Fischer Panda Panda 4K PMS, Panda 5K PMS User Manual

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Page 1

Marine Generator Manual

Panda 4K PMS Panda 5K PMS

230V/50Hz 120V/60Hz

Super silent technology

Panda_4K-5K_PMS_eng.R03 9.2.16

Page 2

Current revision status

Document

Actual: Panda_4K-5K_PMS_eng.R03_9.2.16 Replace: Panda_4K_PMS_eng.R02.2_14.12.15

Revision Page

Handbuch neu aufgebaut R01 Panda 4000 PMS eingefügt Titel Panda 4K umbenannt in 4mini - Handbuch umbenannt Titel in Panda 4K für 120 V und 230 V umbenannt R02.2 Erweiterung auf Panda 5K PMS

Erstellt durch / created by

Fischer Panda GmbH - Leiter Technische Dokumentation Otto-Hahn-Str. 32-34 33104 Paderborn - Germany Tel.: +49 (0) 5254-9202-0 email: [email protected] web: www.fischerpanda.de

Fischer Panda GmbH, 33104 Paderborn, reserves all rights regarding text and graphics. Details are given to the best of our knowledge. No liability is accepted for correctness. Technical modifications for improving the product without previous notice may be undertaken without notice. Before installation, it must be ensured that the pictures, diagrams and related material are applicable to the genset supplied. Enquiries must be made in case of doubt.

FischerPandaGmbH

Otto‐Hahn‐Str.40

D‐33104Paderborn

Germany

Tel.

Fax.

Hotline

Web

+49(0)52549202‐0

+49(0)52549202‐550

+49(0)52549202‐767

[email protected]

www.fischerpanda.de

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Inhalt / Contens

Marine Generator Manual............................................................................................................................ ....... 1

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

1 General Instructions and Regulations.................................................................................................. ..... 10

1.1 Safety first!...................................................................................................................................... .... 10

1.2 Tools............................................................................................................................................... ... . 1 2

1.3 Manufacturer declaration in accordance with the Machinery Directive 2006/42/EC ...................... ..... 14

1.4 Customer registration and guarantee ............................................................................................. .... 14

1.4.1 Technical support ........................................................................................................... .... 14

1.4.2 Caution, important information for start-up! ............................... ..................................... .... 14

1.5 Safety Instructions - Safety First! ................................................................................................... ..... 15

1.5.1 Safe operation ................................................................................................................ .... 15

1.5.2 Observe safety instructions! ........................................................................................... .... 15

1.5.3 Personal protective clothing (PPE) ................................................................................. .... 15

1.5.4 Cleanliness ensures safety ............................................................................................. .... 15

1.5.5 Safe handling of fuels and lubricants .............................................................................. ..... 16

1.5.6 Exhaust fumes and fire protection .................................................................................. .... 16

1.5.7 Safety precautions against burns and battery explosions .............................................. ..... 17

1.5.8 Protect your hands and body from rotating parts! .......................................................... .... 17

1.5.9 Anti-freeze and disposal of fluids ............................................... .... ... ... ... .... ... ... ... ... .... ... . .... 17

1.5.10 Implementation of safety inspections and maintenance ................ ................................. ..... 18

1.6 Warning and instruction signs......................................................................................................... .... 18

1.6.1 Special instructions and hazards of generators ................................... ... .... ... ... ... ... ........ .... 18

1.6.1.1 Protective conductor and potential equalisation:......... ..................................... ..... 19

1.6.1.2 Protective conductor for Panda AC generators:............................................... .... 19

1.6.1.3 Switch off all loads while working on the generator ......................................... .... 19

1.6.1.4 Potential equalisation for Panda AGT DC generators...................................... .... 19

1.6.1.5 Safety instructions concerning cables.............................................................. ..... 20

1.6.2 General safety instructions for handling batteries .......................................................... .... 20

2 In case of Emergency First Aid / Im Notfall - Erste Hilfe.................................................... ................. ..... 21

2.1 WHEN AN ADULT STOPS BREATHING ................. ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... .... ..... 22

3 Basics ...................................................................................................................................................... ..... 23

3.1 Intended use of the machine .......................................................................................................... .... 23

3.1.1 Purpose of the manual and description of the definitions trained person/oper ator/user .... 23

3.1.1.1 Trained persons.................................... .......................................... ... ... ........... .... 23

3.1.2 Operator ......................................................................................................................... .... 23

3.1.2.1 User.................................................................................................................. .... 23

3.2 Panda Transport Box.................................................................................................................. .... .... 24

3.2.1 Bolted Fischer Panda Transport Box .............................................................................. .... 24

3.2.2 Fischer Panda Transport Box with metal tab closure .......................... ........................... .... 24

3.3 Transport and Loading/Unloading .................................................................................................. .... 24

3.3.1 Transporting the generator ............................................................................................. .... 24

3.3.2 Loading/unloading of the generator ..... ... ... ... .......................................... .... ... ... ... ... .... ... . .... 24

3.4 Scope of delivery........................................................................................................................... . .... 25

3.4.1 Asynchronous Generator: ............................................................................................... .... 25

3.4.2 Opening the MPL sound insulation capsule ........................................................... .... ... . ..... 27

3.4.3 Opening the GFK sound insulation capsule ........................................... .... ... ... .............. .... 28

3.5 Special maintenance notes and arrangements at long periods of stand still time or shutdown ..... .... 28

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Inhalt / Contens

3.5.1 Reference note for the starter battery at a long-term standstill ...................... ... .... ... ... ... . .... 29

3.5.2 Arrangements at a short-term standstill .......................................................................... .... 29

3.5.3 Arrangements at a medium-term standstill / winter storage ........................................... .... 29

3.5.3.1 Arrangements for conservation: ....................................................................... .... 29

3.5.3.2 Arrangements for deconservation after a medium-term standstill (3 to 6 months). 30

3.5.4 Arrangements at a long-term standstill / shutdown ......................................................... .... 31

3.5.4.1 Arrangements for conservation: ....................................................................... .... 31

3.5.4.2 Arrangements after a long-term standstill (shutdown) / recommissioning (more than 6

months): ........................................................................................................... .... 32

4 The Panda Generator.............................................................................................................................. .....33

4.1 Type plate at the Generator............................................................................................................ .... 33

4.2 Description of the Generator........................................................................................................... .... 34

4.2.1 Right side view - Panda 4K PMS .................................................................................... .... 34

4.2.2 Left side view - Panda 4K PMS ...................................................................................... .... 35

4.2.3 Front view - Panda 4K PMS ........................................................................................... .....36

4.2.4 Back view - Panda 4K PMS .............................. ... ... .... ... .......................................... ... ... . .... 37

4.2.5 View from above - Panda 4K PMS ................................................................................. .... 38

4.2.6 Right side view - Panda 5K PMS .................................................................................... .... 39

4.2.7 Left side view - Panda 5K PMS ...................................................................................... .... 40

4.2.8 Front view - Panda 5K PMS ........................................................................................... .....41

4.2.9 Back view - Panda 5K PMS .............................. ... ... .... ... .......................................... ... ... . .... 42

4.2.10 View from above - Panda 5K PMS ................................................................................. .... 43

4.3 Details of functional units ........................................................... ... ... ... .... ....................................... .....44

4.3.1 Control panel .................................................................................................................. .... 44

4.3.2 Components of cooling water system (raw water + fresh water) .................................... .... 45

4.3.3 The fuel and combustion air system ............................................................................... .... 46

4.3.4 Sensors and switches for operation surveillance ............................................................ .... 47

4.3.5 The lubrication circuit ...................................................................................................... .... 48

5 Generator operation instruction............................................................................................................ .....49

5.1 Personal requirements......... ... ... ... .... ... ........................................................................................... .... 49

5.2 Hazard notes for the operation ....................................................................................................... .... 49

5.3 General operating instruction.......................................................................................................... .... 49

5.3.1 Operation at low temperatures ....................................................................................... .... 49

5.3.1.1 Pre-heating the diesel motor ............................................................................ .... 50

5.3.1.2 Tips regarding starter battery ........................................................................... .... 50

5.3.2 Light load operation and engine idle ............................................................................... .... 50

5.3.2.1 The soot of the generator is due to the fact that:.............................................. .... 50

5.3.2.2 To prevent the soot of the generator following steps should be observed:...... .... 50

5.3.3 Generator load for a longer period and overload ............................................................ .... 50

5.3.4 Protection conductor: ...................................................................................................... .... 51

5.3.5 Operating control system on the Fischer Panda generator ............................................ .... 51

5.4 Instructions for capacitors - not present at all models..................................................................... .... 51

5.5 Checks before start - see remote control panel data sheet ............................................................ .... 51

5.6 Starting the generator - see remote control panel data sheet......................................................... .... 52

5.7 Stopping the generator - see remote control panel data sheet....................................................... ....52

6 Installation Instructions.......................................................................................................................... ..... 53

6.1 Personal requirements......... ... ... ... .... ... ........................................................................................... .... 53

6.1.1 Hazard notes for the installation ................................................. ... ... .............................. .... 53

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6.2 Preparing the base - Placement .................................................................................................... ..... 55

6.2.1 Advice for optimal sound insulation ................................................................................ .... 55

6.3 Generator Connections.............. ... ... .... .......................................... ... ... ........................................... ... . 5 5

6.4 Installation of the cooling system - raw water................................................................................. .... 56

6.4.1 General Information ........................................................................................................ .... 56

6.4.2 Installation of the through hull fitting in yyachts ...................... ........................................ .... 56

6.4.3 Quality of the Raw Water Sucking In Line ...................................................................... .... 56

6.4.4 Generator installation above waterline .......................................... ... ... ... .... ... ... .............. ..... 57

6.4.5 Generator Installation below waterline ........................................................................... ..... 58

6.4.6 Generator housing cooled by raw water ......................................................................... .... 59

6.4.7 Indirect cooling of the genset housing (by the heat exchanger) ....................... .............. ..... 60

6.5 Installation of the cooling system - fresh water............................................................................... .... 60

6.5.1 Position of the external cooling water expansion tank .................................................... .... 60

6.5.2 Ventilating at the first filling of the internal cooling water circuit ..................................... .... 61

6.5.3 Pressure test for controlling the cooling water circuit ..................................................... .... 62

6.5.4 Scheme for freshwater circuit at two circuit cooling system ........................................... ..... 63

6.6 Installation of the water cooled exhaust system ............................................................................ ..... 64

6.6.1 Installation of the standard exhaust system ................................................................... .... 64

6.7 .Installation of the waterlock ........................................................................................................... .... 65

6.7.1 Possible cause for water in the exhaust hose ................................................................ .... 65

6.7.1.1 Possible cause: exhaust hose...................................................... ... ... ... ... .... ... . .... 65

6.7.1.2 Possible cause: cooling water hose................................................................. .... 65

6.7.2 Installation area of the waterlock .................................................................................... .... 66

6.7.3 The volume of the waterlock ................... ... ... .... ... ... ... ....................................... ... ... .... ... . .... 66

6.7.3.1 Ideal position of the waterlock............................... ... ... .... ... ... ... .... ... ... ... ... .... ... . .... 67

6.7.3.2 Example of the installation of the waterlock off-center and possible effects:... .... 68

6.8 Exhaust / water separator............................................................................................................... .... 70

6.8.1 Installation exhaust water separator ............................................................................... ..... 72

6.9 Installation of the fuel system ........................................................................................................ ..... 74

6.9.1 General references ......................................................................................................... .... 74

6.9.2 The electrical fuel pump ................................................................................................. .... 74

6.9.3 Connection of the fuel lines at the tank .......................................................................... .... 75

6.9.4 Position of the pre-filter with water separator ................................................................. .... 75

6.9.5 Ventilating air from the fuel system ................................................................................ .... 75

6.10 Generator DC system installation................................................................................................... .... 76

6.10.1 Connection of the starter battery block ........................................................................... .... 76

6.10.2 Connection of the remote control panel - see separate control panel manual ............... .... 79

6.11 Generator AC system installation .................................................................................................. ..... 80

6.11.1 Insulation test ................................................................................................................. ..... 82

7 Maintenance Instructions....................................................................................................................... ..... 83

7.1 Personal requirements.................................................................................................................... .... 83

7.2 Hazard notes for the maintenance.................................................................................................. .... 83

7.3 Environmental protection............................................................................................................... . .... 85

7.4 Maintenance interval....................................................................................................................... .... 85

7.5 General maintenance instructions.................................................................................................. .... 85

7.5.1 Checks before each start ..................................... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ........... .... 85

7.5.2 Check of Hoses and rubber parts in the sound insulated capsule ................................. .... 85

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7.6 Oil change intervals ........................................................................................................................ .... 86

7.7 Checking oil-level....... ... ... .... ... ... ..................................................................................................... .... 86

7.7.1 Refilling oil ........... ... ... ... .... .............................................................................................. .... 87

7.7.2 After the oil level check and refilling the oil ..................................................................... .... 87

7.8 Replacement of engine oil and engine oil filter ............................................................................... .... 88

7.8.1 After the oil change ......................................................................................................... .... 90

7.9 Verifying the starter battery and (if necessary) the battery bank..................................................... .... 91

7.9.1 Battery ............................................................................................................................ .... 91

7.9.1.1 Check battery and cable connections .............................................................. .... 91

7.9.1.2 Check electrolyte level ..................................................................................... .... 91

7.9.1.3 Check electrolyte density ................................................................................. .....92

7.10 Ventilating the fuel system .............................................................................................................. .... 92

7.10.1 Replacement of the fuel filter .......................................................................................... .... 94

7.10.1.1 Optional fuel filter with sight glass.................................................................... .... 94

7.11 Checking the water separator in the fuel supply............................................................................. .... 95

7.11.1 Replace the air filter mat ................................................................................................. .... 96

7.11.2 Alternative replacement of the air filter mat with pull out holder ..................................... .... 96

7.11.3 Alternative replacement of the air filter at housing with snap fasteners .......................... .....98

7.11.4 Ventilation of the coolant circuit / freshwater .................................................................. .... 99

7.12 V-belt replacement for the internal cooling water pump.............. ... ... ... .... ... ... ... .............................. .. 101

7.13 The raw water circuit ...................................................................................................................... ...103

7.13.1 Clean raw water filter ...................................................................................................... .. 103

7.14 Causes with frequent impeller waste .............................................................................................. .. 103

7.14.1 Replacement of the impeller ........................................................................................... ...104

7.14.2 Check and discharge the capacitors .................................... .... ... ... ... ... .... ....................... .. 105

7.15 Replacing the electric starter ......................................................................................................... ...108

7.16 Replacing the oil pressure switch ................................................................................................... ...111

7.16.1 Replacing the oil pressure sensor (optional component) ................................................ ...112

7.17 Replacing the operating current relays .......................................................................................... ...113

7.18 Replacing the fuses ....................................................................................................................... ...114

7.19 Replacing a thermoswitch .............................................................................................................. ...115

7.20 Replacing the injection nozzles ...................................................................................................... ...117

7.21 Replacing the glow plugs ................................................................................................................ .. 119

8 Generator Faults ..................................................................................................................................... ...123

8.1 Personal requirements......... ... ... ... .... ... ........................................................................................... .. 123

8.2 Hazard notes for the troubleshooting.............................................................................................. .. 123

8.3 Tools and measuring instruments .................................................................................................. ...125

8.4 Troubleshooting table and flowchart .............................................................................................. ...126

8.4.1 Generator output voltage too low ......................... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .............. .. 126

8.4.2 Generator voltage too high (more than 240 V - 50 Hz .................................................... .. 126

8.4.3 Generator voltage fluctuates ........................................................................................... .. 12 6

8.4.4 Generator not able to start electric motor ......................................... ... .... ... ... ... .............. .. 126

8.4.5 Diesel motor fails to start ................................................................................................ .. 126

8.4.6 Starter is turning motor, but fails to start ......................................................................... .. 126

8.4.7 Motor does not achieve enough speed during starting process ..................................... .. 128

8.4.8 Motor runs unsteady ......................................................................................................... 128

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8.4.9 Motor speed drops .......................................................................................................... .. 128

8.4.10 Motor runs in off position ................................................................................................ .. 128

8.4.11 Motor stops by itself ............................. ... .......................................... ... ... .... ... ... ... ... ........ .. 128

8.4.12 Sooty, black exhaust .... ... .... ... ... ..................................................................................... .. 129

8.4.13 Generator must be shut off immediately if: ..................................................................... .. 129

8.4.14 Troubleshooting for the VCS-Voltage Control System ................................................... .. 129

8.4.15 Troubleshooting flowcharts ............................................................................................. ... 130

8.4.15.1 Details and explanations concerning the troubleshooting flowchart ................ .. 132

8.5 Versions of the generator power terminal box ............................................................................... ...136

8.6 Overloading the generator.............................................................................................................. .. 140

8.6.1 Monitoring the generator voltage .................................................................................... ... 141

8.6.2 Automatic voltage monitoring and auto-shut down ......................................................... .. 141

8.7 Generator output voltage is too low ............................................................................................... ... 142

8.7.1 Discharging the capacitors ............................................................................................. .. 142

8.7.2 Checking the capacitors ......................................................... ... .... ... ... ... .... ... ... ... ... ........ ... 143

8.7.2.1 Checking the electrical connections to the capacitors ..................................... .. 143

8.7.3 Check the generator voltage .......................................................................................... .. 143

8.7.4 Measuring the ohm resistance of the generator windings ...................... .... ... ... ... ... .... .... .. 144

8.7.5 Check the windings for short circuit ................................................................................ .. 144

8.7.6 Measuring the inductive resistance ................................................................................ ... 145

8.8 Generator provides no voltage ....................................................................................................... .. 145

8.8.1 Rotor magnetism loss and „re-magnetising“ ................................................................... .. 145

8.9 Engine starting problems ............................................................................................................... ... 146

8.9.1 Electric fuel solenoid valve ........................................................... ... ... ... .... ... ... ... ... .... ... . .. 146

8.9.2 Re-start with failure bypass switch ................................................................................. .. 146

8.9.3 Lifting solenoid for motor stop - optional ......................................................................... .. 147

8.9.4 Troubleshooting table ................ ... ... .... ... ... .......................................... ... .... ... ... ... ... .... ...... 148

9 Tables....................................................................................................................................................... ... 149

9.1 Technical data ............................................................................................................................... . .. 149

9.2 Rated current.................................................................................................................................. .. 154

9.3 Cable cross section ... ... ... ... .... ... ..................................................................................................... .. 154

9.4 Fuel................................................................................................................................................. .. 155

9.5 Engine oil............................................................................................................................. ........... .. 155

9.5.1 Engine oil classification .................................................................................................. .. 155

9.5.1.1 Operating range:......................................... .......................................... ... .... .... .. 155

9.5.1.2 Quality of oil: .................................................................................................... .. 155

9.6 Coolant specifications...................... .... ... ... ... ... ............................................................................... ..156

9.6.1 Coolant mixture ratio ...................................................................................................... .. 157

9.7 Diameter of conduits....................................................................................................................... .. 157

10 Remote Control Panel P4 Control ........................................................................................................ ... 159

10.1 Remote control panel.................................................................................................................. .... .. 159

10.1.1 Cleaning and Replacing parts at the generator ...... ........................................................ ... 160

10.2 Front side ....................................................................................................................................... ... 161

10.2.1 Back side ...... ... ... .... ........................................................................................................ .. 161

10.3 Operation manual ........................................................................................................................... .. 162

10.3.1 Preliminary remarks ........................................................................................................ .. 162

10.3.2 Override function ............................................................................................................ .. 162

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Inhalt / Contens

10.3.3 Daily routine checks before starting ........... .................... ................... .................... .......... .. 162

10.3.4 Starting the generator ..................................................................................................... .. 163

10.3.5 Stopping the generator ..................................................................................................... 163

10.4 Installation of the panel ................................................................................................................... .. 164

10.4.1 Connection of the remote control panel ...................... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... . .. 164

10.5 Jumper configuration ..................................................................................................................... ...166

10.5.1 Jumper configuration for the input ................................. ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... . .. 166

10.5.1.1 Jumper J101-J103........................................... ... ... .... ...................................... . .. 166

10.5.2 Jumper for configuration of the „Override“ time .............................................................. ...167

10.6 Maximum ratings............................................................................................................................. .. 167

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Page 9

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

9.2.16 Kapitel/Chapter 1: - Seite/Page 9

Page 10

General Instructions and Regulations

1. General Instructions and Regulations

1.1 Safety first!

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

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

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

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

smoking is prohibited.

avoided.

is in progress.

prohibited.

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

PROHIBITED: Do not touch Touching of the corresponding parts and systems is

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: Hazardous electr ic voltage This danger symbol refers to the dan ger of electric shock and 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.

Seite/Page 10 - Kaptitel/Chapter 1: General Instructions and Regulations 9.2.16

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General Instructions and Regulations

WARNING: General warning General warning of a hazard area

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.

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.

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

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

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

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

Warning of substances that cause chemical burns upon contact. These substances can act as cont aminants 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.

9.2.16 Kapitel/Chapter 1: General Instructions and Regulations - Seite/Page 11

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General Instructions and Regulations

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

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

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

Wearing protective gloves provides the hand s fro m haz ar ds like friction, graze, punctures or deep cuts and pro tects 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.

MANDATORY INSTRUCTION: Wear snugly fitting

protective clothing (PPE).

MANDATORY INSTRUCTION: Wear hearing

protection (PPE).

MANDATORY INSTRUCTION: Wear safety

goggles (PPE).

MANDATORY INSTRUCTION: Wear protective

gloves (PPE).

MANDATORY INSTRUCTION: Observe the

instructions in the manual.

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

MANDATORY INSTRUCTION: Comply with

environmental protection requirements.

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

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Page 13

General Instructions and Regulations

Socket wrench set

Hexagon socket wrench set

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

Torque wrench

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

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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.

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General Instructions and Regulations

1.5 Safety Instructions - Safety First!

1.5.1 Safe operation

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

1.5.2 Observe safety instructions!

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

1.5.3 Personal protective clothing (PPE)

For maintenance and repair work on the equipment, do not wear loose, torn, or ill-fitting clothing that may catch on protruding parts or come into cont act with pulleys, cooling disks, or o ther rotatin g part s, 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 n ear 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 ad equate fresh air sup ply is availab le 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 v ery hot; they may cause bu rns under certain circumstances.

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

and cables are in good condition and that there is no chafing. Bare wires, open chafing spots, frayed insulation, and loose cable connections can cause dangerous electric shocks, short-circuit, and fire.

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

CALIFORNIA

Proposition 65 Warning

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

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

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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 only after letting the engine and the coolant cool down. Wear appropriate protective clothing (e.g. safety goggles, gloves).

Prior to operation, ensure that the cooling system is sealed and that all hose clamps are tightened. The battery represents an explosion hazard, this applies both to the starter battery and the battery bank

of the AGT generators. While batteries are being charged, a hydrogen-oxygen mixture is generated, which is highly explosive (electrolytic gas).

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

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

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

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

1.5.8 Protect your hands and body from rotating parts!

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

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

check for proper attachment and function.

1.5.9 Anti-freeze and disposal of fluids

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

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

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General Instructions and Regulations

1.5.10 Implementation of safety inspections and maintenance

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

To prevent sparking due to accidental short-circuiting, always remove the earthing cable (-) first and reconnect it last. Do not start work until the generator and all fluids and exhaus t syst em parts have cooled down .

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

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

1.6 Warning and instruction signs

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

parts.

1.6.1 Special instructions and hazards of generators

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

The generator must not be operated with the cover removed.

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

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

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

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

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General Instructions and Regulations

1.6.1.1 Protective conductor and potential equalisation:

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

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

1.6.1.2 Protective conductor for Panda AC generators:

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

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

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

The battery must always be disconnected if work on the generator or electrical system is to be carried out, so that the generator cannot be sta rted up unintentionally.

1.6.1.3 Switch off all loads while working on the generator

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

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

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

If the generator is switched off normally, the working capacitors are automatically disc harged via the win ding of the generator. The booster capacitors are discharged by means of internal discharge resistors.

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

1.6.1.4 Potential equalisation for Panda AGT DC generators

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

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General Instructions and Regulations

1.6.1.5 Safety instructions concerning cables

Cable types

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

Cable cross-section

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

Cable installation

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

1.6.2 General safety instructions for handling batteries

These instructions shall apply in addition to the instructions of the battery manuf acturer:

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

necessary.

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

• Wear eye protection and protective clothing. Do not touch your eyes while handling batteries.

• 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-a cid 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.

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In case of Emergency First Aid / Im Notfall -

Erste Hilfe

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

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

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

Switch off the generator immediately.

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

Call an emergency doctor as soon as possible.

Immediately start necessary first aid procedures.

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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?

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

Roll Person onto Back.

Roll victim towards you by pulling slowly.

Open Airway.

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

Give 2 Full Breaths.

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

Shout, “Help!“

Call people who can phone for help.

Check for Breathing.

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

Check for Pulse at side of Neck.

Feel for pulse for 5 to 10 seconds.

Begin Rescue Breathing.

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

Phone EMS for Help.

Send someone to call an ambulance.

Recheck Pulse Every Minute.

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

rescue breathing. If no pulse, begin CPR.

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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 voltage control system (VCS).

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

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

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

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

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

the law as required by the country and special situation.

3.1.1.1 Trained persons

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

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

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

3.1.2 Operator

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

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

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

3.1.2.1 User

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

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

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3.2 Panda Transport Box

3.2.1 Bolted Fischer Panda Transport Box

1. Remove the bolts for cover / sidewalls

2. Remove the cover

3. Remove the loose accessories

4. Remove the bolts for sidewalls / floor pallet

5. Remove the sidewalls

6. Open the generator attachment

3.2.2 Fischer Panda Transport Box with metal tab closure

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

2. Remove the cover

3. Remove the loose

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

5. Remove the sidewalls

6. Open the generator attachment

3.3 Transport and Loading/Unloading

3.3.1 Transporting the generator

• The generator must always be upright for transport.

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

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

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

3.3.2 Loading/unloading of the generator

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

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3.4 Scope of delivery

The Fischer Panda PMS generator system contains following components:

3.4.1 Asynchronous Generator:

Fig. 3.3-1: Lifting yoke (example)An adequate lifting yoke shall be used for transport/

representative picture

Fig. 3.4-1: Fischer Panda GeneratorFischer Panda Generator

Fig. 3.4-2: Remote control panelRemote control panel

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

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

representative picture

The Fischer Panda Manual contains following components:

• Clear foil bag with general informations ect.

• Generator manual with added remote control panel manual

Fig. 3.4-3: AC Control BoxAC Control Box

Fig. 3.4.1-4: Fischer Panda ManualFischer Panda Manual

• Spare part catalogue „Installation & Serv ice Gu ide“

• Engine manual from the engine manufacturer.

• Wiring diagram for the generator

representative picture

Optionales components f.e.:

• Fuel pump

• Installation kit

• Water lock

• ect.

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3.4.2 Opening the MPL sound insulation capsule

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

Fig. 3.4-1: Sound insulation capsule, side partT o open the soun d insulation cap sule, the closures must

Fig. 3.4.2-2: Closure lockedClosure locked

Fig. 3.4-3: Closure openClosure open

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3.4.3 Opening the GFK sound insulation capsule

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

Fig. 3.4-1: Lash closuresGFK sound insulation capsule with lash closures

Fig. 3.4-2: Lash closuresTo open the lash closures pull the handle in arrow

3.5 Special maintenance notes and arrangements at long periods of stand

still time or shutdown

Stand still is divided into the following groups:

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

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

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

WarningAt irregular using intervals make shure that th e ge ne r ator runs till the engine is hot every 2 weeks. Without this water can gather in the engine oil and in the exhaust line an d cause generator damage.

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

Notice: Starter batteries

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

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

• Charge the battery on a regular basis. Follow the notes of the battery manufacturer. Before charging the battery, check the acid level according to the type of battery and refill each cell with distilled

water up to the marking if necessary. Today’s starter batteries are normally maintenance-free .

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

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

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

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

Notice: Fischer Panda recommendation:

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

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

• Check contacts for corrosion on a regular basis.

3.5.2 Arrangements at a short-term standstill

Short-term standstill (1 to 3 months)

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

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

• Drain the waterlock. Discon ne ct the ex ha ust line between waterlock and generator. Close the exhaust line of the generator.

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

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

3.5.3 Arrangements at a medium-term standstill / winter storage

Medium-term stand still (3 to 6 months)

3.5.3.1 Arrangements for conservation:

• Check the charge of battery and recharge approximately every 3 months if necessary. Consider the specifications of the battery manufacturer.

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

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

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

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

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

Let engine run for 10 min.

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

Attention!Cover alternator openings.

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

• Clean engine according to the manufacturer.

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

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

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

• Drain sea water circuit.

• Close sea cock.

• Clean sea water filter.

• Remove impeller and store.

Attention!Carry out a deconservation before recommissioning.

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

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

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

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

• Remove preservation agent of the engine with petroleum.

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

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

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

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

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

• Connect battery. Close battery main switch.

• Install impeller.

• Open sea cock.

• Check sea water filter.

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

repeat procedure twice.

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

3.5.4 Arrangements at a long-term standstill / shutdown

Standstill (more than 6 months)

3.5.4.1 Arrangements for conservation:

• Check the charge of battery and recharge approximately every 3 months if necessary. Consider the specifications of the battery manufacturer.

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

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

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

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

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

Let engine run for 10 min.

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

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

Attention!Cover alternator openings.

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

• Clean engine according to the manufacturer.

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

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

• Sprinkle exhaust turbo charger (if existent) with conservation agent at intake and exhaust and close lines again. Sprinkle preserving agent to the intake and exhaust lines than attach again.

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

• Remove injectors and sprinkle the cylinder area with preserving agent. Keep the shut-off lever on the 0-position and turn the engine by hand for several times. Screw in the injectors with new gaskets. Consider the tors ional moments.

• Sprinkle slightly the ra dia to r ca p an d ta nk lid and resp e c tively the radiator cap at the expansion tank and reinstall.

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

• Drain sea water circuit.

• Close sea cock.

• Clean sea water filter.

• Dismount impeller and store.

Attention!Carry out a de-conservation before recommissioning.

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

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

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

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

• Remove preservation agent of the engine with petroleum.

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

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

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

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

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

• Connect battery. Close battery main switch.

• Install impeller.

• Open sea cock.

• Check sea water filter.

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

repeat procedure twice.

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

Notice: Fischer Panda recommendation:

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

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The Panda Generator

4. The Panda Generator

4.1 Type plate at the Generator

Fig. 4.1-1: Type plate at the generator - Picture shows 4000s SC

Fig. 4.1-2: Discription type plate

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4.2 Description of the Generator

06 07

01) Thermostat housing

02) DC alternator

03) Oil filter

04) Fuel filter

05) Sound cover base part

06) Connection point for external ventilation valve

07) Starter motor

08) Thermo switch

09) Heat exchanger

4.2.1 Right side view - Panda 4K PMS

Fig. 4.2.1-1: Right side view

The Panda Generator

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The Panda Generator

01 02

04 05

01) Gernerator terminal box

02) Thermo switch at cylinder head

03) Generator housing with coil

04) Failure bypass switch

05) DC terminal with relays and fuses

06) Sound cover base part

07) Fuel filter

08) Oil dipstick

09) Raw water pump

10) Fuel solenoid valve

4.2.2 Left side view - Panda 4K PMS

Fig. 4.2.2-1: Left side view

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4.2.3 Front view - Panda 4K PMS

01) Thermostat housing

02) Ventilation screw solenoid valve

03) Raw water pump

04) Fuel filter

05) Connection plug for the boost electronic

06) Raw water in

07) Fuel in/out

08) Passage for fuel pump cable

09) Oil drain hose

10) Cable for remote control panel

11) Passage for starter battery cables

12) Connections to external expansion tank

13) Exhaust out

14) Oil filter

15) DC alternator

The Panda Generator

Fig. 4.2.3-1: Front view

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The Panda Generator

01) Capacitors

02) Heat exchanger

03) Thermo switch

04) Generator front plate

05) Sound cove base part

06) Generator terminal box

4.2.4 Back view - Panda 4K PMS

Fig. 4.2.4-1: Back view

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4.2.5 View from above - Panda 4K PMS

04 05

01) Capacitors

02) Generator terminal box

03) Valve cover

04) Fuel stop solenoid

05) Oil filler neck

06) Fuel filter

07) Raw water pump

08) Regulator for DC alternatort

09) Thermo switch at cylinder head

10) Heat exchanger

11) DC alternator

12) Thermostat housing

Fig. 4.2.5-1: View from above

The Panda Generator

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The Panda Generator

05 06

01) Thermostat housing

02) DC alternator

03) Oil filter

04) Sound cover base part

05) Connection point for external ventilation valve

06) Starter motor

07) Thermo switch

08) Heat exchanger

4.2.6 Right side view - Panda 5K PMS

Fig. 4.2.6-1: Right side view

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4.2.7 Left side view - Panda 5K PMS

03 04

01) Gernerator terminal box

02) Generator housing with coil

02) Failure bypass switch

04) Actuator

05) DC terminal with relays and fuses

06) Boost electronic

07) Sound cover base part

08) Fuel filter

09) Raw water pump

10) Oil dipstick

11) Fuel solenoid valve

The Panda Generator

Fig. 4.2.7-1: Left side view

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The Panda Generator

04 06

01) Thermostat housing

02) Raw water pump

03) Fuel filter

04) Raw water in

05) Fuel in/out

06) Passage for fuel pump cable

07) Oil drain hose

08) Cable for remote control panel

09) Passage for starter battery cables

10) Connections to external expansion tank

11) Exhaust out

12) Connection point for external ventilation valve

13) Oil filter

14) DC alternator

4.2.8 Front view - Panda 5K PMS

Fig. 4.2.8-1: Front view

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4.2.9 Back view - Panda 5K PMS

01) Capacitors

02) Heat exchanger

03) Thermo switch

04) Generator front plate

05) Sound cove base part

06) Generator terminal box

The Panda Generator

Fig. 4.2.9-1: Back view

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The Panda Generator

04 05

01) Capacitors

02) Generator terminal box

03) Valve cover

04) Fuel stop solenoid

05) Oil filler neck

06) Raw water pump

07) Regulator for DC alternatort

08) Thermo switch at cylinder head

09) Heat exchanger

10) DC alternator

11) Thermostat housing

4.2.10 View from above - Panda 5K PMS

Fig. 4.2.10-1: View from above

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The Panda Generator

06 07

01) Display operating hours

02) Power „ON/OFF“-button

03) Generator „Start“-button

04) Control light „Override“

05) Warning light for engine temperature

06) Warning light for exhaust temperature

07) Warning light for oil pressure

4.3 Details of functional units

4.3.1 Control panel

The control panel is fitted with various monitoring functions, which increase functional reliability and operating safety of the generator . Various parts of the generator are monitored with sensors which, when triggered, generate an error message and can shut down generator operation under certain circumstances to prevent damage.

Fig. 4.3-1: Remote Control Panel - Front Side

Leere Seite / Intentionally blank

Notice!:See remote control panel data sheet for details!

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The Panda Generator

4.3.2 Components of cooling water system (raw water + fresh water)

Fig. 4.3.2-1: Two circle system

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4.3.3 The fuel and combustion air system

Fig. 4.3.3-1: Fuel and combustion air circle

The Panda Generator

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The Panda Generator

4.3.4 Sensors and switches for operation surveillance

The thermo-switch at the cylinder head serves to monitor the generator temperature.

Fig. 4.3.4-1: TThermo-switch at cylinder headThermo-switch at cylinder head

This thermo switch is located at the water-cooled exhaust elbow union and serves to monitor the temperature of the fresh water cooling system. It takes a measurement at the hottest spot, since the combustion gases are guided from the cylinder head for the exhaust elbow.

1. Generator coil

2. Thermo-switch

3. Housing

Fig. 4.3.4-2: Thermo-switch at exhaust elbowThermo-switch at water-cooled exhaust elbow

Fig. 4.3.4-3: Thermo-switch coilThermo-switch in the generator coil

Two thermo switches are located inside the winding to protect the generator coil, which for safety reasonsare installed independently in parallel.

Sample picture

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Page 48

In order to be able to monitor the lubricatin g oil system, an oil pressure switch is built into the system.

4.3.5 The lubrication circuit

The Panda Generator

Fig. 4.3.4-4: Oil pressure switchOil pressure switch

Fig. 4.3.5-1: Lubrication circuit

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Generator operation instruction

5. Generator operation instruction

5.1 Personal requirements

Only instructed persons are allowed to run the generator. Instructed Persons has read the manual of the generator and all ancillary components and external equipment. He must be acquaint with the specific risks and safety instructions.

Only persons who are expected to perform their tasks reliably are permitted as personnel. Persons whose reaction capability is impaired, e.g. through drugs, alcohol or medication are not permitted.

When selecting the personnel, the stipulations regarding age and occupation applying at the loca tion must be observed.

5.2 Hazard notes for the operation

Notice!:Please note the safety first instructions in front of this

manual.

automatic start device. This means the generator can be started by an external signal.

To avoid an unexpected starting of the generator, the starter battery must be disconnected before start working at the generator.

Do not run the generator with removed sound cove r. If it is necessary to test the generator without sound cover, pay special attention. Never do this work alone. Do all service, maintenance and repair with engine stopped.

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

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

Warning!: Automatic startDanger for life! - The generator can be equipped with a

Attention!: Danger to lifeRotating parts inside of the generator

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

5.3 General operating instruction

5.3.1 Operation at low temperatures

The Generator can be started at temperatures down to - 20 °C, therefor the operation fluids like fuel, cooling water, lubricant oil ect. must be suitable for this t emperatur es. These should be checked before start. Cold start spray ect. are not allowed to use, or the warranty will be lost.

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Generator operation instruction

5.3.1.1 Pre-heating the diesel motor

Pre.champer diesel engines are equipped with a quick gl ow plug. The maximu m pre glow time sho uld not exceed 20 sec. At 20 °C or more the pre glow time should be about 5-6 sec. Below 20 °C the pre glow time should be increased,

Note:If the operation fluids have been drained and then filled with cold weather fluids, always run the generator for 10 minutes to ensure the new fuel is present throug hout the system.

5.3.1.2 Tips regarding starter battery

Fischer Panda recommends normal starter battery use. If an genset is required for extreme winter conditions, then the starter battery capacity should b e doubled. It is recommended that the starter battery be regularly charged by a suitable battery-charging device (i.e., at least every 2 Months). A correctly charged starter battery is necessary for low temperatures.

5.3.2 Light load operation and engine idle

If an engine is operated on a load less than 25-30 % of its rated output, the soot of the generator will be observed which may give cause for concern. The usual results of this operation are heavier than normal lubricating oil consumption, and oil leaks from the air and exhaust manifolds. This condition is particularly evident on standby generator set applications.

5.3.2.1 The soot of the generator is due to the fact that:

The cylinder temperatures are too low to ensure complete burning of all the fuel delivered. A further result is that of abnormal carbon build -up on the valves, piston crowns and exhaust ports. Fuel dilution of

the lubricating oil will also occur.

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

Running on light load should be avoided or reduced to the minimum period. In a period of 50 operation hours the engine or generator set should be run on full load for four hours, to burn off

accumulations of carbon in the engine and exhaust system. This may require the use of a 'dummy load'. The load should be built up gradually from 30 % to 100 % within 3 hours and hold at 100 % fo r one ho ur.

5.3.3 Generator load for a longer period and overload

Ensure the generator is not overloaded. Overloading occurs when the electrical load is higher than the generator can provide. If this occur for a longer period, the engine may be damaged. Overloading may cause rough running, high oil and fuel consumption, increased emissions.

For a long engine life, the long therm load should not exceed 80 % of the nominal load. Long therm load is the load over several hours. It is harmless for the generator to deliver full nominal power for 2-3 hours.

The hole conception of the Fischer Panda generator make sure, that the full power operation at extreme condition will not increase the engine temperatures over. Please note that the emissions of the generator also increase at full power operation.

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Generator operation instruction

5.3.4 Protection conductor:

The standard Panda generator is grounded. The 3-phase connection (delta) centre point is bridged to earth in the AC output terminal box (mounted on the generator). This is the initial earth safety point and is sufficient to ensure safe operation however only as long as no other system is inst alled. This syste m is adapted to enab le test running of the generator before delivery.

The bridge to ground (PEN) is only effective when all components in the electrical system share a common ground. The bridge to ground can be removed and reconnected to another ground system if required for other safety standards.

Full voltage connections are mounted in the electrical cabinet. It must be ensured that the electrical cabinet is secured and closed while the generator is running.

The starter battery cable should be disconnected when work is being done on either the generator or the electrical system in order to prevent accidental starting of the generator.

5.3.5 Operating control system on the Fischer Panda generator

Fischer Panda generators are equipped with various sensors/temperatures switches. The combustion engine is further equipped with a oil pressure control switch, which switches the motor off, if the oil pressure sinks to a particular level.

5.4 Instructions for capacitors - not present at all models

CAUTION! Danger to Life - High voltage

Do not touch the capacitor contact terminals!

The generator's electrical system requires two different groups of capacitors: A) The booster capacitors B) The operating capacitors Both types are mounted in the electrical cabinet. (At some models direct on the generator) Capacitors store an electrical charge. It is p ossible that even af ter they have been disconnecte d stored energy is still

held. Therefore it is essential that the connectors are not touched. Should it be necessary to check or test the capacitors, they should be shorted out by using an insulated screw driver . The operating capacitors are automatically discharged when the generator is stopped in the normal way. The boo-

ster capacitors will be discharged through internal resistors. For safety however, the capacitors have to be discharged (short circuited) prior to carrying out any work on the AC-

Control box.

5.5 Checks before start - see remote control panel data sheet

Note:The instructions and regulations of the remote control

panel data sheet must be respected.

Respect the safety instruction in front of this manual.

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Generator operation instruction

5.6 Starting the generator - see remote control panel data sheet

Note:The instructions and regulations of the remote control panel data sheet must be respected.

Respect the safety instruction in front of this manual.

5.7 Stopping the generator - see remote control panel data sheet

Note:The instructions and regulations of the remote control panel data sheet must be respected.

Respect the safety instruction in front of this manual.

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Installation Instructions

6. Installation Instructions

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

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

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

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

6.1 Personal requirements

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

6.1.1 Hazard notes for the installation

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

Working at a running generator can result in severe personal injury. Therefore before starting work at the generator:

Make sure that the generator is stopped and the starter battery is decanted to guarantee that the genera tor cannot be inadvertently started.

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

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

• Always undertake installation work when the generator is switched off.

Notice!:see “Safety first!” on Page 10.

Warning!: Risk of injury

• 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.

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sources. Therefore:

• No open flames during work on the generator.

• Do not smoke.

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

Installation Instructions

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

Contact with engine oil, antifreeze and fuel can result in damage to health. Therefor:

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

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

• Do not inhale oil and fuel vapours.

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

operation. Risk of severe burns.

Danger!: Danger of poisoning

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

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

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

• Protective clothing

• safety boots

• protective gloves

• Ear defender

• safety glasses

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

Instruction!: protective equipment necessary.

Attention!: disconnect all load

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Installation Instructions

6.2 Preparing the base - Placement

Since Panda generators have extremely compact dimensions, they can be installed in tight locations. Attempts are sometimes made to install them in almost inaccessible places. Please consider that even almost maintenance-free machinery must still remain accessible at least at the front (drive belt, water pump) and the service-side (actuator, dipstick). Please also note that in spite of the automatic oil-pressure sensor it is still essential that the oil level has to be checked regularly.

The generator should not be placed in the proximity of light walls or floors, which can have resonance vibrations because of airborne sounds. If this should be unavoidable, then it is recommended that this surface is lined with 1 mm lead foil, which will change the mass and the vibration behaviour.

You should avoid fixing the generator on a slippery surface with little mass (i.e.). This acts as an amplifier of airborne sounds in the most unreasonable cas e. An impr ovem ent can be achieved by reinforcing these surfaces with ribs. In addition, the breakthroughs, which interrupt these surfaces, should be sawed off. The lining of the surrounding walls with a heavy layer (i.e lead) and foam additionally improve the conditions.

The generator sucks its air from the surrounding engine room . Therefore it must be ensured that suf ficient ventilation openings are present, so that the generator cannot overheat.

High temperature of the intake air decline the power of the generator and increases the coolant temperature. Air temperatures of more than 40 °C reduce the power by 2 % per temperature rise of 5 °C. In order to keep these effects as small as possible, the temperature in the engine room should not be higher than 15 °C in relation to the outside temperature.

6.2.1 Advice for optimal sound insulation

Fig. 6.2.1-1: Generator baseThe convenient base consists of a stable framework, on

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

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

closed soil.

6.3 Generator Connections

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

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

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

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

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Installation Instructions

6.4 Installation of the cooling system - raw water

6.4.1 General Information

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

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

6.4.2 Installation of the through hull fitting in yyachts

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

Fig. 6.4.2-1: Position of the through hull fittingFor Panda generators, the through hull inlet should NOT

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

6.4.3 Quality of the Raw Water Sucking In Line

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

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

genset.

After start-up the cooling water quantity must be measured (e.g. by catching at the exhaust). The flow rate, as well as the necessary cross section of the coo ling water pipe s ee sect ion 9.7, “Diameter of conduits,” on page 157 .

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Installation Instructions

6.4.4 Generator installation above waterline

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

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

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

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

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

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

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

1. Raw water filter

2. Water cock

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

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

Note:Never change the impeller for many years, without

Fig. 6.4.4-1: Installing the generator above the water levelInstallation above water level

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Installation Instructions

6.4.5 Generator Installation below waterline

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

Fig. 6.4.5-1: Vent valvePossible heeling must be taken into consideration if installed

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

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

water pump.

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

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

Fig. 6.4.5-2: Connection Vent Valve

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

Attention: The vent valve must be installed directly behind the

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Installation Instructions

1. Vent valve

2. Coolant connection block

3. Raw water pump

4. Exhaust manifold

5. Raw water filter ø 1"

6. Water cock ø1“

7. Through hull

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

6.4.6 Generator housing cooled by raw water

Fig. 6.4.5-3: Connection vent valve...and bend it upwards.

Fig. 6.4.6-1: Installation scheme for direct cooling

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6.4.7 Indirect cooling of the genset housing (by the heat exchanger)

1. Vent valve

2. Exhaust manifold

3. Raw water pump (Raw water impeller pump)

4. Heat exchanger

5. Raw water filter

6. Water cock

7. Hull inlet

Fig. 6.4.7-1: Installation scheme indirect cooling of the genset housing

Installation Instructions

6.5 Installation of the cooling system - fresh water

6.5.1 Position of the external cooling water expansion tank

Fig. 6.5.1-1: Position of the external cooling water expansion tankPosition of the external cooling water expansion tank

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

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

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Installation Instructions

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

6.5.2 Ventilating at the first filling of the internal cooling water circuit

1. Fill up the external cooling water expansion tank with

coolant.

ATTENTION: maximum fill level = „max.“- mark.

The cover of the external expansion tank temporar ily must be opened (all other closures are now closed!).

Fig. 6.5.2-1: Expansion tankExpansion Tank

2. Open venting screw on the pipe socket of the internal

cooling water pump. Close the vent screw when air free water comes out

• Check the water level in the expansion tank during the

venting. Fill up if necessary.

Never open the vent screw while the generator is running.

Sample picture

vent screw when air free water comes out

• Check the water level in the expansion tank during the

venting. Fill up if necessary.

Never open the vent screw while the generator is running

Sample picture

Fig. 6.5.2-2: Venting screw - internal cooling water pumpVenting Screws

Fig. 6.5.2-3: Venting screw - thermostat housing3. Open vent screw on the thermostat housing. Close the

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

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

5. Repeat the steps 1-4 till no air comes out of the vent

screw at thermostat housing.

6. Close the vent screws.

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Installation Instructions

7. Fill up the expansion tank.

8. Close the expansion tank.

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

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

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

Anti-freeze In the interest of safety, the freezing point of the closed circuit coolant should be checked on a regular basis. Be sure

that the coolant/antifreeze mixture is good for at least -15 °C (5 °F) and if it is possible that your genset experiences lower temperatures, for exam ple during st orage or tran sportation, then th e entire coo ling system shou ld be draine d and purged

6.5.3 Pressure test for controlling the cooling water circuit

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

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

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

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Installation Instructions

1. Expansion tank

2. Exhaust manifold

3. Thermostat housing

4. Freshwater pump

5. Heat exchanger

6. Cooling water connection block

6.5.4 Scheme for freshwater circuit at two circuit cooling system

Fig. 6.5.4-1: Scheme for freshwater circuit at two circuit cooling system

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Installation Instructions

6.6 Installation of the water cooled exhaust system

6.6.1 Installation of the standard exhaust system

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

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

Exhaust diameter see section 9.7, “Diameter of conduits,” on page 157

Fig. 6.6.1-1: Installation scheme standard exhaust system

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6.7 .Installation of the waterlock

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

waterlock.

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

One point in this situation can be clarified definitely:

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

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

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

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

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

6.7.1 Possible cause for water in the exhaust hose

6.7.1.1 Possible cause: exhaust hose

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

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

6.7.1.2 Possible cause: cooling water hose

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

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

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

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

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

6.7.2 Installation area of the waterlock

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

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

The deeper the waterlock is located underneath the generator, the bett er the prot ectio n from entering water into the combustion chamber.

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

6.7.3 The volume of the waterlock

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

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

Fig. 6.7.3.0-1: Volume of the waterlock

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Fig. 6.7.3.0-2: Testing the cooling water levelIf there are any doubts, a verification can easily be made

by temporarily using a clear-sighted hose (1) as exh aust hose. In that way, the cooling water level can be checked very easily.

6.7.3.1 Ideal position of the waterlock

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

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

Fig. 6.7.3.1-1: Ideal position of the waterlock

In Fig. 6.7.3 .1-1, the waterlock is mounted in cen ter unde rneath the gener ator. When the ship tilts, the position of the waterlock related to the critical point at the exhaust hose, changes only slightly.

Fig. 6.7.3.1-2: Tilted position 15 degrees

Tilted position 15 degrees - Fig. 6.7.3.1-2

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

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Fig. 6.7.3.1-3: Tilted position 30 degrees

Tilted position 30 degrees - Fig. 6.7.3.1-3

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

Fig. 6.7.3.1-4: Tilted position 45 degrees

Tilted position 45 degrees - Fig. 6.7.3.1-4

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

risk that water can get straight into the discharge stack area throug h strong rocking motion s („slos hing“). This sh ows that the distance of 600 mm represents a minimum size at which, even when installed ideally, the water c an slosh into the exhaust elbow when the ship is very tilted or rocks very hard.

Summary:

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

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

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

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

Fig. 6.7.3.2-1: waterlock, 500 mm next to the center line

Fig. 6.7.3.2-2: Tilted position 45 degrees

Tilted position 45 degrees - Fig. 6.7.3.2-2

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

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

Fig. 6.7.3.2-3: waterlock, 1000 mm next to center line

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Fig. 6.7.3.2-4: Tilted position 30 degrees

Tilted position 30 degrees - Fig. 6.7.3.2-4

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

Summary:

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

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

6.8 Exhaust / water separator

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

Fig. 6.8-1: Water flow exhaust water separatorWater flow exhaust water separator

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

Fig. 6.8-2: Exhaust water separatorExhaust water separator

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6.8.1 Installation exhaust water separator

1. Generator

2. Silencer / Water lock

3. Exhaust-Water-Separator

4. Silencer

5. Sea cock

6. Hull outlet

Fig. 6.8.1-1: Installation exhaust water separator

Installation Instructions

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

If the through-hull exhaust outlet has to be mounted far from the generator, an exhaust-water separator must definitely be installed. The raw water from the separator must then run along the shortest possible path in the through-hull outlet. For such long exhaust routes, the exhaust hose diameter should also be increased, f.e. from NW40 mm to NW50mm in order to reduce the back-pressure. The exhaust may have a le ng th of over 1 0m (32 ft.) if the exhaust hose diameter is increased. An additional outlet exhaust muffler close to the hull outlet will help further to reduce noise emissions.

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

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Installation Instructions

Example of an unfavourable installation:

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

- Distance water lock to exhaust/water separator too large

Fig. 6.8.1-2: Example for an unfavourable installation

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Installation Instructions

01. Generator / Generator / Génératrice

02. Elektrische Kraftstoffpumpe (DC) / Electric fuel pump (DC) / Pompe électrique carburant (DC)

03. Kraftstoffilter mit Wasserabscheider / Fuel filter with water separator / Filtre de carburant avec séparateur d´eau *)

04. Kraftstoff-Vorlauf / Fuel forward / Amenée du carburant *)

05. Kraftstoff-Rücklauf / Fuel return / Retour du carburant *)

06. Kraftstofftank / Fuel tank / Réservoir de carburant *) not supplied with standard generator.

6.9 Installation of the fuel system

6.9.1 General references

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

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

• The following items need to be installed:

• Fuel supply pump (DC)

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

• Fine particle fuel filter

• Return fuel line to fuel tank (unpress ur ize d) The electric cable for the fuel pump is already installed on the generator (length 5 m).

Fig. 6.9.1-1: Installation Scheme Fuel System

Installationsschema mit Saugpumpe (z.B. Racor) / Installation scheme with lift pump (f.e. Facett )

6.9.2 The electrical fuel pump

With the Panda generator is usually supplied an external, electrical fuel pump (DC).The electrical connections are pre-loaded at the generator with the lead planned.

Diameter of fuel lines: section 9.7, “Diameter of conduits,” on page 157.

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Installation Instructions

6.9.3 Connection of the fuel lines at the tank

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

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

Non-return valve in the suction pipe

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

ATTENTION! Non-return valve for the fuel return pipe

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

6.9.4 Position of the pre-filter with water separator

Fig. 6.9.4-1: 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).

6.9.5 Ventilating air from the fuel system

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

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

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

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

3. After the fuel pump has been running 3 to 4 minutes, because the failure byp a ss switch has been presse d down, the bleeding screw of the solenoid valve has to be unscrewed. The switch has to be continuously depressed, when opening the screw. A piece of cloth or absorbent paper should be put under the connection to avoid fuel entering the sound insulation cover.

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

5. Starting the generator

Now the generator can be started by pushing the „START“-button. The generator should start after a short while. One of the pipe union nuts of an injection hose has to be unscrewed, should the unit not start; then try to restart the generator. After the generator has started, the pipe union nut has to be tightened again.

Main power switch „OFF“

Fig. 6.9.5-1: Vent screw at the fuel stop solenoid valveVent Screw at the fuel stop solenoid valve

Not installed at all models!

6.10 Generator DC system installation

The Panda generators from 6.500 NE upwards have their own dynamo to charge a DC starter battery. It is recommended to install an additional starter battery for the generator. The generator is then independent from the remaining battery set. This enables you to start the genset at any time

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

The generator is then Earth/Ground free.

6.10.1 Connection of the starter battery block

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

The positive cable (+) of the battery is attached directly at the soleno id switch of the starter motor. The negative cable (-) of the battery is attached underneat h th e starter mo tor at the engine mount.

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

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

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

batteries in a row)

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installed as near as possible to the generator. The positive terminal of the battery is attached at the red cable, the negative pole at the blue cable.

NOTE:To avoid large voltage drops the battery should be

It must be guaranteed that first the cables are attach ed 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 ci rcuit breaker in the plus p ole cable of the battery, but with a distance to the battery of up to 300 mm (12 inch) at maximum.

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

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

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

vibrations by appropriate sleeve/protective pipe. It must be shifted in such a way that it doe s not affect rotary parts or parts, that become hot in operation, e.g. wheel, exhaust elbow union, tail pipe and the engine. Do not lay the cable too tautly, since otherwise it could be damaged.

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

Examine regularly the cable laying and the electrical connections.

Fig. 6.10.1-1: Positive battery cable Positive battery cable

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

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

1 2 3

foot.

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

Installation Instructions

Fig. 6.10.1-2: Negative battery cableNegative battery cable

Fig. 6.10.1-3: DC-relayDC-relay

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

1. Starter motor relay

2. Pre-glow relay (glow plugs)

3. Fuel pump relay

Sample Picture - See wiring diagram

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

1. Solenoid switch for starter motor

2. Starter motor

Fig. 6.10.1-4: DC starter motor DC starter motor

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Installation Instructions

1. Generator

2. Battery block

3. Fuse

4. Battery main switch

Fig. 6.10.1-5: Battery installation - Scheme

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

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Installation Instructions

6.11 Generator AC system installation

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

All electrical safety installations have to be made on board. A power source selector switch must be installed between the generator (or if applicable, AC-Control box)

and the ship's electrical supply system. This switch must used to ensure that all AC consumers can be switched off at once. This switch should also be installed to keep the generator and shore (grid) power systems separate.

Fig. 6.11.0-1: 3-Way cam switch3-Way cam switch

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

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

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

additional switch must be installed to keep these systems separate. An alternative to a manual rotating switch is an automatic power relay. When the generator is not running , the r elay

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

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

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

If a separate ground protection cable is necessary (i.e. due to national safety regulations), the bridge between the generator housing and ground (in the AC-Control box) must be disconnected. Once such a ground protection cable is installed, it must be connected to the ground straps of all on board electrical devices.

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

Electrical fuses

It is absolutely essential that the electrical system installation is inspected by a qualified electrical technician. The generator should have its own AC input electrical fuses. Th e fuses should be sized such that the rated current of the generator on each of the individual phases is not exceeded by more than 25 %.

Data for gensets with power output greater than 30 kW on request!

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The fuses must be of the slow type. A 3-way motor protection switch must be installed to pr otect the ele ctr ical motor.

Required fuses see rated current on the type plate

Required cable cross-sections

The following recommended electrical cable dimensions (cross sections) are the minimum required sizes for a safe installation (see section 9.3, “Cable cross section,” on page 154).

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Installation Instructions

6.11.1 Insulation test

Attention: Once the electrical system installation is complete, a ground insulation test must be performed as follows:

1. Switch off all on-board electrical devices.

2. Start the generator.

3. Measure the AC-voltage with a voltmeter (adjust to Volt/AC) between

a. generator housing and AC-Control box b. generator housing and ground. c. the measured voltage must not exceed 50mV (millivolts).

4. Once the safety systems have been installed, they must be checked. If a RCD (Leakage Current Relay) has been

installed, it also has to be tested, in order to ensure that it functions properly. The individual phrase s mu st be checked against each other, and between phase and ground, (the single phase or 4th phase also needs to be checked in this fashion).

5. If the generator is protected by a ground connection, then ALL electrical devices must also be connected to this

„common“ ground (usually ground contacts are attached to the devices' metallic housings).

The electrical system installation must also comply with the hook-up requirements of the shore current grid. Generally a leakage current relay is sufficient for safe electrical operation; however, this must be confirmed by the electrical safety standard in the region where the system is attached to a main land power grid. The relay has to meet the required safety standard regulations.

Checking the electrical connections

There is always the possibility that circuits have been rerouted/changed or individual components have not been not been correctly laid out on the circuit diagrams.

The installation electrician should therefore che ck a nd labe l all e lectr ical con nections to e nsure tha t they co rr espond to the main circuit diagram. The inspection and correct labelling is especially cr itical for terminals L1 / L2/L3/L1'/N (for the 230 V - 50 Hz model) and for terminals L1/L2/L3/N &1/ 2/ 4 for the 60 Hz (120 V) models. The electrician is therefore obliged, before installation to check whether the generator is earth-free. As long as this test has not been carried out all other components for electrical inst allation must be removed. On ce the system has b een inst a lled and inspected, this test should also be performed with all electrical devices (i.e. voltage check between common and metallic housings) while the generator is running.

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Maintenance Instructions

7. Maintenance Instructions

7.1 Personal requirements

All maintenance, if not special marked, can be done by the trained persons. Further maintenance must be done by technical personal or Fischer Panda service points.

7.2 Hazard notes for the maintenance

Notice!:Follow the general safety instruction at the front of this

manual.

Warning!: Automatic startDanger for life! - The generator can be equipped with a automatic start device. This means the generator can be started by an external signal. To avoid an unexpected starting of the generator, the starter battery must be disconnected before start working at the generator.

personal injury. Therefore before starting work at the generator:

Make sure that the generator is stopped and the starter battery is disconnected to guarantee that the generator cannot be inadvertently started.

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

personal injuries or material damage.

• Always undertake installation/maintenance work when the

generator is switched off.

• Ensure there is sufficient installation clearance before start

working.

• 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.

Warning!: Risk of injuryWorking at a running generator can result in severe

Warning!: Risk of injuryImproper installation/maintenance can result in severe

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

• No open flames during work on the generator.

• Do not smoke.

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

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damage to health. Therefor:

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

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

• Do not inhale oil and fuel vapours.

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

operation. Risk of severe burns.

Maintenance Instructions

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

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

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

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

• Protective clothing

• safety boots

• protective gloves

• Ear defender

• safety glasses

avoid damages at the load.

Improper handling can result in battery explosion and leakage. Acid or alkalis can run out. An explosion of the battery is possible.

See the operation and safety instruction from your battery manufacturer.

Instruction!: Personal protective equipment necessary.

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

Warning!:Batteries contains acid or alkalis.

Batteriescontaincorrosiveacidsandlyes. Improperhandlingcancausethebatteriestoheatupand burst.Corrosiveacid/lyemayleak.Underunfavorable conditions,thebatterymayexplode.

Observetheinstructionsfromyourbatterymanufacturer.

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Maintenance Instructions

7.3 Environmental protection

Significant environmental damage can occur, particularly for incorrect disposal, if environmentally hazardous operating materials are mishandled. Therefor e:

• Always observe the instructions mentioned below.

• Take immediate action if environmentally hazardous materials reach the environment. Inform the responsible local authorities about the damage in the case of doubt.

The disposal must be performed by a specialist disposal company.

7.4 Maintenance interval

Environmental protection.Danger to the environment due to mishandling!

For the maintenance interval, please see the „General information for PMS generators“ which are attached to this manual.

At generator with dynamic operation hours (f.e . Generators with iControl2 system ) the maintenance inter val can may be extended.

Note:With the dynamic operation hours the service interval can be raised up to 30 % (200 h max.). Make sure that the dynamic operation hours are not reset accidently between the service interval.

7.5 General maintenance instructions

7.5.1 Checks before each start

• Oil level

• Leaks in the Cooling system

• Visual check for any changes, leaks in the oil drain system, v-belt, cable connections, hose clips, air filter, fuel lines

Once a month

• Grease/oil the servo motor - Trapezoid thread-spindle Maintenance intervals - see separate data sheet

7.5.2 Check of Hoses and rubber parts in the sound insulated capsule

Check all hoses and hose connections for good condition. The rubber hoses are very sensitive to environmental influences. They wear out quickly in an environment of dry air, oil and fuel vapours, and high temperatures. The hoses must be checked regularly for elasticity. There are operating situations, when hoses must be renewed once a year.

Additionally to usual tasks of maintenance (oil level check, oil filter control etc.) further maintenance activities are to be accomplished for marine generators, such as control of the sacrificial anode (cooling wa ter connection bl ock) and the front seal cover at the generator.

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Maintenance Instructions

2/3 Suggestion

Oil Max.

Oil Min.

7.6 Oil change intervals

The first oil change is to be accomplished after a period of operation from 35 to 50 hours. Afterwards the oil is to be changed after 150 hours. For this, the oil SAE30 for temperatures over 20°C and SAE20 for temperatures between 5°C and 20°C is to be used. At temperatures under 5°C oil of the viscosity SAE10W or 10W-30 is prescribed.

For filling quantity, see „Technical Data“ at page 107.

7.7 Checking oil-level

You require:

paper towels / cloth for the oil dip stick

The generator must be placed at level.

• with vehicular generators: Place the vehicle on a levelled surface.

• with PSC generators: Place the generator on a levelled surface.

• with marine generators: Measure the oil-level when the ship is not lop-sided. Run the generator for about 10 minutes to ensure that the engine is warm. Wait for 3 minutes, so the oil can flow

back into the oil pan.

Caution: Burn hazard!Generator and coolant can be hot during and after

operating.

Wear personal protective equipment. (Gloves, protective goggles, protective clothing and safety shoes)

• Assure generator against accidental start.

• Open the generator casing.

• Pull the oil dipstick out of the check rail.

• Clean oil dipstick.

• Put the oil dipstick back into the check rail and wait for 10 seconds.

• Pull the oil dipstick out of the check rail and read off the oil-level at the lower end of the stick.

Fig. 7.7-1: Oil dipstick - SampleOil dipstick

The oil-level is to be checked by means of the oil dipstick. The prescribed filling level must not cross the „Max“-mark.

We recommend an oil-level of 2/3. Sample picture

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Maintenance Instructions

Oil Max.

Oil Min.

2/3 Suggestion

The oil-level is to be checked by means of the oil dipstick. The prescribed filling level must not cross the „Max“-mark.

We recommend an oil-level of 2/3. Sample picture

Oil should be refilled, if the oil-level is under 1/3 between the minimum and the maximum mark. Fischer Panda recommends an oil-level of 2/3 between the minimum an d the maximum mark.

Fig. 7.7-2: Oil dipstickOil dipstick EA 300 Engine

If the oil-level is under the MIN-mark, check how many operating hours went by since the last oil change, by means of your service manual or an existing oil change tag. - with operating hours between 50 and 150 hours it is only necessary to refill oil. See „Refilling oil“ on page 2.

• with 150 operating hours or more the oil should be changed (See your generators’ service table)

• if the oil-level is under the minimum mark by less than 50h, there might be a technical problem! In that case, we

recommend going to a shop or a Fischer Panda service point.

• if the oil is cloudy or even „creamy“, coolant might have mixed with the oil. See a garage or a Fischer Pan da service

point immediately.

7.7.1 Refilling oil

You require:

Engine oil

1. Check oil-level as described under section 7.7, “Checking oil-level,” on page 86.

2. Oil dipstick is pulled out of the check rail.

3. Open the oil filler cap.

4. Fill in oil (approx. 1/2 litre) and wait for about 2 min. so this it can flow into the oil pan.

5. Wipe off the oil dipstick and put it into the check rail.

6. Pull the oil dipstick out of the check rail and check the oil-level. See section 7.7, “Checking oil-level,” on page 86. If oil-level is still too low (under 2/3): repeat steps 4-6.

7.7.2 After the oil level check and refilling the oil

• Put the oil dipstick back into the check rail.

• Close the oil filling cap.

• Remove potential oil stains and splashes from the generator and surroundings.

• Close the generator casing.

• Remove lock against accidental generator start.

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7.8 Replacement of engine oil and engine oil filter

You require:

- Engine oil. See attachment.

- New oil filter (not with generators with EA300 engines)

- Sealing for oil drain screw

- Personal protective gear

- Container to collect used oil (hea t resistant and of sufficient size)

- Open-ended wrench for oil drain screw

Maintenance Instructions

- Paper towels and cloth

- Oil filter wrench

- Oil resistant mat, so prevent used oil from getting into underground water

The generator must be placed at level.

• with vehicular generators: Place the vehicle on a levelled surface.

• with PSC generators: Place the generator on a levelled surface.

• with marine generators: Change the oil when the ship is not lop-sided. Run the generator for about 10 minutes to ensure that the engine is warm. Wait for 3 minutes, so the oil can flow back into the oil pan.

Caution: Burn hazard!Generator and coolant can be hot during and after

operating.

Wear personal protective equipment. (Gloves, protective goggles, protective clothing and safety shoes)

1. Prepare generator.

- Assure generator against accidental start.

- Open the generator casing.

- with generators that have an external oil drain hose: Release the oil drain hose from the mounting.

- with generators that have an internal oil drain hose: Open the lead-through for the oil drain hose (left turn of the sealing). Pull out the sealing with the oil drain hose.

Place an oil resistant mat under the oil drain hose area and prepare the container.

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Maintenance Instructions

Unscrew the oil filling cap. This is necessary, because otherwise a vacuum will form and the oil can not completely drain off. Sample picture

Unscrew the oil drain screw by means of th e open-ended wrench from the oil drain hose (rotating direction left). Use a second open-ended wrench to lock. Make sure to do this over the container. Use spanner size 17 mm.

Fig. 7.8-1: Oil filling cap2. Loosen oil filling cap

Fig. 7.8-2: Oil drain hose3. Open oil drain scre w.

4. Discharge used oil.

Let the entire amount of oil drain out of the engine. This can take several minutes.

Release the oil filter by turning the filter wrench counterclockwise. The filter might be full of oil. Make sure to not spill anything and avoid skin contact. Sample picture

Fig. 7.8-3: Oil filter5. Remove used oil filter / clean oil screen

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The oil screen should be cleaned every 500 operating hours: to do so follow the instructions in the engine manual.

Use spanner size 17 mm.

Sample picture

Clean the engines’ filter holder brush a thin oil layer on the sealing of the new filter.

Maintenance Instructions

Fig. 7.8-4: Oil screenOil screen with generators with EA300 engines

Fig. 7.8-5: Oil screen sealing ring6. Preparing a new filter

7. Mounting the new filter Carefully screw in the new filter by hand. It must not be tightened too much. Screw in the oil drain screw again

and tighten is with the wrench. Use a new sealing for the oil drain screw.

8. Fill in oil. (oil fill capacity: see attachment) Fill the engine oil into the engine via feed hopper. Check oil-level after every 2 litres with the oil dipstick.

9. Check proper filling level. See section 7.7, “Checking oil-level,” on page 86. When the proper filling level is reached, screw in the oil cap again. Run the engine for 10 minutes and then turn it

off. Check the oil-level once more after several minutes with the oil dipstick. If it is too low, refill some oil.

10. Clean up Wipe off all oil splashes from the generator and make sure that the drai n scr ew ha s no leak .

7.8.1 After the oil change

• Put the oil dipstick back into the check rail.

• Close the oil filling cap.

• Remove potential oil stains and splashes from the generator and surroundings.

• Close the generator casing.

• Remove lock against accidental generator start.

• Duly dispose of used oil and filter. Used oil is very toxic and mu st not be disposed with domestic waste. It is prohibited to dispose used oil with

waste water! Make sure that used oil is disposed properly (e.g.: where oil is bought or at collection stations).

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Maintenance Instructions

7.9 Verifying the starter battery and (if necessary) the battery bank

Check the condition of the battery. Proceed here as prescribed by the battery manufacturer. If from the battery manufacturer not otherwise mentioned.

7.9.1 Battery

7.9.1.1 Check battery and cable connections

Fig. 7.9.1.1-1: Battery• Keep batter y clea n an d dry.

• Remove dirty clamps.

• Clean terminal posts (+ and -) and clamps of the battery, and grease with acid-free and acid-resistant grease.

• When reassembling, ensure that clamps make good contact. Tighten clamp bolts hand-tight.

7.9.1.2 Check electrolyte level

• If testers 2 are present:

• Electrolyte level should reach the base of these.

• Without testers:

The electrolyte level should be 10-15 mm above th e top of the plates.

• If necessary, top up with distilled water.

• Screw sealing caps back in.

Fig. 7.9.1.2-1: Battery• Remove sealing caps 1.

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Maintenance Instructions

7.9.1.3 Check electrolyte density

Fig. 7.9.1.3-1: Battery• Measure the electrolyte density of individual cells with a

commercial hydrometer. The hydrometer reading (se e table on following page) indicates the battery’s state of charge. During measurement, the temperature of the electrolyte should preferably be 20 °C.

Electrolyte density in [kg/ l] Charge status Normal Tropical

1.28 1.23 well charged

1.20 1.12 semi-charged, re-charge

1.12 1.08 discharged, immediately charge

AttentionThe gases emitted by the battery are explosive! Keep

sparks and naked flames away from the battery!

Do not allow battery acid to come into contact with skin or clothing!

Wear protective goggles!

Do not rest tools on the battery!

7.10 Ventilating the fuel system

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

Attention:Generators with iControl system do not need a Failure bypass switch. At these generators the fuel pump c an be activated by an option of the control panel. See Control panel manual.

1. Main power switch „OFF“

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Maintenance Instructions

The electrical fuel pump must be audible. Switching on and off the solenoid valve at the generator will be audible by pressing the failure bypass switch (if capsule removed).

Note!

Generators with iControl system has no failure bypass switch. The Fuel pump can be activated at the iControl panel.

Please see iControl manual for details.

minutes will loosen the ventilation screw located at the fuel solenoid valve. The button must continue to be pressed, whilst opening the screw. A large cloth or Kleenex tissue must be laid beneath the connection to prevent escaping fuel running into the capsule. If the fuel runs out without air bubbles, then the ventilation screw can be closed. Only then may the button be released.

Use spanner size 10 mm.

Fig. 7.10-1: Failure bypass switch2. Press failure bypass switch and keep firmly pressed.

Fig. 7.10-2: Ventilation screw at the fuel solenoid valve 3. Pressing the failure bypass switch for approx 3 - 4

generators without fuel solenoid valve, a single ventilation screw is installed.

The machine should start after a short period.

5. If this does not occur, then a connecting nut fitted to the injection line must be loosened and starting procedure repeated. Retighten the washers after successfully starting. The injection line must be raised by several millimetres.

Use spanner size 17 mm.

6. Switch main switch „OFF“.

Note!:Not all generator models has a fuel solenoid valve. At

Fig. 7.10-3: Injection nozzles4. Pressing the starter button can now start the machine.

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7.10.1 Replacement of the fuel filter

should take place after 300 operational hours at the very least. The inlet must be clamped, before exchanging the filter.

Remove the hoses from the used filter and fasten them to the new filter. The arrow on the filter housing indicates the direction of the fuel flow. A clogged filter causes a decreased power output of the generator.

Maintenance Instructions

Fig. 7.10.1-1: Fuel FilterExchanging the filter, depending upon fuel contamination,

7.10.1.1 Optional fuel filter with sight glass

but should be executed every 300 operating hours at the latest.

01. Fuel filter housing

02. Fuel filter element

03. Sight glass

Fig. 7.10.1.1-1: Fuel filterThe filter change depends on the fuels’ degree of pollution,

Fig. 7.10.1.1-2: Fuel filter1. Unscrew the housing from its mount (left hand rotation).

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Maintenance Instructions

rotation).

4. Lubricate the sight glasses o-ring with a heat resistant grease (Spe cification: Antiseize) and screw the sight glass back into its mount (right hand rotation).

Fig. 7.10.1.1-3: Fuel filter2. Unscrew the filter element from the mount (left hand

Fig. 7.10.1.1-4: Fuel filter3. Screw the new filter element into the mount.

7.11 Checking the water separator in the fuel supply

Fig. 7.11-1: Pre-filter with water separatorThe pre-filter with water separ ator has a cock u nderneath, by

which means the water can be drained. This water sinks to the bottom, due to the difference in the

densities of water and fuel. Water is heavier than the diesel

Sample picture

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7.1 1.1 Replace the air filter mat

the housing cover. Use spanner size 8 mm.

Maintenance Instructions

Fig. 7.11-1: Air suction housing1. Open the air suction housing by loosen the six screws on

Fig. 7.11-2: Opened air suction housing2. Change the air filter mat.

3. Close the suction air housing.

7.11.2 Alternative replacement of the air filter mat with pull out holder

Fig. 7.11.2-1: Air suction housing with pull out holder 1. Air filter housing with pull out holder.

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Maintenance Instructions

Fig. 7.11.2-2: Air suction housing with pull out holder 2. Tip the two fasteners 90°.

Fig. 7.11.2-3: Air suction housing with pull out holder 3. Pull the filter mat holder out.

5. Re-assembly in reversed order.

Fig. 7.11.2-4: Air suction housing with pull out holder 4. Replace the air filter mat.

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Maintenance Instructions

7.11.3 Alternative replacement of the air filter at housing with snap fasteners

Fig. 7.11.3-1: Air suction housing1. Open the combustion air housing by loosening the closure

on the right side of the housing.

01. Closure

on the left side of the housing.

01. Closure

4. Lift out the air filter element of the cover of the air filter housing.

01. Air filter

5. Replace cover in reverse procedure.

Sample picture

Fig. 7.11.3-2: Air suction housing2. Open the combustion air housing by loosening the closure

Fig. 7.11.3-3: Air suction housing3. Open the air housing by pulling the cover.

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Maintenance Instructions

7.11.4 Ventilation of the coolant circuit / freshwater

If the cooling water is drained, or if other air has entered the cooling system, it is necessary to ventilate the cooling system.

This ventilating procedure must be repeated several times:

The generator must be switched off before opening the ventilating points!

Pay attention that the external coolant expansion tank is connected with the generator by the intended connection point.

Further it should be guaranteed that the expansion tank is attached in sufficient height (200 m) over the level of the generator highest point.

AttentionSpecial notes for the ventilation of the cooling system

casing. Not present at all models Use spanner size 10 mm.

Fig. 7.11-1: Expansion tankExpansion tank

Fig. 7.11-2: Ventilating screw1. Open the ventilating screw above the cooling water pump

Not present at all models

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Use spanner size 10 mm.

(At generators without filler, The cooling water can be filled into the external expansion tank instead)

4. If the cooling water level no longer drops (the cooling water level in cold waters must cover the tin in the exhaust elbow), close the filler cover and the cooling water screws and then start the generator.

5. Run the generator for approx. 60 Seconds, then switch off

6. Refill cooling water via the compensation tank.

7. The compensation tank is connected to the generator by two hoses.

Maintenance Instructions

Fig. 7.11-3: Ventilating screw on the thermostat housing2. Open the ventilating screw on the thermostat casing.

Fig. 7.11-4: Cooling water filler cap3. Pour cooling water into the cooling water filling necks.

The external compensation tank should be filled to a max 20 % in a cold state. It is very important that a larger expansion area is maintained above the cooling water level.

8. Repeat this procedure 1 - 5 times.

If there is no change to the state of the cooling water level, the generator is re-started for 5 minutes. Thereafter the de-aeration must be repeated two to three times.

The ventilation screw above the cooling water pump casing may not be opened under any circumstances,

Fig. 7.11-5: Ventilation screw above the cooling water pump

casing

whilst the generator is running. Air will be sucked through the opening, if this should happen by mistake. Venting the whole system afterwards is necessary and very difficult.

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