Fischer Panda 8000i, 10000i User Manual

Manual Vehicle Generator

Panda 8000i PVMV-N 230 V - 50 Hz - 8 kVA - 120 V - 60 Hz - 8 kVA

Panda 10000i PVMV-N 230 V - 50 Hz - 10 kVA

Super silent technology

Panda_8000i-10000i_System_PVMV-N_eng.R07.1 16.1.15

Current revision status

Document

Actual: Panda_8000i-10000i_System_PVMV-N_eng.R07.1_16.1.15
Replace: Panda_8000i_System_PVMV-N_eng.R07

Revision Page

iControl2: „Kontrolltätigkeiten vor dem Start eingefügt“
Bilderverknüpfungen eingepflegt.
Jahresupdate R07
Neues Design R07.1

Erstellt durch / created by

Fischer Panda GmbH - Leiter Technische Dokumentation
Otto-Hahn-Str. 32-34
33104 Paderborn - Germany
Tel.: [phone]
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.

Seite/Page 2 - Kaptitel/Chapter 1: 16.1.15

Inhalt / Contens

Manual Vehicle Generator........................................................................................................................... ....... 1

Current revision status . ... ... .... .......................................... ... ... ... .... ... ... ........................................................ ....... 2

1 General Instructions and Regulations.................................................................................................. ..... 12

1.1 Safety first!...................................................................................................................................... .... 1 2

1.2 Tools ............................... ....................................................................... ........................................ ..... 16

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

1.4 Customer registration and guarantee ............................................................................................. .... 18

1.4.1 Technical support ........................................................................................................... .... 18

1.4.2 Caution, important information for start-up! ............................... ..................................... .... 18

1.5 Safety Instructions - Safety First! ................................................................................................... ..... 19

1.5.1 Safe operation ................................................................................................................ .... 19

1.5.2 Observe safety instructions! ........................................................................................... .... 19

1.5.3 Personal protective clothing (PPE) ................................................................................. .... 19

1.5.4 Cleanliness ensures safety ............................................................................................. .... 19

1.5.5 Safe handling of fuels and lubricants .............................................................................. ..... 20

1.5.6 Exhaust fumes and fire protection .................................................................................. .... 20

1.5.7 Safety precautions against burns and battery explosions .............................................. ..... 21

1.5.8 Protect your hands and body from rotating parts! .......................................................... .... 21

1.5.9 Anti-freeze and disposal of fluids ............................................... .... ... ... ... .... ... ... ... ... .... ... . .... 21

1.5.10 Implementation of safety inspections and maintenance ................ ................................. ..... 22

1.6 Warning and instruction signs......................................................................................................... .... 22

1.6.1 Special instructions and hazards of generators ................................... ... .... ... ... ... ... ........ .... 22

1.6.1.1 Protective conductor and potential equalisation:......... ..................................... ..... 23

1.6.1.2 Protective conductor for Panda AC generators:............................................... .... 23

1.6.1.3 Switch off all loads while working on the generator ......................................... .... 23

1.6.1.4 Potential equalisation for Panda AGT DC generators...................................... .... 23

1.6.1.5 Safety instructions concerning cables.............................................................. ..... 24

1.6.2 Recommended starter battery sizes .... ... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... ... . . ... 24

1.6.3 Important instructions for batteries - starter and/or traction batteries ............................. .... 24

1.6.4 General safety instructions for handling batteries .......................................................... .... 25

2 In case of Emergency First Aid / Im Notfall - Erste Hilfe................................ .... ... ... ... .... ... ... .............. ..... 27

2.1 WHEN AN ADULT STOPS BREATHING .................... .......................................... .... ... ... ... ... .... ... . . ... . 28

3 Basics ...................................................................................................................................................... ..... 29

3.1 Intended use of the machine .......................................................................................................... .... 29

3.2 Purpose of the manual and description of the definitions of the trained persons/operators/users. .... 29

3.2.1 Trained persons .............................................................................................................. .... 29

3.2.2 Operator ......................................................................................................................... .... 29

3.2.3 User ................................. ................................................................. .............................. .... 30

3.3 Components of the i system ........................................................................................................... ... . 30

3.4 Range of operation......................................................................................................................... ... . 31

3.5 Panda transport box ....................................................................................................................... .... 31

3.5.1 Bolted Fischer Panda transport box ........................................................................... ... . .... 31

3.5.2 Fischer Panda transport box with metal tab closure ....................................................... .... 31

3.6 Opening the MPL sound insulation capsule ................................................................................... .... 32

3.6.1 Opening the GFK sound insulation capsule ........................ ... ... .... ... ... ... .... ... ... ... ... ........ .... 33

3.7 Transport and Loading/Unloading .................................................................................................. .... 34

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Inhalt / Contens

3.7.1 Transporting the generator ............................................................................................. .... 34

3.7.2 Loading/unloading of the generator ..................................... ........................................... .... 34

3.8 Special Service Instructions and Measures for Extended Machine Downtimes and Decommissioning 34

3.8.1 Instructions for the starter battery for extended downtimes ................. .... ... ... ... .... ... ... ... . .... 35

3.8.2 Measures for short downtimes ................................ ................. ................ ................ ....... .... 35

3.8.3 Measures for medium term downtimes / hibernation ............................... ....................... .... 35

3.8.3.1 Courses for preservation: ................................................................................. .... 36

3.8.3.2 Measures for removing surface protection after medium term downtimes (3 to 6
months). 36

3.8.4 Measures for extended downtimes / decommissioning .................................................. .... 37

3.8.4.1 Courses for preservation: ................................................................................. .... 37

3.8.4.2 Measures for removing surface protection after extended downtimes / recommissioning
(over 6 months): 37

4 The Panda Generator.............................................................................................................................. ..... 39

4.1 Type plate at the Generator............................................................................................................ .... 39

4.1.1 Description of the generator ........................................................................................... .... 40

4.1.2 Right side view ................................................................................................................ .... 40

4.1.3 Left side view .................................................................................................................. .... 41

4.1.4 Front view ....................................................................................................................... .... 42

4.1.5 Back view ........................................................................................................................ .... 43

4.1.6 View from above ............................................................................................................. .... 44

4.2 Details of function units........... ... ... .... ... ... ... .... .......................................... ... ... ................................. .... 45

4.3 The Panda iControl2 panel ............................................................................................................. .... 45

4.3.1 The cooling system ......................................................................................................... .... 46

4.3.2 Components of the fuel, air intake and exhaust system ................................................. .... 47

4.3.3 Components of the electrical system .............................................................................. .... 48

4.3.4 Components of the lubrication system ............................................................................ .... 49

4.3.5 Sensors and switches for operating surveillance ............................................................ .... 50

5 Installation Instructions.......................................................................................................................... ..... 53

5.1 Personal requirements......... ... ... ... .... ... ... ... .... .......................................... ... .................................... .... 53

5.2 Environmental protection ................................................................................................................ .... 55

5.3 Placement ...................................................................................................................................... ..... 56

5.3.1 General instructions ............................. ... ... .... ... ... ... .... .......................................... ... ... .... .... 56

5.3.2 Preparing the base - Placement ..................................................................................... .... 56

5.3.3 Advice for optimal sound insulation ................................................................................ .... 56

5.4 Connections ................................................................................................................................... .....58

5.5 Fuel system installation................................................................................................................... .... 59

5.5.1 Fischer Panda installation kit - Fuel system ................................................................... .... 59

5.5.1.1 The following items need to be installed: ......................................................... .... 61

5.5.2 Connection of the fuel lines at the tank ................................ .... ... ... ... ... .... ... ... ... .... ... ... ... . .... 64

5.5.3 Position of the pre-filter with water separator ................................................................. ..... 65

5.6 Generator DC system installation ................................................................................................... .... 65

5.6.1 Connection of the starter battery block ........................................................................... .... 65

5.6.2 How to connect two 12 V batteries to a 24 V battery bank ............................ ... .... ... ... ... . .... 69

5.6.3 Connection of the remote control panel - see separate control panel manual ............... .... 71

5.7 Connection of electrical components.............................................................................................. .... 71

5.7.1 Connection of the external radiator ................................................................................. .... 72

5.7.2 Installation PMGi inverter - See separate PMGi 8000 inverter manual .......................... .... 73

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5.8 Installation of the cooling system.................................................................................................... .... 73

5.8.1 The cooling system / general instructions ...................................................................... .... 73

5.8.2 Optionally available components for the installation of the cooling system .................... .... 73

5.9 Radiator baseplate.......................................................................................................................... .... 75

5.9.1 Determining the size of the radiator ................................................................................ .... 75

5.9.2 Radiator design .............................................................................................................. .... 76

5.9.3 Radiator types ................................................................................................................ .... 76

5.9.3.1 Installation location for radiators for roof, side, or underfloor mounting on the vehicle
77

5.9.3.2 Roof installation................................................................................................ ..... 78

5.9.3.3 Installation on the vehicle wall.......................................................................... ..... 79

5.9.3.4 Underfloor installation of radiator ..................................................................... ..... 80

5.9.3.5 Installation location for radiator in the vehicle wall or cabin wall...................... ..... 81

5.9.3.6 Installation location for radiator in a tunnel....................................................... ..... 82

5.9.3.7 Installation location for generators of the PVK-UK series................................ ..... 83

5.9.4 Coolant hoses ................................................................................................................ .... 83

5.9.5 Connection of the external radiator ................................................................................ .... 84

5.9.6 Coolant expansion tank .................................................................................................. .... 84

5.9.7 Installation of a coolant temperature indicator ............................... ................................. . ... 84

5.9.8 Permissible coolant temperatures .................................................................................. .... 84

5.9.9 Coolant pump ................................................................................................................. .... 84

5.9.10 Radiator fan .................................................................................................................... .... 85

5.9.11 Anti-freeze and corrosion protection ............................................................................... .... 85

5.9.12 Logging the temperature values during initial start-up .................................................... .... 85

5.10 Custom installations............................. ... ... ... ... .... ... ... ... .... ... ................................................ ........... .... 86

5.10.1 External heat exchangers ............................................................................................... .... 86

5.10.2 External engine pre-heater ............................................................................................. .... 86

5.10.3 Keel cooling ..... ... .... ... ... ... .......................................... .... ... .............................................. .... 86

5.11 Installation schematics ................................................................................................................... ..... 87

5.11.1 Installation for vertical radiator installation ...................................................................... .... 87

5.11.2 Installation for mounting the radiator under the vehicle .................................... ... ... ........ ..... 88

5.11.3 Installation schematic for roof mounted radiator with expansion tank ............................ ..... 89

5.12 Radiator fan control / electronic fan control.................................................................................... .... 90

5.13 Standard fan control for 1-phase and 3-phase generators............................ ... ... ... .... ... ... ... ... .... ... . .... 90

5.14 Electronic fan control for DC fans RE 0201.................................................................................... .... 92

5.15 Brief description...................................................................................................................... ........ .... 92

5.15.1 Function ..................... ................................ .................................... ................................. .... 92

5.15.2 Master - Slave - Operation ............................................................................................. .... 93

5.15.3 Function of the clamps for the Master-Slave-Operation ...... ........................................... .... 94

5.15.4 Remote controlled switching on and off of the fan controller .................................. .... ... . .... 94

5.15.5 12V / 24V - Operation ..................................................................................................... .... 94

5.16 Technical Data............................................................................................................................... . .... 95

5.17 Electronic fan control for single phase fans PKE-2.5V_Ziehl Abegg .. ... ... .... ... ... ........................... ..... 97

5.17.1 Preset for the use with Fischer Panda generators ......................................................... .... 97

5.17.2 Connection of the sensor (Ziehl Abegg KTY) ................................................................. ..... 98

5.18 Electronic fan control for single phase fans PXET6Q_Ziehl Abegg .............. ... ... ... .... ... ... ... ... .... ... . . ... . 99

5.18.1 Preset for the use with Fischer Panda generators ......................................................... .... 99

5.18.2 Connection of the sensor (Ziehl Abegg KTY) ................................................................. ... 100

5.19 Electronic fan control for 3 phase fans PKD T5 Ziehl Abegg.................................................. .... ... . .. 101

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Inhalt / Contens

5.19.1 Configuration of the electronic fan control PKD T5 for Fischer Panda Generators ........ .. 102

5.20 Exhaust installation ......................................................................................................................... .. 103

5.21 Isolation test............................................... .... ... ... .......................................... ................................. .. 103

5.22 Set into operation............................................................................................................................ .. 104

5.23 ........................................................................................................................................................ .. 104

6 Generator operation instruction............................................................................................................ ... 105

6.1 Personal requirements......... ... ... ... .... ... ... ... .... .......................................... ... .................................... .. 105

6.2 Hazard notes for the operation ....................................................................................................... .. 105

6.3 General operating instruction.......................................................................................................... .. 105

6.3.1 Operation at low temperatures ....................................................................................... .. 105

6.3.1.1 Pre-heating the diesel motor .............................................. ... .... ... ... ... .... ... ... ... . . . 106

6.3.1.2 Tips regarding starter battery ........................................................................... .. 106

6.3.2 Light load operation and engine idle ............................................................................... .. 106

6.3.2.1 The soot of the generator is due to the fact that:.............................................. .. 106

6.3.2.2 To prevent the soot of the generator following steps should be observed:...... .. 106

6.3.3 Generator load for a longer period and overload ............................................................ .. 106

6.3.4 Protection conductor: ...................................................................................................... .. 107

6.3.5 Operating control system on the Fischer Panda generator ............................................ .. 107

6.4 Instructions for capacitors - not present at all models..................................................................... .. 107

6.5 Checks before start - see remote control panel data sheet ............................................................ .. 107

6.6 Starting the generator - see remote control panel data sheet......................................................... .. 108

6.7 Stopping the generator - see remote control panel data sheet....................................................... ..108

7 Maintenance Instructions....................................................................................................................... ... 109

7.1 Personal requirements......... ... ... ... .... ... ... ... .... .......................................... ... .................................... .. 109

7.2 Hazard notes for the maintenance.................................................................................................. .. 109

7.3 Environmental protection ................................................................................................................ .. 111

7.4 Maintenance Requirements............................................................................................................ .. 111

7.5 Maintenance interval....................................................................................................................... .. 111

7.6 Checking oil-level....... ... ... .... ... ... ... .... ... .......................................... ... .............................................. .. 111

7.6.1 Refilling Oil ........................ .......................................... ... ... .............................................. . . 113

7.6.2 After the oil level check and refilling the oil ..................................................................... .. 113

7.7 Replacement of engine oil and engine oil filter ............................................................................... .. 113

7.7.1 After the oil change ......................................................................................................... .. 116

7.8 Verifying the starter battery and (if necessary) the battery bank..................................................... .. 116

7.8.1 Battery ............................................................................................................................ .. 116

7.8.1.1 Check battery and cable connections .............................................................. .. 116

7.8.1.2 Check electrolyte level .......................... .......................................... ................. .. 117

7.8.1.3 Check electrolyte density ................................................................................. .. 117

7.9 Ventilating the fuel system.............................................................................................................. .. 118

7.9.1 Replacement of the fuel filter ..... .... ... ... ... ... .... ... ... ... .... ... ... ... .... ... ... ................................. .. 119

7.9.1.1 Optional fuel filter with sight glass............ .... ... ... ... .... ... ... ................................. .. 119

7.10 RReplacing the Air Filter ................................................................................................................. .. 120

7.10.1 Ventilation of the coolant circuit / freshwater .................................................................. .. 121

7.10.2 ......................... .......................................... .......................................... ........................... .. 124

7.11 V-belt replacement for the internal cooling water pump.............. ... ... ... .... ... ... ... ... .... ... ... ... .............. .. 124

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7.12 Replacing the Electric Starter ........................................................................................................ ... 126

7.13 Replacing the Injection Nozzles ..................................................................................................... ... 129

7.14 Replacing the Glow Plugs............................................................................................................... .. 131

7.15 Replacing the Oil Pressure Switch ................................................................................................ ... 134

7.15.1 Replacing the oil pressure sensor (optional component) ............................................... ... 135

7.16 Replacing the Stop Solenoid (Energize to stop) ............................................................................ ... 136

7.17 Replacing the valve cover gasket at Kubota 02 series .................................................................. ... 140

7.18 Replacing the Water Pump at Kubota 02 series ............................................................................ ...141

7.19 Adjusting the valve clearance at Kubota 02 series ........................................................................ ... 142

7.20 Replacing the Operating Current Relays ....................................................................................... ... 144

7.21 Replacing the fuses ....................................................................................................................... ... 145

7.22 .............. .............................................. ............................................. .............................................. ... 146

8 Generator Failure.................................................................................................................................... ... 147

8.1 Personal requirements.................................................................................................................... .. 147

8.2 Hazard notes for the maintenance.................................................................................................. .. 147

8.3 Environmental protection................................................................................................................ .. 149

8.4 Tools and measuring instruments................................................................................................... .. 149

8.5 Overloading the Generator............................................................................................................. .. 149

8.5.1 Overloading the Generator with Electric Motors ............................................................. .. 149

8.5.2 Generator Voltage Fluctuations and Monitoring ............................................................. .. 150

8.5.3 Automatic Voltage Monitoring and Auto-Shut Down ...................................................... .. 150

8.6 Starting Problems...................... ... ... .... ... ... ... ... .... ... ... .......................................... ... .... ... ......... ........ .. 150

8.6.1 Fuel Solenoid Valve ........................................................................................................ .. 150

8.6.2 Stop solenoid - optional .................................................................................................... 151

8.6.3 Damage to starter motor ................................................................................................. .. 152

8.6.4 Dirty fuel filter ....................................... ... ... ... .... ... .......................................... ... .............. .. 152

8.7 Troubleshooting Table.................................................................................................................... .. 152

9 Tables....................................................................................................................................................... ... 157

9.1 Technical Data................................................................................................................................ .. 157

9.2 Diameter of conduits vehicle generators ....................................................................................... . .. 162

9.3 Cable cross section for vehicle generator.. ... ... .... ... ... ... .... .......................................... .................... .. 164

9.4 Coolant specifications...................... .... ... ... ... ... .... ... ... .......................................... ... .... .................... .. 164

9.4.1 Coolant mixture ratio ...................................................................................................... .. 165

9.5 Engine oil................................................................................................................................ ........ .. 165

9.5.1 Engine oil classification .................................................................................................. .. 165

9.5.1.1 Operating range:...................... ... ... .... ... ... ... .... ... .......................................... ... . .. 165

9.5.1.2 Quality of oil: .................................................................................................... .. 165

9.6 Fuel................................................................................................................................................. .. 166

Panda iControl2............................................................................................................................................ ... 167

Current revision status . ... ... .... .......................................... ... ... ... .... ... ... ........................................................ ... 168

Hardware....................................................................................................................................................... ... 168

10 Safety instructions for the Panda iControl2.................................................... .... ... ... ... .... ... ................. ... 169

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10.1 Personnel........................................................................................................................................ .. 169

10.2 Safety instructions................................................................ ... .... ... ... ... .... ....................................... .. 169

11 General operation ................................................................................................................................... ... 171

11.1 The Panda iControl2 panel ............................................................................................................. .. 171

11.2 Starting preparation / Checks (daily)................. ... ... ........................................................................ .. 172

11.2.1 Marine version ................................................................................................................ .. 172

11.2.2 Vehicle version ............................................................................................................... .. 172

11.3 Operation ........................................................................................................................................ .. 173

11.3.1 Switching the controller on and off .................................................................................. .. 173

11.3.2 The default display screen .............................................................................................. .. 173

11.3.3 Operating modes ....... ... .... ... ... ... .... ... ... .......................................... ... ... ........................... .. 174

11.3.3.1 Stand-by mode......................................... .... .......................................... .......... .. 174

11.3.3.2 Start-up mode........................................ ... .... ... ... ... .... ...................................... . . . 175

11.3.3.3 Override mode.......... ... .... ... ... ... ... .... ... .............................................................. .. 176

11.3.3.4 Operation mode............................................................................ ... ... .... ... ... ... . . . 176

11.3.3.5 Stop mode........................................................................................................ ... 179

11.3.3.6 Autostart mode...................................................................... .... ... ... ... .... ... ....... .. 179

11.4 Other operating functions ............................................................................................................... ...181

11.4.1 Set-up menu ................................................................................................................... .. 181

11.4.2 Setting the brightness of the backlight ("backlight" and "dimtime") ................................ ...182

11.4.3 The configuration menu ("config") .......................... .... ... ... ... ....................................... ... . . . 183

11.4.4 The network ID ............................................................................................................... .. 183

11.4.5 Saving settings and exiting the set-up menu ("Save & Exit") .............. .... ... ... ... .... ... ... ... . . . 183

11.4.6 Activating/deactivating the autostart function ("Autostart") ............................................. .. 183

11.4.7 Resetting the service interval ("Service") ....................................... ... ... .... ... ... ................. .. 185

11.4.8 Priming the fuel system ("Prime Fuel") ........................................................................... .. 186

11.4.9 Selecting and saving a unit for the temperature value output ......................................... .. 186

12 Installation ............................................................................................................................................... ... 187

12.1 Personnel........................................................................................................................................ .. 187

12.1.1 Hazard warnings for installation .................................. ... ... .............................................. .. 187

12.2 Disposal of the components............................................................................................................ .. 188

12.2.1 Panda iControl2 panel with installation housing ............................................................. .. 189

12.2.2 Terminal assignments on the Panda iControl2 panel ....................................... .... ... ... ... . . . 189

12.3 Dimensions ..................................................................................................................................... .. 190

12.4 Wiring of the Panda iControl2 controller ......................................................................................... .. 191

12.4.1 Terminal assignments on the Panda iControl2 controller ................................. .... ... ... ... . . . 192

12.4.1.1 Terminal assignment of 18-pin connector .... ... ... ... .... ... ... ... ... .... ... ... ... .............. .. 192

12.4.1.2 Fischer Panda standard bus ..................................... ... ... ... ... ........................... .. 192

12.4.1.3 Fischer Panda CAN bus..... ... ... ... .... ... ... ... ........................................................ .. 192

12.5 Start-up ........................................................................................................................................... .. 193

13 Maintenance ............................................................................................................................................ ... 195

13.1 Maintenance of the iControl2 controller .......................................................................................... .. 195

13.1.1 Cleaning the iControl2 controller .................................................................................... .. 195

13.2 Maintenance of the iControl2 remote control panel ........................................................................ ..195

13.2.1 Cleaning the iControl2 controller .................................................................................... .. 195

14 Warnings and error messages............................................................................................................... ... 197

14.1 Warnings......................................................................................................................................... .. 197

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14.1.1 Examples of warnings on the display: ............................................................................ .. 197

14.1.2 Warning messages .......................... .... ... ... ... .... ... ... ... .... ... ... ..............................................198

14.2 Faults.............................................................................................................................................. .. 198

14.2.1 Error messages ............................ ... .... ... ... ... .... .......................................... ... ... ... ... ........ ... 199

14.2.2 Warning and fault thresholds .......................................................................................... .. 199

14.2.3 Bus errors ....................................................................................................................... .. 200

15 Annex....................................................................................................................................................... ... 201

15.1 Technical data ................................................................................................................................ .. 201

15.1.1 Technical data for iControl2 control unit ......................................................................... .. 201

15.1.2 Technical data for iControl2 remote control panel .......................................................... .. 201

16 Inverter Panda PMGi 8000 / PMGi 10000.............................................................................................. ... 203

16.1 Safety instruction ............................................................................................................................ .. 204

16.2 Type plate....................................................................................................................................... .. 204

16.3 Front side/connection side.............................................................................................................. .. 205

16.3.1 Socket pins of the PMGi 8000 ......... .... ... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ........... ... 206

16.4 Back side .................................................................................................................................... .... .. 207

16.5 Settings for the use of iGenerators with power inverter ................................................................. ...208

16.5.1 Settings in the Victron VE Configure II Software - General ............................................ .. 208

16.5.1.1 Uninterrupted AC power (UPS function) .......................................................... .. 208

16.5.1.2 Dynamic current limiter .................................................................................... .. 208

16.5.2 Settings in the Victron VE Configure II Software - Inverter ............................................. .. 209

16.5.2.1 Assist current boost factor................................................................................ .. 209

16.6 Operation manual .......................................................................................................................... ... 210

16.6.1 Primary remarks / Winter operation ................................................................................ .. 210

16.6.2 Load at the PMGi ........................................................................................................... .. 210

16.6.3 Automatic start ................................................................................................................ .. 210

16.7 Status LED´s................................................................................................................................... .. 210

16.8 Cooling of the PMGi.................................................................................................................... .... .. 210

16.9 Installation of the PMGi .................................................................................................................. ... 211

16.9.1 Electrical connection. ...................................................................................................... .. 211

16.9.1.1 Connection to a system with RCD ................................................................... .. 211

16.9.1.2 Connection to a system with isolation control .................................................. .. 211

16.10 Technical Data................................................................................................................................ .. 212

16.10.1 General Data .................................................................................................................. .. 212

16.10.2 Generator Specification .................................................................................................. .. 212

16.10.3 PMGi out ........................................................................................................................ .. 212

16.10.4 Overload - switch point ................................................................................................... .. 218

16.10.5 Short circuit ..................................................................................................................... .. 218

16.1.15 Inhalt/Contens Seite/Page 9

Leere Seite / Intentionally blank

Seite/Page 10 Kapitel/Chapter 2: 16.1.15

Dear Customer,

Thank you for purchasing a Fischer Panda Generator and ch oo sing Fisch er Panda as your p artne r for mobile powe r
on board. With your generator, you now have the means to produce your own power – wherever you are - and
experience even greater independence. Not only do you have a Fischer Panda generator on board, you also have
worldwide support from the Fischer Panda Team. Please take the time to read this and find how we can support you
further.

Installation Approval and Warranty

Every generator has a worldwide warranty. You can apply for this warranty through your dealer when the installation
is approved. If you have purchased an extended warranty, please ensure that it is kept in a safe place and that the
dealer has your current address. Consult your dealer about warranty options especially if you have purchased a
used generator. He will be able to advise about authorised Fischer Panda Services worldwide.

Service and Support

To ensure that your generator operates reliably, regular maintenance checks and tasks as specified in this manual
must be carried out. Fischer Panda can supply Service Kits which are ideal for regular servicing tasks. We only
supply the highest quality components which are guaranteed to be the RIGHT parts for your generator. Service
“Plus” Kits are also available and ideal for longer trips where more than one service interval may be required.

If you require assistance – please contact your Fischer Pan da Dealer. Please do not attempt to undertake any repair
work yourself, as this may affect your generator warranty. Your dealer will also be able to assist in finding your
nearest Fischer Panda service sta tio n. Your nearest service station can also be found in our Global Service Network
which can be downloaded from our homepage.

Product Registration

Please take the time to register your Fischer Panda Generator on our website at
http://www.fischerpanda.de/mypanda
By registering, you will ensure that you will be kept up to date on any technical upgrades or specific information on

the operation or servicing of your generator. We can even let you know about new Fischer Panda products –
especially helpful if you are planning to upgrade or expand your installation at a later date.

Fischer Panda Quality - Tried and Tested

DIN-certified according DIN ISO 9001

Thank you for purchasing a Fischer Panda Generator.
Your Fischer Panda Team

16.1.15 Kapitel/Chapter 1: - Seite/Page 11

General Instructions and Regulations

1. General Instructions and Regulations

1.1 Safety first!

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

WARNING: Hazardous materials Can cause acute or chronic health impairments or death
even in very small quantities if inhaled, swallowed, or
absorbed through the skin.

WARNING: Important information! This warning symbol draws attention to special warnings,
instructions or procedures which, if not strictly observed, may
result in damage or destruction of equipment.

ignition source (cigarettes, hot surfaces, sparks, etc.).

smoking is prohibited.

avoided.

is in progress.

WARNING: Fire hazard Warning of materials that may ignite in the presence of an

PROHIBITED: No smoking In the environment described / during the work specified,

PROHIBITED: No fire or naked light Fire and naked light are ignition sources that must be

PROHIBITED: Do not activate/start up The equipment shall not be activated or started up while work

Seite/Page 12 - Kaptitel/Chapter 1: General Instructions and Regulations 16.1.15

General Instructions and Regulations

prohibited.

result in severe personal injury.

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

draws attention to special warnings, instructions or
procedures which, if not strictly observed, may result in
severe personal injury or loss of life due to electric shock.

PROHIBITED: Do not touch To uch in g of the co rr esponding parts and systems is

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

WARNING: Hazardous electric voltage This danger symbol refers to the danger of electric shock and

Can cause acute or chronic health impairments or death
even in very small quantities if inhaled or ingested.

contact. Especially dangerous for persons with heart
problems or pacemakers.

WARNING: General warning General warning of a hazard area

WARNING: Danger due to inhalation and/or
ingestion

WARNING: Risk of electric shock upon contactWarning of live parts that may cause electric shock upon

WARNING: Danger due to rotating parts Danger of injury due to being pulled into equipment. Bruising

and torn off body p art s possible. Risk of b eing pulled i n when
touching with body part, loose-fitting clothing, scarf, tie, etc.

16.1.15 Kapitel/Chapter 1: General Instructions and Regulations - Seite/Page 13

certain conditions, e.g. presence of heat or ignition sources.

General Instructions and Regulations

WARNING: Explosion hazard Warning of substances that may cause an explosion unde r

WARNING: Hot surface Warning of hot surfaces and liquids. Burn/scalding hazard.

Warning of substances that cause chemical burns upon
contact. These substances can act as contaminants if
introduced into the body.

abruptly and expel hot gases and fluids. Risk of injury due to
parts flying about, burn hazard due to liquids and gases.

WARNING: Danger due to corrosive substances,

potential contamination of person

WARNING: System may be pressurised! When the system is opened, the pressure can be relieved

WARNING: Hearing damageWarning of hearing damages.

WARNING: Magnetic fieldWarning of magnetic field.

WARNING: OverpressureWarning of overpressure.

Seite/Page 14 - Kaptitel/Chapter 1: General Instructions and Regulations 16.1.15

General Instructions and Regulations

Wearing the applicable snugly fitting protective clothing
provides protection from hazards and can prevent damage to
your health.

Wearing hearing protection provides protection from acute
and gradual hearing loss.

Wearing safety goggles protects the eyes from damage.
Optical spectacles are not a replacement for the
corresponding safety goggles.

MANDATORY INSTRUCTION: Wear snugly fitting
protective clothing (PPE).

MANDATORY INSTRUCTION: Wear hearing
protection (PPE).

MANDATORY INSTRUCTION: Wear safety
goggles (PPE).

Wearing protective gloves provides the hands from hazards
like friction, graze, punctures or deep cuts and protects them
from contact with hot surfaces.

Compliance with the instructions in the manual can avert
danger and prevent accidents. This will protect you and the
generator.

Environmental protection saves our living environment. For
you and for your children.

MANDATORY INSTRUCTION: Wear protective
gloves (PPE).

MANDATORY INSTRUCTION: Observe the
instructions in the manual.

MANDATORY INSTRUCTION: Comply with
environmental protection requirements.

16.1.15 Kapitel/Chapter 1: General Instructions and Regulations - Seite/Page 15

General Instructions and Regulations

1.2 Tools

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

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

Hook wrench for oil filter

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

Multimeter, multimeter with capacitor measuring unit

Socket wrench set

Hexagon socket wrench set

Seite/Page 16 - Kaptitel/Chapter 1: General Instructions and Regulations 16.1.15

General Instructions and Regulations

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

Torque wrench

16.1.15 Kapitel/Chapter 1: General Instructions and Regulations - Seite/Page 17

General Instructions and Regulations

1.3 Manufacturer declaration in accordance with the Machinery Directive

2006/42/EC

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

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

The evaluation of “protection agai nst contact“ must be carried out when installed, in conjunction with the respective
system. This also includes correct electrical connections, a safe ground wire connection, foreign body and humidity
protection, protection against moisture due to excessive condensation, as well as overheating through appropriate
and inappropriate use of the equipment in its installed state. The responsibility for implementing these measures lies
with those who undertake the installation of the generator in the final system.

1.4 Customer registration and guarantee

Use the advantages of registering your product:

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

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

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

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

1.4.1 Technical support

Technical Support via the Internet: [email protected]

1.4.2 Caution, important information for start-up!

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

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

operation.

3. After receiving the commissioning log, Fischer Panda will make out the official guarantee certificate and send it to

the customer.

4. If warranty claims are made, the document with the guarantee certification must be submitted.
If the above requirements are not or only partly fulfilled, the warranty claim shall become void.

Seite/Page 18 - Kaptitel/Chapter 1: General Instructions and Regulations 16.1.15

General Instructions and Regulations

1.5 Safety Instructions - Safety First!

1.5.1 Safe operation

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

1.5.2 Observe safety instructions!

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

1.5.3 Personal protective clothing (PPE)

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

Wear appropriate safety and protective clothing during work.

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

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

1.5.4 Cleanliness ensures safety

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

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

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General Instructions and Regulations

1.5.5 Safe handling of fuels and lubricants

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

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

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

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

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

1.5.6 Exhaust fumes and fire protection

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

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

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

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

The generator shall be integrated in the existing fire safety system by the operating company.

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the State of

California to cause cancer, birth defects, and other reproductive harm.

Exhaust gases from diesel motors and some components are carcinogenic and can cause
deformities and other genetic defects.

Seite/Page 20 - Kaptitel/Chapter 1: General Instructions and Regulations 16.1.15

General Instructions and Regulations

1.5.7 Safety precautions against burns and battery explosions

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

The cooling system may be pressurised. Open the cooling system on ly af ter letting th e engine and
the coolant cool down. Wear appropriate protective clothing (e.g. safety goggles, gloves).

Prior to operation, ensure that the cooling system is sealed and that all hose clamps are tightened .

The battery represents an explosion ha za rd, th is app lies both to th e starter battery and the battery
bank of the AGT generators. While batteries are being charged, a hydrogen-oxygen mixture is
generated, which is highly explosive (electrolytic gas).

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

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

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

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

1.5.8 Protect your hands and body from rotating parts!

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

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

devices securely and check for proper attachment and function.

1.5.9 Anti-freeze and disposal of fluids

Anti-freeze contains toxic substances. To prevent injury , wear rubber glove s and wash off any anti­freeze immediately in case of skin contact. Do not mix different anti-freeze agents. The mixture
may cause a chemical reaction generating harmful substances. Use only anti-freeze that was
approved by Fischer Panda.

Protect the environment. Collect drained fluids (lubricants, anti-freeze, fuel), and dispose of them
properly. Observe the local regulations for the respective country. Ensure that no fluids (not even
very small quantities) can drain into the soil, sewers, or bo die s of wate r.

16.1.15 Kapitel/Chapter 1: General Instructions and Regulations - Seite/Page 21

General Instructions and Regulations

1.5.10 Implementation of safety inspections and maintenance

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

- MAINTENANCE IN PROGRESS“ to prevent unintentio n al start-up.
To prevent sparking d ue to acciden t al short-circu iting, always r emove th e earthing ca ble (-) first an d

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

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

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

1.6 Warning and instruction signs

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

parts.

1.6.1 Special instructions and hazards of generators

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

The generator must not be operated with the cover removed.

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

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

All servicing, maintenance, or repair work may only be carried out when the motor is not running.
Electrical voltages above 48 volts (battery chargers greater than 36 volts) are always dangerous

to life. The rules of the respective regional authority must be adhered to during installation. For
safety reasons, only an electrician may carry out the installatio n of the electrical connectio ns of the
generator.

Seite/Page 22 - Kaptitel/Chapter 1: General Instructions and Regulations 16.1.15

General Instructions and Regulations

1.6.1.1 Protective conductor and potential equalisation:

Electric current below 48 V may be life-threatening. Fort this reason systems are grounde d with a prote ctive
conductor. In connection with a RCD the current supply will be disconnected in case of a failure.

Appropriate safety precautions like the RCD and corresponding fuses have to be provided by the customer
to guarantee a save operation of the generator.

1.6.1.2 Protective conductor for Panda AC generators:

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

This „neutralisation“ (Protective Earthing Neutral - PEN) is only effective if all par t s of the electrical
system are jointly „earthed“ to a common potential. The shunt can be removed if this is necessary
for technical reasons and another protective system has been set up instead.

While the generator is being operated, the full voltage is applied to the AC control box, as
well. Therefore, it is essential to ensure that the control box is closed and secured against
touch while the generator is running.

The battery must always be disconnec ted if work on the gener ator or ele ctrical sy stem is to
be carried out, so that the generator cannot be started up unintentionally.

1.6.1.3 Switch off all loads while working on the generator

All loads must be disconnected prior to working on the generator to avoid damage to the devices. In addition, the
semiconductor relays in the AC control box must be disconnected in order to avoid the booster capacitors being
activated during set-up. The negative te rminal of the battery must be disconnected.

Capacitors are required to run the generator. These have two varying functions:
A) The working capacitors
B) The booster capacitors
Both groups are located in a separate AC control box.
Capacitors store electrical energy. High voltages may remain across the capacitor contacts even after they ha ve

been disconnected from the mains. As a safety precaution, do not touch the contacts. If the capacitors must be
replaced or inspected, the contacts shall be short-circuited by connecting an electrical conductor to discharge
potentially remaining potential differences.

If the generator is switched off normally, the working capacitors are automatically discha rged via the windin g of the
generator. The booster capacitors are discharged by means of internal discharge resistors.

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

1.6.1.4 Potential equalisation for Panda AGT DC generators

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

16.1.15 Kapitel/Chapter 1: General Instructions and Regulations - Seite/Page 23

General Instructions and Regulations

1.6.1.5 Safety instructions concerning cables

Cable types

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

Cable cross-section

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

Cable installation

It is recommended to install a self-draining cable conduit classified as V-2 or higher in compliance with UL 94 in the
area of the cable guide inside the capsule. It must be ensured that the cable guide is not routed along hot surfaces
such as the exhaust manifold or the engine oil drain screw but instead is installed free from any influence due to
friction and crushing.

1.6.2 Recommended starter battery sizes

Use only batteries approved by the manufacturer as starter batteries.
Use the battery capacity recommended by the engine manufacturer.

ATTENTION!
Prior to installation, verify that the voltage of the starter battery complies with the start-up system

voltage.
e.g. 12 V starter battery for 12 V start-up system
e.g. 24 V starter battery for 24 V start-up system (e. g. 2x 12 V in series)

1.6.3 Important instructions for batteries - starter and/or traction batteries

ATTENTION!!! Start-up:

Installation of battery connection lines.
Observe the instructions installation guidelines of the battery manufacturer.

Observe the regulations “ABYC regulation E11 AC and DC electrical systems on boats“, as EN
ISO 10133:2000 “Small craft -- Electrical systems -- Extra-low-voltage DC installations“, as
applicable!

The battery compartment and the corresponding installation shall be dimensioned
adequately.

The batteries can be separated mechanically or with an adequate power relay.

Seite/Page 24 - Kaptitel/Chapter 1: General Instructions and Regulations 16.1.15

General Instructions and Regulations

Observe the applicable instructions concerning fire and explosion protection of the battery
manufacturer.

Install a fuse of appropriate size in the positive connection of the starter battery. Install as close to
the battery as possible but with a max. distance of 300 mm (12 in) fro m th e ba tte ry.

The cable from the battery to the fuse shall be protected with a conduit/protective sleeve against
fraying.

Use self-extinguishing and fire-protected cables for installation that are designed for max. temperatures of 90 °C,
195 °F.

Install the battery cables in such a way that the insulation cannot be removed by chafing or other mechanical
stresses.

The battery terminals must be protected against accidental short-circuiting.
Inside the Fischer Panda generator capsule, the positive battery cable must be routed so that it is protected from

heat and vibrations by means of an adequate conduit/protective sleeve. It must be installed so that it does not come
into contact with rotating parts or such that heat up during operation such as pulley, exhaust manifold, exhaust pipe,
and motor itself. Do not overtighten the cable, as it may be damaged otherwise.

After completing the installation, perform a test run of the generator and check the battery cable installation during
and after the test run. Implement corrections as necessary.

Fig. 1.6-1: Sample diagram for starter battery installation

1.6.4 General safety instructions for handling batteries

These instructions shall apply in addition to the instructions of the battery manufacturer:

• While you are working on the batteries, a second person should be within earshot to help you if
necessary.

• Keep water and soap ready in case battery acid is burning your skin.

• Wear ey e pr otection and protective clothing. Do not touch you r ey es while ha nd lin g ba tte r ies.

16.1.15 Kapitel/Chapter 1: General Instructions and Regulations - Seite/Page 25

General Instructions and Regulations

• If you have acid splashes on the skin or clothing, wash them out with lots of water and soap.

• If acid sprays into your eyes, immediately flush them with clean water until no more burning is
felt. Immediately seek medical assistance.

• Do not smoke near the batteries. Avoid naked fire. The area around batteries is a potentially
explosive atmosphere.

• Ensure that no tools are dropped on the battery terminals; cover them as necessary.

• Do not wear jewellery or watches on your arms during installation that might short-circuit the
battery. Otherwise, there is a risk of skin burns.

• Protect all battery contacts against accidental contact.

• For battery banks: Use only deep cycle batteries. Starter batteries are not suitable. Lead-acid gel
batteries are recommended. They are maintenance- free, cycle stable, and do not release gases.

• Never charge a frozen battery.

• Avoid battery short-circuits.

• Ensure proper ventilation of the battery to vent gases that may be released.

• Battery connection terminals must be checked for proper seating before operation.

• Battery connection cables shall be installed with utmost care and shall be checked for excessive
heating under load. Check the battery near vibrating components regularly for chafing and
insulation defects.

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

voltage of the generator.

Seite/Page 26 - Kaptitel/Chapter 1: General Instructions and Regulations 16.1.15

In case of Emergency First Aid / Im Notfall -

11

1

2

1

3

1

4

1

5

Erste Hilfe

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

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

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

Switch off the generator immediately.

If you cannot switch off the generator, pull, push, or lift the person to safety using a
wooden pole, rope or some nonconducting material.

Call an emergency doctor as soon as possible.

Immediately start necessary first aid procedures.

16.1.15 Kapitel/Chapter 2: In case of Emergency First Aid / Im Notfall - Erste Hilfe - Seite/Page 27

2.1 WHEN AN ADULT STOPS BREATHING

Warning:DO NOT attempt to perform the rescue breathing
techniques provided on this page, unless certified.
Performance of these techniques by uncertified
personnel could result in further injury or death to the

victim.

In case of Emergency First Aid / Im Notfall -

Erste Hilfe

Does the Person Respond?

1

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

Roll Person onto Back.

3

Roll victim towards you by pulling slowly.

Open Airway.

4

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

Give 2 Full Breaths.

6

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

Shout, “Help!“

2

Call people who can phone for help.

Check for Breathing.

5

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

Check for Pulse at side of Neck.

7

Feel for pulse for 5 to 10 seconds.

Begin Rescue Breathing.

9

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

Phone EMS for Help.

8

Send someone to call an ambulance.

Recheck Pulse Every Minute.

10

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

rescue breathing. If no pulse, begin CPR.

Seite/Page 28 - Kaptitel/Chapter 2: In case of Emergency First Aid / Im Notfall - Erste Hilfe 16.1.15

Basics

3. Basics

3.1 Intended use of the machine

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

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

Sufficient amount of fuel and combustion air is necessary for this process. Arising exhaust and heat must be
conducted according to the specification.

If the electrical power is fed to a local net, the regulations and installation instructions of the system operator and the
regional authorities with reference to the power network/shipboard power supply system must be respected. Safety
applications and safety devices (including lightening conduc tor, personal protection switch, ect.) have to be inst alled.

Misapplication of the product can damage and destroy the product and the electrical net inclusive all load which is
attached to the net, and contain hazards like short circuit, ect. It is not allowed to modify the product in any case.
Never open the sound cover during operation! The safety and hazard notes of the manual must be respected !

3.2 Purpose of the manual and description of the definitions of the trained persons/operators/users

This manual contains the working instructions and operating guidelines for the owner and user of Fischer Panda
generators.

The manual is the base and the guideline for the correct installation and maintenance of Fischer Panda generators.
It does not substitute the technical evaluation and should be used as an example guide only. The installation must
be undertaken and proved by a suitable qualified/trained person and should be in accordance with the law as
required by the country and special situation. All work has to be undertaken a cco rd ing to the state of the technology.

3.2.1 Trained persons

Qualified persons for the mechanical components are motor mechanics or persons with similar
qualification and training.

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

After the installation the trained person has to instruct the owner about the operation and maintenance of the
generator. This must include the hazards of the generator use.

3.2.2 Operator

The operator is responsible for the operation of the generator.

After the installation, the operator must be instructed concerning the operation and maintenance of the generator.
This has to include the hazards during operation of the generator, different operating conditions, and instructions for
the maintenance.

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

16.1.15 Kapitel/Chapter 3: Basics - Seite/Page 29

Basics

3.2.3 User

Users are persons, established by the operator, to operate the generator.

The operator has to ensure that the user has read and understood the manual and that all hazard notes and safety
instructions are respected. The user must be instructed by the operator regarding his activity at the generator,
especially concerning the maintenance.

3.3 Components of the i system

Fig. 3.3-1: Panda i generator1. Panda i PMS Generator

Permanent-Magnet-Generator

representative picture

generator

representative picture

Fig. 3.3-2: iControl panel2. Panel Panda iControl with electronic board at the

Seite/Page 30 - Kaptitel/Chapter 3: Basics 16.1.15

Basics

representative picture

The Fischer Panda manual comprises the following
components:

Fig. 3.3-3: PMGi inverter3. Panda PMGi Inverter AC/AC

Fig. 3.3-4: Manual4. Fischer Panda manual

a.- Transparent envelope with general information, war-

ranty terms, installation certificates, and service list.
b.- Generator manual
c.- Spare parts catalogue „Installation & Service Guide“
d.- Engine manual from the engine manufacturer
e.- Generator circuit diagram

representative picture

3.4 Range of operation

Reliable power supply on sailing boats.

3.5 Panda transport box

3.5.1 Bolted Fischer Panda transport box

1. Remove the bolts for cover / sidewalls

2. Remove the cover

3. Remove the loose accessories

4. Remove the bolts for sidewalls / floor pallet

5. Remove the sidewalls

6. Open the generator attachment

3.5.2 Fischer Panda transport box with metal tab closure

1. Bend up the metal tab closures on the tr ansport box lid

16.1.15 Kapitel/Chapter 3: Basics - Seite/Page 31

2. Remove the cover

3. Remove the loose

4. Bend open the metal tab closures at the bottom of the transport box

5. Remove the sidewalls

6. Open the generator attachment

3.6 Opening the MPL sound insulation capsule

be rotated roughly 180° counter-clockwise. Use a flat
head screwdriver . Pull th e sidewalls out by g rip ping into
the slots.

Basics

Fig. 3.6-1: Sound insulation capsule, side partT o open the sound insulation cap sule, the clo sures must

Fig. 3.6-2: Closure lockedClosure locked

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Basics

3.6.1 Opening the GFK sound insulation capsule

Fig. 3.6-3: Closure openClosure open

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

Fig. 3.6-1: Lash closuresGFK sound insulation capsule with lash closures

Fig. 3.6-2: Lash closuresTo open the lash closures pull the handle in arrow

16.1.15 Kapitel/Chapter 3: Basics - Seite/Page 33

Basics

3.7 Transport and Loading/Unloading

3.7.1 Transporting the generator

• The generator must always be upright for transport.

• For transport, the Fischer Panda transport box shall be used for the generator. The generator shall be securely
attached to the bottom of the box.

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

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

3.7.2 Loading/unloading of the generator

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

Fig. 3.7.2-1: Lifting yoke (example)An adequate lifting yoke shall be used for transport/

loading.

3.8 Special Service Instructions and Measures for Extended Machine

Downtimes and Decommissioning

Note: The decommissioning and storage mu st be un de rtaken and

proved regarding the operation and storage situation.

Fischer Panda takes no responsibilty for damages
through wrong decommissioning and storage.

Downtimes are categorised in the following groups:

• Short downtime (1 to 3 months)

• Medium term downtime / hibernation (3 to 6 months)

• Extended downtime / decommissioning (more than 6 months)

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Basics

3.8.1 Instructions for the starter battery for extended downtimes

Note: Information starter batteryStarter batteries

Self-discharge of batteries is a physical and chemica l
process and cannot be avoided even if the battery is
disconnected

• For extended downtimes, the battery shall be disconnected from the genset.

• Charge battery regularly. Observe instructions of the battery manufacturer.
Depending on the battery type, check the acid level before charging and refill each cell up to the marking using

distilled water as necessary.
Modern starter batteries are typically maintenanc e- fr ee .

Deep discharge will damage the battery and can render it unusable.

Keep battery clean and dry. Clean battery poles (+ and -) and terminals regularly and coat with acid-free and acid­resistant grease. During assembly, ensure good contact of the terminal connections.

General limits for lead-acid batteries:

2.1 V / cell corresponds with full battery (charged).

1.95 V / cell corresponds with empty battery - recharge.
For a 12 V battery, the following applies:

- 11.7 V lower open-circuit voltage (battery empty), recharge battery.

- 12.6 V upper open-circuit voltage (full battery) - trickle charge full battery at 13.2 V.
For a 24 V battery, the following applies:

- 23.4 V lower open-circuit voltage (battery empty), recharge battery.

- 25.2 V upper open-circuit voltage (full battery) - trickle charge full battery at 26.4 V.

These values are based on a battery temperature of 20-25°C. Observe the instructions from the battery
manufacturer.

Note: Starter battery recommendationFischer Panda recommends:

• Install battery circuit breaker and switch to OFF on the
machine. (Cutting the battery circuit.)

• Secure the battery plus terminal close to the battery.

• Regularly check contacts for corrosion.

3.8.2 Measures for short downtimes

Short downtime (1 to 3 months)

• Measure battery charge status based on open-circuit voltage.

• During downtimes >7 days, disconnect battery (e.g. battery main switch to position 0).

• Check the battery within 2 months and allow the engine to warm up for min. 10 min.

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

3.8.3 Measures for medium term downtimes / hibernation

Medium term downtimes (3 to 6 months)

16.1.15 Kapitel/Chapter 3: Basics - Seite/Page 35

Basics

3.8.3.1 Courses for preservation:

• Check battery charge status and recharge regularly, roughly every 2 months, as necessary. Observe instructions
of the battery manufacturer.

• Check cooling water anti-freeze level and refill as necessary.

The anti-freeze agent must not be older than 2 years. The anti-freeze conte nt shall be between 40 % and 60 % to
ensure corrosion protection of the cooling water circuit. Top off coolant if necessary.

If the cooling water is drained, e.g. after engine surface protection is applied, no water may remain inside the
engine during the downtime. The control unit must be marked accordingly with a note specifying “NO COOLING
WATER“.

• Drain engine oil as specified. Refill engine with preservative oil to the max. level on the oil dipstick.

• Drain diesel from tank and refill with a protective mixture (90 % diesel and 10 % preservative oil) (level to full).

Crank engine without start.

• Dismount V-belt as specified, wrap and store in a dry location. Protect against UV radiation.

Attention! Cover alternator apertures.

Cleaning fluids and preservatives must not enter the
alternator. Risk of destroying the alternator.

• Clean engine as per manufacturer's instructions.

• Spray engine parts and V-belt disks with preservative.

• Clean air filter housing and spray with preservative (metal housing only).

• Close off intake and exhaust apertures (e.g. with tape or end caps).

Attention! Before recommissioning, remove preservatives and

protective measures.

3.8.3.2 Measures for removing surface protection after medium term downtimes (3 to 6

months).

• Check battery charge status and recharge if necessary. Observe instructions of the battery manufacturer.

• Check cooling water anti-freeze level and cooling water level and refill as necessary.

• Drain engine oil. Replace oil filter and engine oil as per the specification.

• Remove preservatives from the engine with petroleum spirit.

• Degrease V-belt disks and mount V-belt according to instructions. Check V-belt tension!

• If applicable, open turbocharger oil pressure line and fill clean engine oil into channel.

• Hold engine stop lever in zero delivery position and crank engine manually several times.

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

• Remove covers from exhaust aperture and intake apertures.

• Connect battery. Close battery main switch.

• Hold stop lever on generator m otor in neutral position and crank starter for approx. 10 seconds. Then, pause for 10
seconds. Repeat this procedure 2 times.

• Perform visual check of the generator similar to initial commissioning and start up generator.

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Basics

3.8.4 Measures for extended downtimes / decommissioning

Downtimes (more than 6 months)

3.8.4.1 Courses for preservation:

• Check battery charge status and recharge regularly, roughly every 3 months, as necessary. Observe instructions
of the battery manufacturer.

• Check cooling water anti-freeze level and refill as necessary.

The anti-freeze agent must not be older than 2 years. The anti-free ze content shall be betwe en 40 % and 60 % to
ensure corrosion protection of the cooling wa ter ci rcu it. Top off coolant if necessary.

If the cooling water is drained, e.g. after engine surface protection is applied, no water may remain inside the
engine during the downtime. The control unit must be marked accordingly with a note specifying “NO COOLING
WATER“.

• Drain engine oil as specified. Refill engine with preservative oil to the max. level on the oil dipstick.

• Drain diesel from tank and refill with a protective mixture (90 % diesel and 10 % preservative oil) (level to full).

Crank engine without start.

• Dismount V-belt as specified, wrap and store in a dry location. Protect against UV radiation.

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

Attention! Cover alternator apertures.

Cleaning fluids and preservatives must not enter the
alternator. Risk of destroying the alternator.

• Clean engine as per manufacturer's instructions.

• Spray engine parts and V-belt disks with preservative.

• Clean air filter housing and spray with preservative (metal housing only).

• Spray preservative on intake and exhaust side of exhaust tu rbocharger (where applicable) an d reconnect the lines.

• Remove valve cover and spray inside of valve cover, valve stems, springs, rocker, etc. with preservative oil.

• Remove injection nozzle and coat cylinder surface with preservative oil. Hold stop lever in zero delivery position
and crank engine manually several times. Refit injection nozzles with new seals (at an operation hour of min. 100
hours after the last change). Observe torque values.

• Spray radiator cover and tank cover or radiator cover on expansion tank lightly with preservative oil and refit.

• Close off intake and exhaust apertures (e.g. with tape or end caps).

Note: For storage for more than 12 months, the preservation
measures shall be checked annually and supplemented
as necessary.

Attention! Before recommissioning, remove preservatives and
protective measures.

3.8.4.2 Measures for removing surface protection after extended downtimes /

recommissioning (over 6 months):

• Check battery charge status and recharge if necessary. Observe instructions of the battery manufacturer.

16.1.15 Kapitel/Chapter 3: Basics - Seite/Page 37

Basics

• Check cooling water anti-freeze level and cooling water level and refill as necessary.

• Drain engine oil. Replace oil filter and oil as per the specification.

• Remove preservatives from the engine with petroleum spirit.

• Degrease V-belt disks and mount V-belt according to instructions. Check V-belt tension!

• If applicable, open turbocharger oil pressure line and fill clean engine oil into channel.

• Hold engine stop lever in zero delivery position and crank engine manually several times.

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

• Remove covers from exhaust aperture and intake apertures.

• Connect battery. Close battery main switch.

• Hold stop lever on generator m otor in neutral position and crank starter for approx. 10 seconds. Then, pause for 10
seconds. Repeat this procedure 2 times.

• Perform visual check of the generator similar to initial commissioning and start up generator.

Note: Fischer Panda recommends:

After extended downtimes, a full 150 h inspection as per the
inspection list should be performed.

Seite/Page 38 - Kaptitel/Chapter 3: Basics 16.1.15

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

16.1.15 Kapitel/Chapter 4: The Panda Generator - Seite/Page 39

4.1.1 Description of the generator

01

03

05

07

02

06

08 09 10 1211

13

04

14

15

16

17

18

01) Thermostat housing

02) DC-alternator

03. V-Belt

04) Oil pressure switch

05) Oil filter

06) Cooling water pipe to water pump

07) Sound cover base part

08) Starter motor

09) Cooling water input

10) Generator housing with coil

11) Cooling water output

12) Exhaust output

13) Watercooled silencer

14) Compensator under heat isolation

15) Air suction housing

16) Cooling water pipe

17) Thermosensor exhaust elbow

18) Watercooled exhaust elbow

4.1.2 Right side view

The Panda Generator

Fig. 4.1.2-1: Right side view

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The Panda Generator

01

11

02

04 05

10

16

08

17 15 14

06

07

09

1213

03

01) Connection external expansion tank

02) Sound cover base part

03) Electrical fuse

04) Generator housing with coil

05) Capacitor for fan control

06) Actuator

07) Housing with iControl electronic board (DO NOT OPEN)

08) Oil dipstick

09) Fuel filter

10) Fuel solenoid switch

11) Pulley for internal cooling water pump

12) Thermostat housing

13) Suction hose, air suction housing - induction elbow

14) Thermoswitch cylinder head

15) Air suction housing

16) Charge controller for DC-alternator

17) Ventilation hose to external expansion tank

18) Water cooled silencer

4.1.3 Left side view

Fig. 4.1.3-1: Left side view

16.1.15 Kapitel/Chapter 4: The Panda Generator - Seite/Page 41

4.1.4 Front view

05

04

08

09

14

06

07

18

15

02

01

03

16

10

11 13

19

17

12

01) Fuel stop solenoid

02) Oil dipstick

03) Fuel filter

04) Sound cover base part

05) Fuel IN

06) Fuel OUT

07) Cable for fuel pump

08) Oil drain hose

09) Cable for PMGi 8000i inverter

10) Cable for iControl panel

11) Cable for FP bus to PMGi

12) DP+ put

12) Passage for starter battery cable (-)

13) Passage for starter battery cable (+)

15) Oil filter

16) V-belt

17) DC-alternator

18) Thermostat housing

19) Pulley for internal cooling water pump

The Panda Generator

Fig. 4.1.4-1: Front view

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The Panda Generator

02

01

05

03

04

01) Water cooled silencer

02) Exhaust outlet

03) Sound cover base part

04) Connection to external expansion tank

05) Ventilation hose to external expansion tank

4.1.5 Back view

Fig. 4.1.5-1: Back view

16.1.15 Kapitel/Chapter 4: The Panda Generator - Seite/Page 43

4.1.6 View from above

16

01 02 04 05 06

14 13 12 11 1018

08

07

0917 15

03

01) Ventilation hose to external expansion tank

02) Charge controller for DC-alternator

03) Air suction housing

04) Thermoswitch cylinder head

05) Suction hose, air suction housing - induction elbow

06) Fuel solenoid valve
07 Ventilation screw internal cooling water pump

08) Pulley for internal cooling water pump

09) V-belt

10) Ventilation screw thermostat housing

11) DC-alternator

12) Oil filler neck with cap

13) Valve cover

14) Watercooled exhaust elbow

15) Actuator power modul

16) Compensator under heat isolation

17) Cooling water pipe

18) Pre-silencer

The Panda Generator

Fig. 4.1.6-1: View from above

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The Panda Generator

1. On/Off button: Switching the Panda iControl2 controller on and off

2. Start/Stop button: Starting and stopping the generator, confirming values in selection menus (Enter key)

3. Cursor-up button Switching between display screens (up), counting values up in selection menus

4. Cursor-down button Switching between display screens (down), counting values down in selection menus.

4.2 Details of function units

4.3 The Panda iControl2 panel

The "Panda iControl2 panel" control panel is the control and display unit for the Panda iControl2 control system and
represents the interface between the user and the Panda iControl2 controller. The integrated display serves to
present the most important data of the system as well as warnings and error messages.

The control panel is equipped with four buttons for operating the Panda iControl2 controller:

Fig. 4.3-1: Panda iControl 2 panel

16.1.15 Kapitel/Chapter 4: The Panda Generator - Seite/Page 45

4.3.1 The cooling system

The Panda Generator

Fig. 4.3.1-1: Cooling system

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The Panda Generator

4.3.2 Components of the fuel, air intake and exhaust system

Fig. 4.3.2-1: Fuel, air intake and exhaust system

16.1.15 Kapitel/Chapter 4: The Panda Generator - Seite/Page 47

4.3.3 Components of the electrical system

Fig. 4.3.3-1: Electrical system

The Panda Generator

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The Panda Generator

4.3.4 Components of the lubrication system

Fig. 4.3.4-1: Lubrication system

16.1.15 Kapitel/Chapter 4: The Panda Generator - Seite/Page 49

4.3.5 Sensors and switches for operating surveillance

The thermo-switch at the engine is used for monitoring the
engine temperature.

The Panda Generator

Fig. 4.3.5-1: TThermoswitch cylinder headhermoswitch cylinder head

Another thermoswitch is located in the stator coil.

Fig. 4.3.5-2: Thermosensor exhaust elbowThermossensor exhaust elbow

Fig. 4.3.5-3: Thermoswitch coilThermoswitch coil

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The Panda Generator

In order to be able to monitore the lubricating oil system, an
oil pressure switch is built into the system.

Fig. 4.3.5-4: Oil pressure switchOil pressure switch at the engine

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The Panda Generator

Leere Seite / Intentionally blank

Seite/Page 52 Kapitel/Chapter 4: The Panda Generator 16.1.15

Installation Instructions

5. Installation Instructions

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

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

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

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

5.1 Personal requirements

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

Hazard notes for the installation

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

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

DANGER: Automatic start-up Danger for life! Working at a running generator can
result in severe personal injury.

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

Warning!: Risk of injuryImproper installation can result in severe personal
injuries or material damage.

• Always undertake installation work when the generator is

switched off.

• Ensure there is sufficient installation clearance before start

working.

• Ensure tidiness and cleanliness at the workplace. Loose

components and tools lying around or on top of each other
are sources of accidents.

• Only perform installation work using commercially available

tools and special tools. incorrect or damaged tools can
result injuries.

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 53

sources. Therefore:

• No open flames during work on the generator.

• Do not smoke.

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

damage to health.Therefor:

• Avoid skin contact with engine oil, fuel and antifreeze.

• Remove oil and fuel splashes and antifreeze from the skin
immediately.

• Do not inhale oil and fuel vapours.

installation and maintenance can result in severe
personal injury and/or material damage.

Installation Instructions

-Warning!: Danger of fire Oil and fuel vapours can ignite on contact with ignition

Danger!: Danger of poisoningContact with engine oil, antifreeze and fuel can result in

ATTENTION!: Danger to Life - High voltageDanger for Life. Improper handling, operation,

Electrical voltages above 48 volts (battery chargers greater
than 36 volts) are always dangerous to life). The rules of the
respective regional authority must be adhered to. Only an
electrician may carry out installation of the electrical
connections for safety reasons.

operation. Risk of severe burns.

Incorrect use can warm up and burst the batteries. Diluted
sulphuric acid / base can escape. Under unfavourable
conditions there is a risk of explosion

Observe the instructions from your battery manufacturer.

During Installation/maintenance personal protective
equipment is required to minimize the health hazards.

Warning!: Hot surface/materialGenerator, oil and antifreeze can be hot during/after

Warning:Batteries contain diluted sulphuric acids and bases

Instruction!: Personal protective equipment
necessary.

• Protective clothing

• safety boots

• protective gloves

• Ear defender

• safety glasses

Attention!: disconnect all loadDisconnect all load during the work at the generator to

avoid damages at the load.

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Installation Instructions

5.2 Environmental protection

Collect discharged engine liquids and dispose it properly.
Batteries should be disposed properly.

Environmental protection.Engine liquids/batteries are harmful for the environment.

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 55

Installation Instructions

5.3 Placement

5.3.1 General instructions

• It is important to pay attention to the fresh air intake.

• Sufficient space must be available below/next to the gener ator, in order to allow flow of cooling air. (Under side and
side: Underneath is not sufficient!)

• The radiator may not be covered.

• Untrained personnel should never open the generator.

5.3.2 Preparing the base - Placement

Since Panda generators have extremely compact dimensions, they can be installed in tight loc ations. 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 slippe ry surface wit h little mass (i.e.). This act s as a n amplifier of airb orne
sounds in the most unreasonable case. An improvement can be achieved by reinforcing these sur faces with ribs. In
addition, the breakthroughs, which interrupt th ese 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 powe r of the generator and increases the coolant temperature. Air
temperatures of more than 40 ° C reduce the power by 2 % per temperature rise of 5 ° C. In order to keep these
effects as small as possible, the temperature in the engine room should not be higher than 15 ° C in relation to the
outside temperature.

5.3.3 Advice for optimal sound insulation

The convenient base consists of a stable framework, on which the generator is fastened by means of
shockmounts. The combustion air can be sucked in unhindered.

Fischer Panda recommend captive shock mount!

Seite/Page 56 - Kaptitel/Chapter 5: Installation Instructions 16.1.15

Installation Instructions

representative picture

Fig. 5.3.3-1: Shock mountShock mount

Fig. 5.3.3-2: Captive shock mountCaptive shock mount

representative picture

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 57

Installation Instructions

1 2 3 4

5

7

8

9

6

1. Connection fuel IN

2. Connection fuel OUT

3. Cable for fuel pump

4. Cable for iControl panel

5. Oil drain hose

6. Cable for fan

7. Cable for PMGi 6000 inverter

8. Passage for starter battery minus (-)

9. Passage for starter battery plus (+)

5.4 Connections

Sample for the connection at the Fischer Panda generator. See the description of the generator for the original
location.

Fig. 5.4.0-1: Connections - sample

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Installation Instructions

1 2 3

4

1. Connection cooling water IN

2. Connection cooling water OUT

3. Connection exhaust OUT

4. Connection to external expansion tank

Fig. 5.4.0-2: Connections - sample

5.5 Fuel system installation

5.5.1 Fischer Panda installation kit - Fuel system

the specified installation. You can purchase them as an
installation kit or separately at Fischer Panda.

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 59

Note:The following additional components will be required for

representative picture

representative picture

Installation Instructions

Fig. 5.5.1-1: Fuel hoseFuel hose

Fig. 5.5.1-2: No return valveNo return valve

representative picture

Fig. 5.5.1-3: Pre filter with water separatorPre filter with water separator

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Installation Instructions

Alternative Article
representative picture

representative picture

Fig. 5.5.1-4: Pre filter with water separatorPre filter with water separator

Fig. 5.5.1-5: Quick connector for fuel linesQuick connector for fuel lines

representative picture

5.5.1.1 The following items need to be installed:

• Fuel supply pump (DC)

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

• Fine particle fuel filter

• Return fuel line to fuel tank (unpressurized)
The external Fuel pump should be installed near the tank

Fig. 5.5.1-6: Hose clampsHose clamps

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 61

With the Fischer Panda generator is usually supplied an
external, electrical fuel pump (DC). The fuel pump must
be installed close at the fuel tank. The electrical connec­tions is prepared at the generator.

Some generators (f.e. with Deutz diesel engine) has an
engine driven internal fuel pump. At these generators the
electrical fuel pump is optional,.

Installation Instructions

Fig. 5.5.1-1: electrical fuel pumpElectrical fuel pump

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Installation Instructions

5

2

3

4

1

6

1. Fuel tank

2. external fuel pump

3. external fuel prefilter with water separator

4. Non return valve

5. Fuel fine filter

6. Generator

Fig. 5.5.1-2: Fuel system - schema

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 63

At generators with Kubota EA 300 or Farymann engines, the
fine filter is delivered with the generator. This fine filter should
be installed in the fuel feed line next to the generator.

representative picture

5.5.2 Connection of the fuel lines at the tank

Installation Instructions

Fig. 5.5.1-3: externer FeinfilterExternal fine filter

Note:General fuel feed and return line must be connected to the
tank at separate connection points.Lead the return fuel pipe
connected to the day tank to the floor

Connection of the return pipe to the tank

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 pip e, which prevents the fuel flowing back after the generator has
been switched off, if it is not possible to use the return flow pipe as a submerge pipe placed in the tank. The instruc­tions „Bleeding Air from the Fuel System“ must be read after initial operation or after it has stood still for a long
period, in order to preserve the starter battery.

ATTENTION! Non-return valve for the fuel return pipe

If the fuel tank should be installed over the level of the
generator (e.g. daily tank), then a non-return valve must
be installed into the fuel return pipe to guarantee that
through the return pipe no fuel is led into the injection
pump.

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Installation Instructions

5.5.3 Position of the pre-filter with water separator

Inside the generator capsule itself, th ere is the fuel filter inst alled (exce ption: Panda 4500). Additio nal 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.

Fig. 5.5.3-1: Pre-filter with water separatorAdditionally 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).

representative picture

5.6 Generator DC system installation

The Panda generators from 6000 upwards have their own dynamo to charge a DC starter battery.
It is recommended to install an additional starter battery for the generator.
The generator is then independent from the remaining battery set. This enables you to start the genset at any time

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

The generator is then Earth/Ground free.

5.6.1 Connection of the starter battery block

IAn own separate starter battery must be installed for the generator.

The positive cable (+) of the battery is attached directly at the solenoid switch of the starter motor (position 1). The
negative cable (-) of the battery is attached underne ath the starter motor at the engine mount (position 2).

NOTE:Panda Generators Panda 6000 and higher normally
provided with an alternator/dynamo to charge the starter
battery. At generators without alternator/dynamo it is
needed to charge the starter battery with an external
battery charger.

ATTENTION!Make sure that the voltage of the starter battery fits to
the start system voltage

f.e. 12 V starter battery for a 12 V start system
f.e. 24 V starter battery for a 24 V start system (2x12 V

batteries in a row)

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 65

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.

Installation Instructions

NOTE:To avoid large voltage drops the battery should be

It must be guaranteed that first the cables are att ached at the
generator and then at the battery.

ATTENTION!: Consider correct connection
sequence

ATTENTION!: Right connection of the battery.Battery connection

Wrong connection of the battery bank can cause a short­circuit and fire.

Install an appropriate fuse and a battery circuit breaker in the plus pole ca ble of the batter y, but with a distance to the
battery of up to 300 mm (12 inch) at maxim um .

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

90 °C, 195 °F.
The batteries must be installed in such a way that they do not chafe through or other mechanical load can be

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

vibrations by appropriate sleeve/prote ctive pip e. It must be shif ted in such a way that it does not af fect rot ary p art s or
parts, that become hot in operation, e.g. wheel, exhaust elbow union, tail pipe and the engine. Do not lay the cable
too tautly, since otherwise it could be damaged.

Make a test run after the installation and ch eck the laying of the batteries during the test run and afterwards. If
necessary, correct the laying.

Examine regularly the cable laying and the electrical connections.

Seite/Page 66 - Kaptitel/Chapter 5: Installation Instructions 16.1.15

Installation Instructions

1

2

The positive (+) battery cable is connected directly to the
solenoid switch of the starter.

Fig. 5.6.1-1: Positive battery cablePositive battery cable

Fig. 5.6.1-2: Negative battery cableNegative battery cable

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

Note! The battery negative pole may not be connected
with the boat ground or with the protective grounding of
the 12 V installation!

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

1. Solenoid switch for starter motor

2. Starter motor

Fig. 5.6.1-3: DC starter motorDC starter motor

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 67

Fig. 5.6.1-4: Connection starter battery 12V - schema

1. Generator

2. Battery block

3. Fuse

4. Battery main switch

1. Generator

2. Battery block

3. Fuse

4. Battery main switch

Installation Instructions

Fig. 5.6.1-5: Connection starter battery 24V - schema

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Installation Instructions

5.6.2 How to connect two 12 V batteries to a 24 V battery bank

1. (+) cable of first battery

Fig. 5.6.2-1: Installation starter batteryThe starter batteries have to be connected in this order:

Fig. 5.6.2-2: Installation starter battery2. (-) cable of second battery

Fig. 5.6.2-3: Installation starter battery3. (+) cable of second battery

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 69

5. Disconnect the batteries in reverse procedure.

Installation Instructions

Fig. 5.6.2-4: Installation starter battery4. (-) cable of first battery

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Installation Instructions

1

2

3

4

5

6

7

1. Generator

2. Fuel pump

3. iControl panel

4. Generator output

5. PMGi inverter

6. Starter battery

7. Radiator

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

5.7 Connection of electrical components

Fig. 5.7.0-1: Connection of electrical components - Scheme

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 71

5.7.1 Connection of the external radiator

2

1

1. Generator 2. External radiator

Fig. 5.7.1-1: Connection of the external radiator

Installation Instructions

Seite/Page 72 - Kaptitel/Chapter 5: Installation Instructions 16.1.15

Installation Instructions

5.7.2 Installation PMGi inverter - See separate PMGi 8000 inverter manual

5.8 Installation of the cooling system

5.8.1 The cooling system / general instructions

The Fischer Panda vehicle generator is delivered without a radiator, with the exception of generators with perma­nently installed radiators such as the PVK-UK or the PSC series.

Depending on the purpose an d installation situation, a wide variety of Fischer Panda radiators are available for the
optimum customization of the system. Operation with a commercially available vehicle radiator is possible. The cor­responding dimensioning must be implemented by the installer.

Note:For generators with a permanently inst alled radiato r (e.g.
PVK-UK series), the radiator dimensioning and the
installation are not necessary.

5.8.2 Optionally available components for the installation of the cooling system

For the installation of the cooling system, additional components will be required, these can be procured individually
or as an installation kit from Fischer Panda.

Fig. 5.8.2-1: Coolant hosesCoolant hoses

For use in outdoor areas, check the technical data (e.g. UV
resistance).

Example

Fig. 5.8.2-2: Pipe elbowsPipe elbows

With hose connector or thread

Example

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 73

e.g. for connecting the external expansion tank.

Example

for temperature sensors/ switches for fan open-loop/closed­loop control

Installation Instructions

Fig. 5.8.2-3: T-fittingsT-fittings

Fig. 5.8.2-4: Connection piece sensorConnection piece sensor

Example

in single or double design

Example

Fig. 5.8.2-5: Roof feed-throughsRoof feed-throughs

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Installation Instructions

Example

Example

Fig. 5.8.2-6: External expansion tanksExternal expansion tanks

Fig. 5.8.2-7: Hose clipsHose clips

Fig. 5.8.2-8: RadiatorRadiator

Various radiator models are a vailable for roof mounting, side
mounting, or underfloor installation.

The output levels are adapted to the generators and the
application (e.g. radiators with increased output for use in hot
regions).

Example

5.9 Radiator baseplate

The radiator baseplate shall be dimensioned in accordance with the purpose . The corres ponding checks and entries
in the vehicle papers shall be implemented by the operator.

5.9.1 Determining the size of the radiator

The size of the radiator must be dimensioned in accordance with the total thermal load, the operating conditions,
and the installation situation.

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 75

times the electrical rated power (1.8 times with a water­cooled silencer , 1.2 times with a dry silencer) in kW. This
means that e.g. a Panda 12000 PVMV-N generator with a
rated power of 10 kW has a thermal load of 18 kW.

Installation Instructions

Note:In principle, the thermal load of the generator equals 1.8

The radiator must always be dimensioned taking into
account a safety margin adjusted for the operating
conditions. Undersized radiators will result in an
emergency shut-down. This may damage other
equipment that is connected to them.

Warning: Include safety margin in the calcula­tion.

5.9.2 Radiator design

The radiator consists in 3 main component s:

1. Radiator. Depending on the version, includes an integrated expansion tank or an external expansion tank.

2. Fan. Depending on the generator, as a DC fan (e.g. 12 V-24 V) or as an AC fan (e.g. 230 V 50 Hz) with
respective input voltage.

3. Cover (optional).

5.9.3 Radiator types

In principle, the following radiator types are differentiated.

1. Flange-mounted radiator for installation on top of, on the side of, or under the vehicle - Siehe “Installation location
for radiators for roof, side, or underfloor mountin g on the vehicle” auf Seite 77.

2. Built-in radiator for installation in the vehicle wall or cabin wall - Siehe “Installation location for radiator in the
vehicle wall or cabin wall” auf Seite 81.

3. Permanently installed radiators for the PVK-UK series

4. Permanently installed radiators for the PSC series for op eration inside co ntainer s or for tunnel inst allation - Siehe
“Installation location for radiator in a tunnel” auf Seite 82.

The radiator must be installed away from the generator in a well ventilated area. In doing so, it must be ensured that
the air outflow of the radiator is completely uninhibited. Turbulence and thermal short-circuiting must be avoided.

The radiator can be installed in a vertical or a horizontal position. It must be taken into account that the air intake is
located above the fan motor.

The best results will be achieved if the radiator can be mo un te d ho riz on tally on the veh icle roo f.

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Installation Instructions

2

1

3

1. Radiator mounted on the roof

2. Radiator mounted in vertical position

3. Radiator mounted under the vehicle

5.9.3.1 Installation location for radiators for roof, side, or underfloor mounting on the vehicle

Fig. 5.9.3-1: Radiator installation - example

Fig. 5.9.3.1-2: Radiator dimensions

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 77

5.9.3.2 Roof installation

Please note:

• Minimum distance to vehicle roof: 100 mm.

• Minimum dis tance to ne xt ve rtic al wa ll: 1/2 ra di at or width.

• Min. distance to gas exhaust (heat and dirt source): 500 mm.

• The max. permissible vehicle height must not be exceeded.

• Install warnings stating new vehicle height inside driver's cab.

• During operation, the exhaust flow must be uninhibited for at least 3 meters.

Fig. 5.9.3.2-1: Schematic: radiator, roof installation

Installation Instructions

Fig. 5.9.3.2-2: Schematic: radiator, roof installation

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Installation Instructions

5.9.3.3 Installation on the vehicle wall

Please note:

• Minimum distance to vehicle wall: 100 mm.

• Min. distance to gas exhaust (heat and dirt source): 500 mm.

• The max. permissible vehicle length or width must not be exceeded.

• During operation, the exhaust flow must be uninhibited for at least 3 meters.

Fig. 5.9.3.3-1: Schematic: radiator, vehicle wall installation

Fig. 5.9.3.3-2: Schematic: radiator, vehicle wall installation

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 79

5.9.3.4 Underfloor installation of radiator

Please note:

• Minimum distance to vehicle floor: 100 mm.

• Minimum dis ta nce to gr ou n d: 1/2 radiator width

• Min. distance to gas exhaust (heat and dirt source): 500 mm.

• The max. permissible vehicle height must not be exceeded.

installation. The radiator ca n q uickly b eco me dirt y. Rock
impacts can result in damage to the radiator. The
efficiency of the radiator will drop due to thermal short­circuiting. The radiator may have to be dimensioned
larger to compensate.

not) depends on the airflow direction of the fan. The
airflow must be always from the vehicle side through the
radiator to the ground.

Installation Instructions

Note:Fischer Panda does not recommend underfloor

Attention:The installation position of the radiator (upside down or

Fig. 5.9.3.4-1: Underfloor installation of radiator

Fig. 5.9.3.4-2: Underfloor installation of radiator

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Installation Instructions

5.9.3.5 Installation location for radiator in the vehicle wall or cabin wall

A cabin installation is achieved if the set-up location is freely accessible during operation and serves as a working
space, if applicable.

Please note:

• If persons are present in the set-up space during operation, a safety circuit must ensure that the air intake is open ed.

Fig. 5.9.3.5-1: Incorrect installation in the cabinIncorrect installation in the cabin

• Air intake too narrow

• Generator air intake too close to the wall

• Hot air can be taken in next to the radiator

• Exhaust gas line not insulated, heats up combustion air

• Air intake is min. radiator size (safety grating and decorative

grille must be taken into account)

• Uninhibited air intake for generator

• Exhaust flow direction of radiator is shielded and air exhaust

enlarged (safety grating and decorative grille were taken
into account)

• Exhaust line insulated

Fig. 5.9.3-2: Correct installation in the cabinCorrect installation in the cabin

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 81

Installation Instructions

5.9.3.6 Installation location for radiator in a tunnel

A tunnel installation is implemented if the set-up location is separated from the vehicle cab by constructive
measures.

Please note:

• The total of the air intakes must be at least equal to the radiator width (

• The total of the cross-sections of the air ducts incl. lateral air intake must be at least equal to the radiator width

• The distance between generator and radiator must equal at least 1/2 the radiator width

• Lateral air supply between generator and radiator can be designed on the side, above, or below

Fig. 5.9.3.6-1: Incorrect installation in a tunnelIncorrect installation in a tunnel

• Air intake too narrow

• Generator air intake too close to the wall

• Hot air can be taken in next to the radiator

• Exhaust gas line not insulated, heats up combustion air

• Air intake (C) is min. radiator size (B) (safety grating and
decorative grille must be taken into account)

• Total of air intakes (A ) eq uals min . th e ra dia to r size (B )

• Uninhibited air intake for generator

• Exhaust flow direction of radiator is shielded and air exhaust
enlarged (safety grating and decorative grille were taken
into account)

• Exhaust line insulated

Fig. 5.9.3-2: Correct installation in a tunnelCorrect installation in a tunnel

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Installation Instructions

5.9.3.7 Installation location for generators of the PVK-UK series

Generators of the PVK-UK series are designed for lateral installation on the vehicle chassis

Please note:

• Min. distance between radiator and vehicle chassis must be 1/2 B.

• Min. distance to gas exhaust (heat and dirt source): 500 mm.

• The exhaust flow area must be unobstructed. No impairment to the vehicle chassis or installations.

Fig. 5.9.3.7-1: PVK-UK installation location

5.9.4 Coolant hoses

• The diameter of the coolant hoses must be equal to or greater than the diameter of the generator connections.

• A vacuum-tight and temperature resistant hose (min. 120 °C) must be used.

• The hoses must be pressure resistant under vacuum conditions.

• Depending on the application location, the hoses must be UV resistant.

• The hoses must be weather resistant and chemical resistant (resistant to oil, etc.).

• The bending radii of the hose type shall be taken into account.

• The hoses must have a general operating permit (ABE) / approval certificate.

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 83

Installation Instructions

5.9.5 Connection of the external radiator

see Kapitel 5.11, “Installation schematics,” auf Seite 87

5.9.6 Coolant expansion tank

Coolant expansion tan k for systems with a radiator below the generator.

For operation, a coolant expansion tank must be installed at least 100 mm above the level of the exhaust manifold
and the radiator.

The ventilation line of the radiator and the generato r shall be installed on the top connection. The bottom connection
is used to refill the coolant circuit and is integrated in the coolant circuit at a low-lying location using a T-fitting.

The coolant expansion tank can be procured from the Fischer Panda accessories.

Coolant expansion tan k for systems with a radiator installed above the generator.

If the radiator is installed min. 100 mm above th e exhaust manifold , a radiato r with integrated co olant exp ansion t ank
can be used. In this case, the ventilation line of the generator is connected to the return line to the radiator (hot side)
using a T-fitting. If is refilled via the feed line (cold side) to the generator.

5.9.7 Installation of a coolant temperature indicator

Where sensitive systems are installed (e.g. in television transmission vehicles, rescue vehicles, or other vehicles
with sensitive metrological installations) a remote indicator for coolant temperatures should be installed. It is, howe­ver, highly recommended to install two indicator instruments:

1. coolant feed line (cold side)

2. coolant return line (hot side)

The exact location of the measuring unit is not important, here.

Note:A corresponding indicator kit can be procured from

Fischer Panda.

For subsequent installation, Fischer Panda T-fittings are
available for hose elements in which the temperature sensor s
are then installed.

5.9.8 Permissible coolant temperatures

• The radiator must be dimensioned such that the feed line to the generator (cold side) does not get hotter than 70°C
during normal operation. The coolant feed line must be connected to the coolant pump.

• The coolant volume flow must be dimensioned such that the temperatur e difference between engine inflow (coolant
pump) and engine outflow (exhaust manifold) is no greater than 12 K under full load.

Note:To ensure this, the coolant hoses shall be routed without
kinks or sharp bends. Resistance, e.g. due to narrowed
points in transition pieces or shut-off valves, shall be
avoided.

5.9.9 Coolant pump

• The generator is equipped with a normally suctioning (not self-priming) coolant pump.

Seite/Page 84 - Kaptitel/Chapter 5: Installation Instructions 16.1.15

Installation Instructions

• The coolant pump is designed so that a max. distance of 5 m between pump and radiator is possible.
Note:If the necessary coolant volume flow is not achieved (e.g.

due to a special installation situation), an external coolant
pump with the corresponding output must be installed in
the coolant circuit to increase the coolant volume flow.

Warning: The pressure in the coolant circuit must not exceed

0.7°bar!

Required coolant volume flow:

Fig. 5.9.9-1: Coolant volume flow

Generator type Coolant volume flow

Panda 4500 min. approx. 10 L/min
Panda 8000 - 10000 approx. 16 to 22 L/min
Panda 12000 - 15000 approx. 24 to 28 L/min
Panda 18 - 24 approx. 32 to 38 L/min
Panda 30 - 32 approx. 40 to 45 L/min
Panda 42 - 65 approx. 50 to 60 L/min

5.9.10 Radiator fan

Radiator fans are wearing parts. To ensure a long service life, there must be no object s impa iring or blocking th e free
movement of the fan during operation. Such obje cts include:

• Snow

• Ice

• Leaves

• Branches

• Increased air resistance due to dirty radiator

5.9.11 Anti-freeze and corrosion protection

At the factory, the coolant is adjusted to a 50% concentration of G48 anti-freeze solution (approx. -40°C). If lower
temperatures are possible during transport or storage, the coolant filling must be drained or adjusted for the lower
temperatures.

After draining the coolant, the system must be blown dry with compressed air at 0.5 bar. This will ensure that the
system is complete drained.

The anti-freeze agent also serves to protect the system against corrosion. The anti-freeze concentration in the
coolant must not drop below 30%.

5.9.12 Logging the temperature values during initial start-up

It is mandatory to measure the temperature values of the circulating coolant in the circuit after installing the genera­tor for the initial start up. Two remote thermometers must be used for this purpose. One connection must be moun­ted to the coolant feed line to the engine, the second one on the coolant ou tfeed. The ge nerator must then be loade d
with min. 75% of the rated power after a brief warm-up phase. The circulation of the coolant must be checked. The
values must fall within the following limits:

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 85

Installation Instructions

1. Coolant feed line max. 70 °C in permanent operation mode at maximum load

2. Coolant return line max. 85 °C in permanent operation
mode.

3. Differential of the two values: This item is of particular importance and provides information on the circulation of
the coolant. The difference should be max. 17 K for a coolant water system with an integrated water-cooled muff­ler. It should, however, typically be between 10 and 12 °K.

If the difference is greater than 15°K, the coolant circulation is not sufficient. The water circulation must then be
increased. This can be solved by e.g. improving the line routing, or by reducing the belt pulley diameter. It is absolu­tely necessary to measure the output of the cooling system after installing the generator. The values given above
shall be considered maximum permissible values. They apply to operation in increased temperatures, as well. In
permanent operation mode at external temperatures around 20 °C, the values must fall near the lower limit of the
tolerance.

Note:Each manual includes insta llation certificates, which
must be filled in after installation and returned to the
manufacturer (copy).

Returning the installation cer tificates and
commissioning logs is an important component of the
warranty conditions.

5.10 Custom installations

The effects on the warranty must be agreed on a case-by-case basis with Fischer Panda.

5.10.1 External heat exchangers

External heat exchangers shall be installed as per the specifications of the respective manufacturers.

5.10.2 External engine pre-heater

The external engine pre-heater shall be installed as per the manufacturer's instructions.
This applies to:

• electrical pre-heater systems (e.g. Defa),

• diesel-operated pre-heater systems,

• petrol-operated pre-heater systems.

5.10.3 Keel cooling

The keel cooling system shall be dimensioned and installed as per the manufacturer's instructions.

Seite/Page 86 - Kaptitel/Chapter 5: Installation Instructions 16.1.15

Installation Instructions

1

2

3

4

5

6

01. Coolant expansion tank

02. Engine bleed line

03. Fan for radiator

04. Radiator

05. Thermal switch (on the hot side)

06. T-fitting

5.11 Installation schematics

5.11.1 Installation for vertical radiator installation

Fig. 5.11.1-1: Vertical radiator - schematic

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 87

5.11.2 Installation for mounting the radiator under the vehicle

1

2

3

4

5

6

01. Ventilation line

02. Coolant expansion tank

03. T-fitting with connection for thermal switch

04. T-fitting

05. Radiator

06. Fan for radiator

Fig. 5.11.2-1: Underfloor radiator - schematic

Installation Instructions

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Installation Instructions

1

2

3

4

5

1. Engine bleed line

2. Radiator (horizontal)

3. Coolant expansion tank (integrated)

4. T-fitting for bleed line

5. T-fitting with connection for thermal switch

5.11.3 Installation schematic for roof mounted radiator with expansion tank

Fig. 5.11.3-1: Roof-mounted radiator - schematic

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 89

Installation Instructions

5.12 Radiator fan control / electronic fan control

To control the radiator fan, various controls/electronic controls can be chosen from the Fischer Panda delivery
program.

Note!:In the following the basic functions of the fan controls
are described. The original manual/ data sheet with
further informations of the fan control must be
respected.

5.13 Standard fan control for 1-phase and 3-phase generators.

In the standard kit, the generators will be equipped with a one step fan control.

Fig. 5.13.0-1: Fan control 230VFan control 230 V

representative picture

Seite/Page 90 - Kaptitel/Chapter 5: Installation Instructions 16.1.15

Installation Instructions

Fig. 5.13.0-2: Fan control 230V

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 91

5.14 Electronic fan control for DC fans RE 0201

For DC Fans the fan control RE 0201 can be used.

Fig. 5.14-1:

Installation Instructions

5.15 Brief description

Temperature-dependent continuous speed controlling device for one or two DC-fans.

5.15.1 Function

The speed regulation of the fan is made by pulse tracing modulation (PWM) of the operatin g volt age. Pulse/no pulse
ratio becomes over an external temperature sensor (NTC resistance to attach at clamp 7 and 8) dependent on the
coolant temperature. Between the lower limit temperature (starting temperature) and the upper limit temperature the
fan is controlled with 30 to 100% of the available operating voltage (PWM = 30% to 100%).

Potentiometer for adjustment concerning temperature and PWM behaviour

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Installation Instructions

Poti Start: Adjusting the starting temperature (fan start-up). The start temperature is with left stop 60°C and with right stop 80°C. Ex

factory a starting temperature of 70°C is adjusted (potentiometer position: In the middle).

Poti Window: Adjusting the temperature window: With the potentiometer „Window“ the size of the window between starting temperature

and temperature for full number of revolutions (upper limit temperature) can be adjusted. The temperature window can
be adjusted from 5°C to 20°C. Is the starting temperature adjusted to 70°C and the temperature window to 10°C thus the
fan start-up with 70°C and reaches the maximum speed with 80°C (upper limit temperature). Ex factory a temperature
window of 12,5°C is adjusted (potentiometer position: In the middle).

Poti Freq: Adjusting of the PWM frequency. Desired to many customers a potentiometer was added for changing the PWM

frequency. A selection of the frequency between approx. 1,7 and 3,5kHz is possible, which can serve for the avoidance
of unwanted oscillation/resonances. Ex factory a PWM frequency of 2 kHz is adjusted.

Function of the temperature sensors (NTC-resistance, extern und intern):
extern: Over this temperature sensor the coolant temperature is collected. The starting temperature (fan start-up) and the upper

limit temperature can be adjusted by means of potentiometer present at the plate. The PWM ratio starts with the
exceeding of the starting temperature with approx. 40% (for 2 seconds), so that the fan starts reliably. According to
expiration of the 2 seconds the PWM ratio is determined by coolant temperature and potentiometer adjust. Since the
coolant temperature will not continue to rise in the 2 seconds, the PWM ratio will jump back to the minimum value of 30%.
At, from here, far rising coolant temperature, the PWM ratio will then rise linear with the temperature. If the upper limit
temperature is nearly reached, the PWM ratio rose to 85%. By 85% to 100% PWM ratio with reaching the upper limit
temperature switching over is made by one step, in order to avoid very short turn-off times. Likewise switch-back is made
with falling coolant temperature of 100% to 85% PWM ratio. If the coolant temperature falls under the starting
temperature, the minimum PWM ratio is not fallen below of 30%, but remains constant. If the coolant temperature sinks
approx. 3°C under the starting temperature, then the fan is switched off completely. All data exclusively apply on use of
the temperature sensor type S891-100k of the manufacturer Epcos.

intern: Over this temperature sensor the temperature of the output stage is collected. If the temperature of the output stage rises

over 85°C, the PWM ratio, independently of the coolant temperature, is set to 100%, in order to avoid the switching losses
and cool the output stage down again. If the temperature of the output stage continues to rise nevertheless and beyond
90°C, the fan controller switches itself off. NOTE: The cooling of the generator is not ensured anymore. If the output
stage temperature sinks again under 85°C, the fan controller restarts itself. Such output stage temperatures cannot occur
however with intended use of the equipment.

Light emitting diodes: The 3 light emitting diodes (LED's) indicate the operating condition of the fan controller and have the following
meaning:

LED (green): Shines with normal operation. After the self check and successful recognizing of the sensors the fan controller jumps into

the normal operating condition, in which the fan regulates, if the temperature lies in the appropriate range.

LED (yellow): Shines if the fan controller is in slave-mode.
LED (red): Shines with the occurrence of the following errors:

Incorrect external temperature sensor. If the temperature sensor for the cooling water is defective or the feeder line to it
interrupted (cable break), then the fan is accessed with 100% PWM.

Incorrect internal temperature sensor. If the temperature sensor for the output stage is defective or the feeder line to it
interrupted (cable break), then this is indicated over the LED. The fan controller continues working normally.

Overheating of the output stage. If the output stage of the fan controller becomes too hot, then this switches itself off.
Please read in addition the description of the function of the internal temperature sensor.

5.15.2 Master - Slave - Operation

Two or three fan controllers can be connected with each other that over one temperature sensor for the cooling
water, all fan controllers cam be operated synchronous.

On the connection between master and slave the PWM signal of the masters will transfer. The slave takes over of it
the PWM ratio and the frequency. The slave spends its PWM impulse only then if that of the masters is terminated.
Thus even load of the current supply is reached. The second slave (if available) regards the first slave as its master
(see also drawing).

The slave operation is activated automatically, by the presence of a PWM signal at the slave control inlet. As soon
as such a signal is present, the slave follows the control signal and ignores its own adjusts and its own temperature
measuring input. If the master does not spend a PWM signal, because the coolant temperature is under its starting
temperature, the slave drops back into the master operation and uses its own adjusts and analyses its own
temperature measuring input. So that the slave behaves correctly now, a 100k fixed resistor must be attached at its
temperature measuring input, which corresponds to a coolant temperature below the starting temperature.

The plug-able plug-in for the master-slave-connection and the 100k fixed resistor belong not to the normal scope of
supply and must be ordered separately.

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 93

Installation Instructions

Fig. 5.15.2-1:

5.15.3 Function of the clamps for the Master-Slave-Operation

Clamp 11+12: Control input for slave operation. Clamp 11 is the positive input. Clamp 12 is the negative input. The input is floating, so

that via this input connected fan controllers of the same source can be supplied, without a ground loop develops.

Clamp 13+14: Output for the master-slave-operation. At clamp 13 is the signal and at clamp 14 is ground.

5.15.4 Remote controlled switching on and off of the fan controller

he fan controller can be switched on and/or off over the connection „ON“ (clamp 9). If at connection „ON“ lies the
same voltage as at the connection „BAT +“, the fan controller is switched on. If at connection „ON“ lies no voltage,
the fan controller is switched off. If this option is not needed, then the connection „ON“ can connected directly on the
printed circuit board, over the solder joint J101, with the connection „BAT +“.

• J101 closed: Fan control always on

• J101 open: Fan control only on if operation voltage at

connection „ON“

The solder joint J101 is seen from the direct line clam p directly behind the main safety device (main fuse) on the
printed circuit board.

5.15.5 12V / 24V - Operation

For 12V and/or 24V-operation the pre-resistor for the operating voltage of control electronics must be adapted. This
pre-resistor consists of two resistances, which are conn ected in series. For 12V-operation one of these resistances
is short circuit with the solder joint J102. For 24V-Betrieb the solder joint J102 must be ope ned . Additiona lly different
safety devices (fuses) must be installed depending upon operating voltage.

Main fuse (flat fuse on the printed circuit board):

12V-operation : 50 A flat fuse
24V-operation : 30 A flat fuse

Output fuse

(plug fuse on the terminal block, each two pieces):

12V-operation: 25A plug fuse
24V-operation: 20A plug fuse

Seite/Page 94 - Kaptitel/Chapter 5: Installation Instructions 16.1.15

Installation Instructions

5.16 Technical Data

Characteristics
closed current (electronics off) 0,5mA
closed current (electronics on) 10 - 15mA
Benchmark figure of the temperature control:
fan start-up 60°C - 80°C
max. number of revolution 65°C - 100°C
tolerance of the temperatures ± 5%
Maximum ratings
maximum ambient temperature (for operation) 50°C
Maximum ratings: Battery operation 12V
nominal load operating voltage (continuity) 11 VDC - 14.4 VDC
load operating voltage (15min) - 16.0 VDC
maximum idle speed operating voltage (3 sec) 17 VDC
nominal load current (continuity) 40 A
maximum load current (3 sec) 44 A
nominal voltage fan 12 VDC
Maximum ratings: Battery operation 24V
nominal load operating voltage (continuity) 18 VDC - 28.0 VDC
load operating voltage (15min) - 28.8 VDC
maximum load operating voltage (3 sec) 30 VDC
idle speed voltage (continuity) 34 VDC
maximum idle speed operating voltage (3 sec) 36 A
nominal load current (continuity) 20 A
maximum load current (3 sec) 22 A
nominal voltage fan 24 VDC
Maximum ratings: Transformer operation 12V
sieving in the power supply  10000µF 63V (depending on the load current)
data for secondary winding after rectification/sieving
nominal load operating voltage (continuity) 11 VDC - 14.4 VDC
load operating voltage (15min) - 16.0 VDC
maximum load operating voltage (3 sec) 17 VDC
idle speed operating voltage (continuity) 28 VDC
maximum idle speed operating voltage (3 sec) 30 VDC
nominal load current (continuity) 40 A
maximum load current (3 sec) 44 A
nominal voltage fan 12 VDC
Maximum ratings: Transformer operation 24V
sieving in the power supply 10000µF 63V (depending on the load current)
data for secondary winding after rectification/sieving
full load operating voltage (15min) 18 VDC - 28.0 VDC
load operating voltage (15min) - 28.8 VDC
maximum full load operating voltage (3 sec) 30.0 VDC
maximum partial load operating voltage 36.0 VDC
idle speed operating voltage (continuity) 39.0 VDC
maximum idle speed operating voltage (3 sec) 40.0 VDC
maximum input peak voltage 44.0 VDC *1)
maximum output peak voltage 44.0 VDC *1)
nominal load current (continuity) 24 A

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 95

maximum load current (3 sec) 28 A
nominal voltage fan 24 VDC

*1) The maximum input and/or output peak voltage is measured over the appropriate
clamps of the fan controller. It may be exceeded at no time. This applies independently
of whether a voltage increased height was possibly caused by the fan controller or an
external component. To this belong the switch off-transient of the fan (pulse width
modulation = fan will be 2000 times per second switched on and off), and by outside
switching operation caused glitches.

Installation Instructions

• solder joint J101 closed

• solder joint J102 open

Attention!: Configuration at delivery for 24V-

operation.

• main fuse 30A installed

• output fuse 20A installed

For 12V-operation the installed fuses must be replaced
against the provided fuses, as described above. The pr e­resistors for the operating voltage of control electronics
must be configured like above described.

Assembly: Vertical on standard rail, pa y attention to good ventilation.
At breach of specification can destroy one or more components of the system or shorten the life span

substantially.
Subject to change without prior notice.

Seite/Page 96 - Kaptitel/Chapter 5: Installation Instructions 16.1.15

Installation Instructions

5.17 Electronic fan control for single phase fans PKE-2.5V_Ziehl Abegg

The electronic fan control variety the fan rpm stepless.

5.17.1 Preset for the use with Fischer Panda generators

The Ziehl Abegg fan control is preset for the use with Fischer Panda generators. For the preset following data and
jumper settings are used.

Fig. 5.17-1: Preset

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 97

Installation Instructions

line

230V 50Hz

T

temperature

sensor

1

2

-R

M

fan

PE

-M

4,2kOhm

2

1

-R

R1

A

B

J5

J4

R2 R3

n-max

Set

n-min Pband

PKE-2,5V(E)

Ziehl-Abegg

fan control

PE

PE

N

L1

U1

U2

GND

+24V

E

-A

5.17.2 Connection of the sensor (Ziehl Abegg KTY)

The sensor is connected to E/GND. A resistor 4,2kOhm must be connected parallel to the sensor.

Fig. 5.17.2-1: Connection plan

Seite/Page 98 - Kaptitel/Chapter 5: Installation Instructions 16.1.15

Installation Instructions

5.18 Electronic fan control for single phase fans PXET6Q_Ziehl Abegg

The electronic fan control variety the fan rpm stepless.

5.18.1 Preset for the use with Fischer Panda generators

The Ziehl Abegg fan control is preset for the use with Fischer Panda generators. For the preset following data and
jumper settings are used.

Fig. 5.18-1: Preset

16.1.15 Kapitel/Chapter 5: Installation Instructions - Seite/Page 99

Installation Instructions

012

3

4 5 67 89

Datum

Bearb.

Gepr.

Norm

Urspr. Ers.dErs.f

Blatt 1

Bl.

=

+

von 1

Zust. Änderung Datum Name

Zeichnungsnummer:

D-33104 Paderborn

Otto-Hahn-Str. 32-34

www.fischerpanda.de

+49(0)5254/9202-0

Projektnummer:

Fischer Panda

Generatoren

Fischer Panda GmbH

Bröckling

070367_00_00---

---070367_00_00 ---

Schönberger

26.08.2010

connectionplan - fan control ZA PXET6Q / PXET6Q

M

fan

PE

-M

4,2kOhm

2

1

-R

T

temperature

sensor

1

2

-R

line

230V 50Hz

E1

110

on

Ziehl Abegg PXET6Q

PE

PE

N

N

L1

L1

U1

U1

U2

U2

11

12

14

TB

TB

D1

D1

A1

GND

E1

GND

24V

GND

-A

.

-F

5.18.2 Connection of the sensor (Ziehl Abegg KTY)

The input TB and D1 are bridget.
The sensor is connected to E1/GND. A resistor 4,2kOhm must be connected parallel to the sensor.

Fig. 5.18.2-1: Connection plan

Seite/Page 100 - Kaptitel/Chapter 5: Installation Instructions 16.1.15