position of the water collector related to the critical point at the exhaust duct changes only slightly.
The distance from the exhaust elbow to the hydrostatic head derated to 540 mm.
Fig. 5.6.5.2-1: Ideal position of the water collector
Fig. 5.6.5.2-2: Tilted position 15 degreesTilted position 15 degrees
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Installation Instructions
The distance of the water level, even in ideal position, chan­ges in a way that only 458 mm distance remain. So the criti­cal distance is under-run already.
Fig. 5.6.5.2-3: Tilted position 30 degreesTilted position 30 degrees
Fig. 5.6.5.2-4: Tilted position 45 degreesTilted position 45 degrees
In this case the water level rose so high, that the distance constitutes only 325 mm.
Even when the collector is mounted in the ideal spot, at an extremely tilted position of 45 degrees there is still the risk that water can get straight into the discharge stack area through strong rocking motion (’Sloshing’). This shows that the distance of 600 mm represents a minimum size at which, even when installed ideally, the water can slosh into the exhaust elbow when the ship is very tilted or rocks very hard.
Summary:
The preset minimum height of 600 mm must be regarded unconditionally and is only valid, if the water collector is mounted in its ideal position in center underneath the generator. A higher position is highly recommended if it has to be reckoned with tilted positions of 45 degrees.
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Installation Instructions
5.6.5.3 Example of the installation of the water collector off-center and possible effects:
The following pictures are primarily relevant for an installation of the generator with the water collector on sailing yachts. A change in the mounting position caused by tilted position does not have to be reckoned concerning motor yachts. Here it is only necessary to regard that the volume of the water collector is measured so large, that it can take the entire amount of water flowing backand at the same time maintains the minimum distance of 600 mm.
A) Installation of the water collector 500 mm next to the generators center line:
Fig. 5.6.5.3-1: Water collector, 500 mm next to the center line
The distance is only 404 mm instead of the original 600 mm. So this is very close to the critical point.
Fig. 5.6.5.3-2: Tilted position, 15 degreesTilted position 15 degrees
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Installation Instructions
The distance between the hydrostatic head and the critical point at the exhaust elbow is only 216 mm. This means that in a tilted position of 30 degrees you already face the highest risk of sea water sloshing into the combustion chamber.
Fig. 5.6.5.3-3: Tilted position 30 degreed Tilted position 30 degreed
Fig. 5.6.5.3-4: Tilted position 45 degreesTilted position 45 degrees
The water level is now at the same height as the critical point at the exhaust elbow. If the ship is sailed in a tilted position of 45 degrees with an installation like this, the infiltration of coo­lant into the combustion chamber is inevitable. Irreparable damages are preprogrammed.
B) Installation distance between exhaust water collector and generators’ center line 1000 mm
Fig. 5.6-5: Exhaust water collector, 1000 mm next to center line
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The distance is, contrary to the original 600 mm, only 327 mm. This is very close to the critical point already.
Installation Instructions
Fig. 5.6.5.3-6: Tilted position 15 degreesTilted position 15 degrees
Fig. 5.6.5.3-7: Tilted position 30 degreesTilted position 30 degrees
The water level and the critical point at the exhaust elbow are at the same level now. If the ship is sailed in a tilted position of 30 degrees with an installation like that, the infiltration of coolant into the combustion chamber is inevitable. Irrepara­ble damages are preprogrammed.
Summary:
Concerning sailing yachts it must be regarded, that the water collector is mounted in center underneath the genera­tor, at least in reference to the ships’ center line. Thus the water collector is prevented from ’leaking’ very strongly when the ship is tilted.
The ’leaking’ of the water collector leads to a rise of the water level which then gets too close to the exhaust elbows’ critical point.

5.6.6 Exhaust / water separator

In order to reduce the noise level of the generator unit to a minimum, an optional exhaust outlet muffler can be mounted next to the thru-hull fitting. Additionally there is a component at Fischer Panda, which acts as both an "exhaust goose neck", and water separator. With this "exhaust/water separator" the cooling water is derived over a separate pipe. The exhaust noises emanating from the exterior of the yacht are strongly decreased. Particularly the "water splash".
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Installation Instructions
Water flow exhaust water Separator
The water flow on the exhaust/water separator unit has an inner diameter (ID) of 30 mm. If the path from the water sepa­rator to the raw water outlet is very short, the hose can be fur­ther reduced to 1" (25mm) ID.
(1) Raw water outlet ø 30mm (2) Hose connector ø 30mm (3) Reducer 30/20mm (if required) (4) Hose
Fig. 5.6.6-1: Water Flow Exhaust Water Separator
Fig. 5.6.6-2: Exhaust Water Separator
(5) Hose connector (6) Sea cock (7) Hull outlet (8) Hose Clips
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5.6.7 Installation exhaust water separator

1
5
6
2
3
4
1. Generator
2. Silencer / Water lock
3. Exhaust-Water-Separator
4. Silencer
5. Sea cock
6. Hull outlet
Fig. 5.6.7-1: Installation Exhaust Water Separator
Installation Instructions
If the exhaust water separator was sufficiently highly installed, a goose neck is no longer necessary. 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 thru-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 is the thru-hull outlet. For such long exhaust routes, the exhaust hose diameter should also be increased from NW40mm to NW50mm in order to reduce the back-pressure. The exhaust may have a length of over 10m (32 ft.) if the exhaust hose diameter is increased to 50mm. An additional outlet exhaust muffler close to the hull outlet will help further to reduce noise emissions.
The generator will not disturb your boat neighbours, if the "Super silent Exhaust System has been correctly installed. The exhaust noise should be almost inaudible.
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Installation Instructions
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. 5.6.7-2: Expample for an unfavourable Installation
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Installation Instructions
1
2
3
4
5
8
7
6
1. Generator
2. Fuel stopcock
3. Fuel filter
4. Fuel return
5. Condensation water suction pump (optional)
6. Fuel tank
7. Fuel supply
8. Electrical fuel pump (DC)

5.7 Installation of the fuel system

5.7.1 General references

Inside the generator capsule itself, there is the fuel filter installed (exception: Panda 4200 and 4500). Additional fuel filters (with water separator) must be mounted outside the capsule in easily accessible places in the fuel lines bet­ween the tank intake fuel pump and the diesel motor's fuel pump.
Generally forward and return fuel flow pipes must be mounted to the diesel tanks. Do not connect the generator fuel supply lines with any other fuel lines of other diesel systems.
• The following items need to be installed:
• Fuel supply pump (DC)
• Pre-filter with water separator (not part of the delivery)
• Fine particle fuel filter
• Return fuel line to fuel tank (unpressurized) The fuel supply pump should be mounted as close to the fuel tank as possible. The electric cable for the fuel pump
is already installed on the generator (length 5 m).
Fig. 5.7.1-1: Installation Scheme Fuel System
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Installation Instructions

5.7.2 The Electrical Fuel Pump

Electrical fuel pump
Fig. 5.7.2-1: Electrical Fuel Pump
With the Panda generator is usually supplied an external, electrical fuel pump (DC). The fuel pump must be installed close at the fuel tank. The electrical connections are pre­loaded at the generator with the lead planned.
Suction hight of the pump: max. 1,2 m at 02, bar
Diameter of fuel lines: section 8.10, “Diameter of conduits,” on page 177.

5.7.3 Connection of the fuel lines at the tank

Lead the return fuel pipe connected to the day tank to the floor
The return pipe connected to the tank must be dropped to the same depth as the suction pipe, if the generator is mounted higher than the tank, in order to prevent fuel running back into the tank after the motor has been switched off, which can lead to enormous problems, if the generator is switched off for a long period.
Non-return valve in the suction pipe
A non-return valve must be fitted to the suction pipe, which prevents the fuel flowing back after the generator has been switched off, if it is not possible to use the return flow pipe as a submerge pipe placed in the tank. The 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.
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.
ATTENTION!
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5.7.4 Position of the pre-filter with water separator

Installation Instructions
Additionally to the standard fine filter a pre-filter with water separator must be installed outside of the sound insulation capsule in the fuel system line (not included in the delivery).
Fig. 5.7.4-1: Pre-filter with water separator

5.7.5 Ventilating air from the fuel system

Normally, the fuel system is designed to vent air itself i.e. as soon as the electric starter motor starts; the fuel pump starts working and the fuel system will be air-vent automatically after some time. It is, nevertheless essential, to vent the system as follows prior to the first operation (as all hoses are empty):
1. Switch main power switch on control panel "ON".
2. Push failure bypass switch and hold tight. The electric fuel pump has to be run audibly. By moving the failure bypass switch you can hear the solenoid valve of
the generator starting and stopping (when the sound insulation cover is taken off).
3. After the fuel pump has been running 3 to 4 minutes, because the failure bypass switch has been pressed down, the bleeding screw of the solenoid valve has to be unscrewed. The switch has to be continuously depressed, when opening the screw. A piece of cloth or absorbent paper should be put under the connection to avoid fuel entering the sound insulation cover.
4. The air vent screw can be screwed in again, as soon as fuel runs out without bubbles. Then release the depres­sing the failure bypass switch.
5. Starting the generator Now the generator can be started by pushing the "START"-button. The generator should start after a short while.
One of the pipe union nuts of an injection hose has to be unscrewed, should the unit not start; then try to restart the generator. After the generator has started, the pipe union nut has to be tightened again.
Main power switch "OFF"
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Installation Instructions
Vent Screw at the fuel stop solenoid valve
Not installed at all models!
Fig. 5.7.5-1: Vent Screw at the Fuel Stop Solenoid Valve

5.8 Generator DC system installation

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 any time
with its own starter battery even if the other batteries are discharged. A further advantage of a separate starter bat­tery is that it isolates the generator's electric system from the rest of the boat's DC system, i.e. minus pole (-) is not connected electrically to Earth/Ground.
The generator is then Earth/Ground free.

5.8.1 Connection of the starter battery block

IAn own separate starter battery must be installed for the generator.
The positive cable (+) of the battery is attached directly at the solenoid switch of the starter motor (position 1). The negative cable (-) of the battery is attached underneath the starter motor at the engine mount (position 2).
Panda Generators Panda 6000 and higher normaly provided with an alternator/dynamo to charge the starter battery. At generators without alternator/dynamo it is needed to charge the starter battery with an external battery charger.
Make shure that the voltage of the starter battery fits to the start system voltage
f.e. 12 V starter battery for a 12 V start system f.e. 24 V starter battery for a 24 V start system (2x12 V batte-
rys in a row)
NOTE:
ATTENTION!
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Installation Instructions
To avoid large voltage drops the battery should be installed as near as possible to the generator. The positive terminal of the battery is attached at the red cable, the negative pole at the blue cable.
It must be guaranteed that first the cables are attached at the generator and then at the battery.
Battery connection
Wrong connection of the battery bank can cause a short-cir­cuit and fire.
NOTE:
Attention!: Consider correct connection sequence
Attention!: Right connection of the battery.
Install an appropriate fuse and a battery circuit breaker in the plus pole cable of the batterie, but with a distance to the battery of up to 300 mm (12 inch) at maximum.
The cable from the battery to the safety device must be secured with protective pipe/sleeve against chafing through. For the connection use self-extinguishing and fire-protected cables, which are appropriate for temperatures up to 90
°C, 195 °F. The batteries must be layed in such a way that they do not chafe through or other mechanical load can be stripped. The battery poles must be secured against unintentional short-circuit. The positive battery cable within the generator must be shifted in such a way that it is protected against heat and
vibrations by appropriate sleeve/protective pipe. It must be shifted in such a way that it does not affect rotary parts or parts, that become hot in operation, e.g. wheel, exhaust elbow union, tail pipe and the engine. Do not lay the cable too tautly, since otherwise it could be damaged.
Make a test run after the installation and check the laying of the batteries during the test run and afterwards. If necessary, correct the laying.
Examine regularly the cable layings and the electrical connections.
Positive battery cable
Fig. 5.8.1-1: Positive Battery Cable
The positive (+) battery cable is connected directly to the solenoid switch of the starter.
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Installation Instructions
1 2 3
1
2
Negative battery cable
The negative (-) battery cable is connected to the engine foot.
Note! The battery negative pole may not be connected with the boat ground or with the protective grounding of the 120 V installation!
DC-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
Fig. 5.8.1-2: Negative Battery Cable
Fig. 5.8.1-3: DC-Relay
2. Pre-glow relay (glow plugs)
3. Fuel pump relay
Sample Picture - See wiring diagram
DC Starter Motor
All Panda generators are equipped with an independent DC starter motor.
1. Solenoid switch for starter motor
2. Starter motor
Fig. 5.8.1-4: DC Starter Motor
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Fig. 5.8.1-5: Battery installation - Scheme
1
2
4
3
1. Generator
2. Battery block
3. Fuse
4. Battery main switch
Installation Instructions

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

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Installation Instructions
1
2
3
1. Generator
2. AC-Control Box
3. Distribution panel

5.9 Generator AC System Installation

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

5.9.1 Installation with looped in AC-Control box

Fig. 5.9.1-1: Installation with looped in AC-Control box
ATTENTION!
All electrical safety installations have to be made on board.
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5.9.2 Installation AC-Box / distribution panel separate connected

1
2
3
1. Generator
2. AC-Control Box
3. Distribution panel
Fig. 5.9.2-1: 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.
3-Way Cam Switch
Fig. 5.9.2-2: 3-Way Cam Switch
A 3-way cam switch should be used. This switch basic positi­ons: "Shore power" - "OFF" - "Generator". If an (DC-AC) inverter is used, a fourth position will be required.
0. OFF I. Generator II. Shore power connection III. Inverter
The cam-type switch must have 2 poles, so that "MP" and "phase" can be switched off. If a 3-phase current system is also installed with the option of supplying from either the generator or shore power, an
additional switch must be installed to keep these systems separate. An alternative to a manual rotating switch is an automatic power relay. When the generator is not running, the relay
remains in the shore power position. As soon as the generator is running, the power relay switches automatically to the generator position.
Note: If the system has both single and 3-phase AC, it is CRITICAL that the two systems remain SEPARATE! Protection conductor
The generator is provided with a PEN safety system, as standard, which connects the 3-phase delta centre point "N" to the safety ground strap.
If a separate ground protection cable is necessary (i.e. due to national safety regulations), the bridge between the
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Installation Instructions
generator housing and ground (in the AC-Control box) must be disconnected. Once such a ground protection cable is installed, it must be connected to the ground straps of all on board electrical devices.
In order to monitor the electrical system, it is recommended to install a voltmeter (and, if possible, a current meter) down line from the power source selector switch so that all respective power sources can be monitored. A separate voltmeter for the generator, itself, is therefore not required.
Electrical fuses
It is absolutely essential that the electrical system installation is inspected by a qualified electrical technician. The generator should have its own AC input electrical fuses. The fuses should be sized such that the rated current of the generator on each of the individual phases is not exceeded by more than 25%.
Data for gensets with power output greater than 30 kW on request! The fuses must be of the slow type. A 3-way motor protection switch must be installed to protect the electrical motor.
Required fuses see rated currend 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. (siehe see “Cable cross section” on page 171.)
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Installation Instructions
1
3
2

5.9.3 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-inforcement (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).
ATTENTION! Before working on the System read the "Section Safety Instructions in this Manual".
AC-Control Box
Inlet VCS-connection (X1) Inlet measuring voltage (X3) Excitation cable to generator (X4)
Danger - High voltage
Fig. 5.9.3-1: Opened AC Control Box
AC-Control Box - from Panda 30 upwards
Fig. 5.9.3-2: Opened AC Control Box from Panda 30 upwards
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Installation Instructions
1
6
5
4
2
3
7
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

5.9.4 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 the injection pump can increase the engine
speed by up to 8%. If the generator is run without load, the voltage should be 231V with a frequency of approx 48.5 to 49Hz. The fre-
quency (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 215 V.
Fig. 5.9.4-1: VCS Control
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5.9.4.1 Alternative Mini VCS
Alternative for generators without AC control box the Mini VCS. The Mini VCS and the capacitators are is mounted at the generator.
Fig. 5.9.4.1-1: Mini VCS at the Panda 6000 ND PMSMini VCS at the Panda 6500 NE PMS
Installation Instructions
Note:
The Mini VCS has no internal fuse.
Fig. 5.9.4.1-2: Capacitors at the Panda 6000 ND PMSCapacitors at the Panda 6500 NE PMS
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Installation Instructions
1
2
1. Generator 2. Distribution panel

5.9.5 Installation with mini VCS mounted at the generator

Fig. 5.9.5-1: Installation with mini VCS mounted at the generator
All electrical safety installations have to be made on board.

5.9.6 Jump start at high starting current (Booster)

Additionally, the automatic start booster is located on the circuit control board. The starting current is increased by connecting a second group of capacitors (C2), if the voltage drops below a pre-set voltage. The starting current can be increased by 300% for a short period by combining both components voltage/speed control and ASB Start boo­ster.
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Page 96

5.9.7 Insulation test

Installation Instructions
Once the electrical system installation is complete, a ground insulation test must be performed as follows:
ATTENTION:
1.) Switch off all on-board electrical devices.
2.) Start the generator.
3.) Measure the AC-voltage with a voltmeter (adjust to Volt/AC) between a) generator housing and AC-Control box b) generator housing and ground. The measured voltage must not exceed 50mV (millivolts).
6. Once the safety systems have been installed, they must be checked. If a RCD (Leakage Current Relay) has been installed, it also has to be tested, in order to ensure that it functions properly. The individual phrases must be checked against each other, and between phase and ground, (the single phase or 4th phase also needs to be checked in this fashion).
7. If the generator is protected by a ground connection, then ALL electrical devices must also be connected to this "common" ground (usually ground contacts are attached to the devices' metallic housings).
The electrical system installation must also comply with the hook-up requirements of the shore current grid. Gene­rally a leakage current relay is sufficient for safe electrical operation; however, this must be confirmed by the electri­cal safety standard in the region where the system is attached to a main land power grid. The relay has to meet the required safety standard regulations.
Checking the electrical connections
There is always the possibility that circuits have been rerouted/changed or individual components have not been not been correctly laid out on the circuit diagrams.
The installation electrician should therefore check and label all electrical connections to ensure that they correspond to the main circuit diagram. The inspection and correct labelling is especially critical for terminals L1/ L2/L3/L1'/N (for the 230 V - 50 Hz model) and for terminals L1/L2/L3/N &1/ 2/ 4 for the 60 Hz (120 V) models. The electrician is the­refore obliged, before installation to check whether the generator is earth-free. As long as this test has not been car­ried out all other components for electrical installation must be removed. Once the system has been installed and inspected, this test should also be performed with all electrical devices (i.e. voltage check between common and metallic housings) while the generator is running.
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Maintenance Instructions

6. Maintenance Instructions

6.1 Personal requirements

All maintenance work - if not specially marked - can be made by the trained persons. Further maintenance work must only be made by Technical personel or Fischer Panda service points.

6.2 Hazard notes for this chapter

see “Safety instructions - Safety first!” on Page 18.
Follow the general safety instruction at the front of this manual.
Danger for life! - The generator can be equipped with a automa­tik start device. This means the generator can be started by an external signal. To avoid an unexpected starting of the genera­tor, the starter battery must be disconected before start wor­king at the generator.
Working at a running generator can result in severe personal injury. Therfore before starting work at the generator:
Make shure that the generator ist stopped and the starter battery is dicon­nected to guarantee that the generator cannot be inadvertently started.
Do not run the generator with removed sound isolation cover.
Improper installation/maintenance can result in servere perso­nal injuries or material damage.
Notice!:
Warning!: Automatic start
Warning!: Risk of injury
Warning!: Risk of injury
- Always make installation/maintenance work only when the generator is switched off.
- Ensure that there is sufficient space for maintenance work before starting.
- Ensure tidiness and cleanliness at the workplace. Loose components and tools laying around or on top of each other are sources of accidents.
- Only use commercially avalilable tools and special tools for maintenance work. Incorrect or damaged tools can lead to injuries.
Oil and fuel vapours can ignite on contact with ignition sources. Therfore:
- No open flames during work on the generator.
- Do not smoke.
- Remove oil and fuel residues from the generator and floor.
22.3.11 Panda PMS 8.000 NE - 42 NE Manual.R05 - Kapitel/Chapter 6: Maintenance Instructions Seite/Page 97
Warning!: Danger of fire
Page 98
Maintenance 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 immediatlly.
- Do not inhale oil and fuel vapours.
Danger for Life. Improper handling, operation, installation and maintenance can result in sévere personal injury and/or mate­rial damage.
Electrical voltages above 48 volts (battery chargers greater than 36 volts) are always dangerous to life). The rules of the respective regional authority must be adhered to. Only an electrician may carry out installation of the elec­trical connections for safety reasons.
Generator, oil and antifreeze can be hot during/after operation. Risk of severe burns.
During Installation/mainenance personal protective equipment is required to minimize the helth hazards.
Danger!: Danger of poisoning
ATTENTION!: Danger to Life - High voltage
Warning!: Hot surface/material
Instruction!: Personal protective equipment necessary.
- Protective clothing
- safety boots
- protective gloves
- Ear defender
- safety glasses
Disconnet all load during the work atthe generator to avoid damages at the load.
Batteries contains acid or alkalis.
Improper handling can result in battery explosion and leakage. Acid or alka­lis can run out. An explosion of the battery is possible.
See the operation and safety instruction from your battery manufacturer.
Attention!: Disconnect all load
Warning!:
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Maintenance Instructions

6.3 Environmental protection

Danger to the environment due to mishandling!
Significant environmental damage can occur, particularly for incorrect dispo­sal, if environmentally hazardous operating materials are mishandled. The­refore:
– Always observe the instructions mentioned below.
– Take immediate action if environmentally hazardous materials reach the environment. Inform the responsible local authorities about the damage in the case of doubt.
The disposal must be performed by a specialist disposal company.

6.4 General maintenance instructions

6.4.1 Checks before each start

• Oil level
• Leaks in the Cooling system
• Visual check for any changes, leaks in the oil drain system, v-belt, cable connections, hose clips, air filter, fuel lines
Environmental protection.
Once a month
• Grease/oil the servo motor - Trapezoid thread-spindle
Maintenance intervals - see seperate datasheet

6.4.2 Check of Hoses and Rubber Parts in the sound insulated capsule

Check all hoses and hose connections for good condition. The rubber hoses are very sensitive to environmental influences. They wear out quickly in an environment of dry air, oil and fuel vapours, and high temperatures. The hoses must be checked regularly for elasticity. There are operating situations, when hoses must be renewed once a year.
Additionally to usual tasks of maintenance (oil level check, oil filter control etc.) further maintenance activities are to be accomplished for marine generators, such as control of the sacrificial anode (cooling water connection block) and the front seal cover at the generator.

6.5 Oil Change Intervals

The first oil change is to be accomplished after a period of operation from 35 to 50 hours. Afterwards the oil is to be changed after 150 hours. For this, the oil SAE30 for temperatures over 20°C and SAE20 for temperatures between 5°C and 20°C is to be used. At temperatures under 5 °C oil of the viscosity SAE10W or 10W-30 is prescri bed.
For filling quantity, see „Technical Data“ at page 107.

6.5.1 Checking oil-level

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Page 100
You require:
2/3 Suggestion
Oil Max.
Oil Min.
Oil Max.
Oil Min.
2/3 Suggestion
paper towels / cloth for the oildipstick
The generator must be placed at level.
- with vehicular generators: Place the vehicle on a leveled surface.
- with PSC generators: Place the generator on a leveled surface.
- with marine generators: Measure the oil-level when the ship is not lop-sided. Run the generator for about 10 minutes to ensure that the engine is warm.
Wait for 3 minutes, so the oil can flow back into the oil pan.
Maintenance Instructions
Generator and coolant can be hot during and after operating.
Wear personal protective equipment. (Gloves, protective goggles, protective clothing and safety shoes)
Caution: Burn hazard!
- Assure generator against accidental start.
- Open the generator casing.
- Pull the oildipstick out of the check rail.
- Clean oildipstick.
- Put the oildipstick back into the check rail and wait for 10 seconds.
- Pull the oildipstick out of the check rail and read off the oil-level at the lower end of the stick.
Oildipstick
The oil-level is to be checked by means of the oildipstick. The prescribed fil­ling level must not cross the „Max“-mark.
We recommend an oil-level of 2/3.
Sample picture
Fig. 6.5-1: Oildipstick - Sample
Oildipstick EA 300 Engine
The oil-level is to be checked by means of the oildipstick. The prescribed fil­ling level must not cross the „Max“-mark.
We recommend an oil-level of 2/3.
Sample picture
Seite/Page 100 Panda PMS 8.000 NE - 42 NE Manual.R05 - Kapitel/Chapter 6: Maintenance Instructions 22.3.11
Fig. 6.5-2: Samplepicture Oildipstick
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