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Panda 5000i PMS
User Manual
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Fischer Panda Panda 5000i PMS User Manual

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Page 1

Marine Generator Manual

Panda 5000i PMS
Super silent technology
230 V/400 V 120 V/240 V 50 Hz/60 HZ 5kVA
Panda_5000i_PMS_eng.R08 14.7.16
Page 2

Current revision status

Document
Actual: Panda_5000i_PMS_eng.R08_14.7.16 Replace: Panda_5000i_PMS_eng.R07.1
Revision Page
iControl 2 eingepflegt PMGi mit Lade/Wechselrichtern (R04) iControl2 berichtigt (Seeventil) Jahresupdate R07 60 Hz eingefügt R07.1 PMGi uni eingepflegt R08
Erstellt durch / created by
Copyright Duplication and change of the manual is permitted only in consultation with the manufacturer!
Fischer Panda GmbH, 33104 Paderborn, reserves all rights regarding text and graphics. Details are given to the best of our knowledge. No liability is accepted for correctness. Technical modifications for improving the product without previous notice may be undertaken without notice. Before installation, it must be ensured that the pictures, diagrams and related material are applicable to the genset supplied. Enquiries must be made in case of doubt.
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Page 3
Inhalt / Contens
Marine Generator Manual............................................................................................................................ ....... 1
Current revision status . ... ... .... .......................................... ... ... ... .... ... ... ........................................................ ....... 2
3 General Instructions and Regulations.................................................................................................. ..... 10
3.1 Safety first!...................................................................................................................................... .... 10
3.2 Tools.................................................................................................................................... ........... .... 12
3.4 Customer registration and guarantee ............................................................................................. .... 14
3.4.1 Technical support ........................................................................................................... .... 14
3.4.2 Caution, important information for start-up! ............................... ..................................... .... 14
3.5.1 Safe operation ................................................................................................................ .... 15
3.5.2 Observe safety instructions! ........................................................................................... .... 15
3.5.3 Personal protective clothing (PPE) ................................................................................. .... 15
3.5.4 Cleanliness ensures safety ............................................................................................. .... 15
3.5.6 Exhaust fumes and fire protection .................................................................................. .... 16
3.5.8 Protect your hands and body from rotating parts! .......................................................... .... 17
3.5.9 Anti-freeze and disposal of fluids ............................................... .... ... ... ... .... ... ... ... ... .... ... . .... 17
3.6 Warning and instruction signs......................................................................................................... .... 18
3.6.1 Special instructions and hazards of generators ................................... ... .... ... ... ... ... ........ .... 18
3.6.1.2 Protective conductor for Panda AC generators:............................................... .... 19
3.6.1.3 Switch off all loads while working on the generator ......................................... .... 19
3.6.1.4 Potential equalisation for Panda AGT DC generators...................................... .... 19
3.6.2 General safety instructions for handling batteries .......................................................... .... 20
4 In case of Emergency First Aid / Im Notfall - Erste Hilfe................................ .... ... ... ... .... ... ... .............. ..... 21
5 Basics ...................................................................................................................................................... ..... 23
5.1 Intended use of the machine .......................................................................................................... .... 23
5.2 Purpose of the manual and description of the definitions of the trained persons/operators/users . .... 23
5.2.1 Trained persons .............................................................................................................. .... 23
5.2.2 Operator/Owner ............................ ................................. ................................ ................. .... 23
5.2.3 User ................................. ................................................................. .............................. .... 24
5.3 Components of the i-system........................................................................................................... .... 24
5.4 Panda transport box ....................................................................................................................... .... 25
5.4.1 Bolted Fischer Panda transport box ........................................................................... ... . .... 25
5.4.2 Fischer Panda transport box with metal tab closure ....................................................... .... 26
5.5 Opening the MPL sound insulation capsule ................................................................................... .... 26
5.5.1 Opening the GFK sound insulation capsule ........................ ... ... .... ... ... ... .... ... ... ... ... ........ .... 27
5.6 Transport and loading/unloading.................................................................................................... .... 28
5.6.1 Transporting the generator ............................................................................................. .... 28
5.6.2 Loading/unloading of the generator ..... ... ... ... .............................................. ... ... ... ... .... ... . .... 28
5.7 Special service instructions and measures for extended machine downtimes and decommissioning 28
5.7.1 Instructions for the starter battery for extended downtimes ............................................ .... 29
5.7.2 Measures for short downtimes ....................................................................................... .... 29
5.7.3 Measures for medium term downtimes / hibernation ........................................ ... ... .... ... . .... 29
5.7.3.1 Courses for preservation:................................................................................. .... 30
5.7.3.2 Measures for removing surface protection after medium term downtimes (3 to 6 months). 30
5.7.4 Measures for extended downtimes / decommissioning .................................................. .... 31
5.7.4.1 Courses for preservation:................................................................................. .... 31
5.7.4.2 Measures for removing surface protection after extended downtimes / recommissioning
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Inhalt / Contens
(over 6 months): 31
5.8 ........................................................................................................................................................ .... 32
6 Panda 5000i PMS generator.................................................................................................................. ..... 33
6.1 Type plate at the generator............................................................................................................. .... 33
6.1.1 Right Side View .............................................................................................................. .... 34
6.1.2 Left Side View ................................................................................................................. .... 35
6.1.3 Front View ....................................................................................................................... .... 36
6.1.4 Back View ....................................................................................................................... .... 37
6.1.5 View from Above ............................................................................................................. .... 38
6.2 Details of function units........... ... ... .... ... ... ... .... .......................................... ... ... ................................. .... 39
6.2.1 Remote control panel - see iControl manual .................................................................. .... 39
6.2.2 Components of the Cooling System (Raw Water) .......................................................... .... 39
6.2.3 Components of the Cooling System (Fresh Water) ........................................................ .... 40
6.2.4 Components of the Fuel System .................................................................................... .... 41
6.2.5 Components of Combustion Air .................................. ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... . . ... 42
6.2.6 Components of the Electrical System ............................ ... ... .... ... ... ... ... .... ... .................... .... 43
6.2.7 Components of the Oil Circuit ................................. .... .......................................... ... ... ... . .... 44
6.2.8 Sensors and switches for operating surveillance ............................................................ .... 44
6.3 Operation Instructions - see separate control panel manual........................................................... ....46
6.3.1 Daily routine checks before starting - See iControl manual. ........................................... .... 46
6.3.2 Starting Generator - See iControl manual. ..................................................................... .... 46
6.3.3 Stopping the Generator - See iControl manual. .............................................................. .... 46
7 Installation Instructions.......................................................................................................................... .....47
7.1 Personal requirements......... ... ... ... .... ... ... ... .... .......................................... ... .................................... .... 47
7.1.1 Hazard notes for the installation ............................. .... ... ... ... .... ... ... ... ... .... ... ... ... .............. .... 47
7.2 Place of installation......................................................................................................................... .... 49
7.2.1 Preliminary remark .......................................................................................................... .... 49
7.2.2 Preparing the base - placement ...................................................................................... .... 49
7.2.3 Advice for optimal sound insulation ................................................................................ .... 50
7.3 Generator Connections................................................................................................................... .... 50
7.4 Installation of the cooling system - raw water ................................................................................. .... 51
7.4.1 General information ............................. ... ... .... ... ... ... .... ... .......................................... ... .... .... 51
7.4.2 Installation of the through hull fitting in Yachts - scheme ................................................ .... 51
7.4.3 Quality of the raw water sucking in line .......................................................................... .... 51
7.4.4 Generator installation above waterline ........................................................................... .... 52
7.4.5 Generator installation below waterline ..................................... ....................................... .... 52
7.4.5.1 Raw water installation scheme......................................................................... .... 53
7.5 Installation of the cooling system - fresh water............................................................................... .... 54
7.5.1 Position of the external cooling water expansion tank .................................................... .... 54
7.5.2 De-aerating at the first filling of the internal cooling water circuit ......... .... ... ... ... .... ... ... ... . .... 54
7.5.3 Pressure Test for Controlling the Cooling Water Circuit ................................................. .... 55
7.6.1 Installation of the standard exhaust system ................................ ... ... ... .... ... ... ... .... ... ... ... . .... 56
7.7 .Installation of the waterlock............................................................................................................ .... 56
7.7.1 Possible cause for water in the exhaust hose ................................................................ .... 57
7.7.1.1 Possible cause: exhaust hose.......................................................................... .... 57
7.7.1.2 Possible cause: cooling water hose ................................................................. .... 57
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7.7.2 Installation area of the waterlock .................................................................................... .... 57
7.7.3 The volume of the waterlock ................... ... ... .... ... ... ... ..................................................... .... 58
7.7.3.1 Ideal position of the waterlock............................... ... ... .... ... ... ... .... ... ... ... ... .... ... . .... 58
7.7.3.2 Example of the installation of the waterlock off-center and possible effects:... .... 60
7.8 Exhaust / water separator............................................................................................................... .... 61
7.9 Installation exhaust water separator............................................................................................... .... 62
7.10 Fuel system installation ....................... ... ... ... ... .... ... ... ... .... ... ... ................................................ ........ .... 63
7.10.0.1 The following items need to be installed: ......................................................... .... 63
7.10.1 Connection of the fuel lines at the tank .......................................................................... .... 64
7.10.2 Position of the pre-filter with water separator ................................................................. .... 65
7.11 Ventilating the fuel system.............................................................................................................. .... 65
7.12 Generator DC system installation................................................................................................... .... 66
7.12.1 Connection of the starter battery block ........................................................................... .... 66
7.12.2 Connection of the remote control panel - See Panda iControl panel manual ................. .... 69
7.12.3 Fuse ............................................................................................................................... .... 69
7.12.4 Installation of the iControl panel - See iControl Manual ................................................. .... 70
7.13 Generator AC System Installation .................................................................................................. .... 70
7.13.1 Installation PMGi inverter - See separate PMGi 5000 inverter manual .......................... .... 71
7.13.2 Power source selector .................................................................................................... .... 71
7.14 Checking and filling of the oil circuit........................................................................................ ........ .... 73
7.15 Isolation test......................................................................................................................... ........... .... 73
7.16 Initial operation ............................................................................................................................... .... 73
8 Maintenance Instructions....................................................................................................................... ..... 75
8.1 Personal requirements.................................................................................................................... .... 75
8.2 Personal requirements.................................................................................................................... .... 75
8.3 Hazard notes for the maintenance and failure................................................................................ .... 75
8.4 Environmental protection................................................................................................................ ... . 77
8.5 General maintenance instructions.................................................................................................. .... 77
8.5.1 Checks before each start ..................................... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ........... .... 77
8.6 Maintenance interval....................................................................................................................... .... 77
8.6.1 Check of Hoses and Rubber Parts in the sound insulated capsule ............ ... ... ... ... .... ... . .... 77
8.7 Oil Change Intervals ....................................................................................................................... ... . 78
8.8 Checking oil-level............................................................................................................................ .... 78
8.8.1 Refilling Oil ......... .... ... .......................................... ... ... .......................................... ........... .... 79
8.8.2 After the oil level check and refilling the oil .................................................................... . .... 79
8.9 Replacement of engine oil and engine oil filter............................................................................... .... 80
8.9.1 After the oil change ........................................................................................................ .... 82
8.10 Verifying the starter battery and (if necessary) the battery bank .................................................... .... 82
8.11.1 Exchange of the Fuel Filter ............................................................................................. .... 83
8.11.2 De-aerating the fuel system ............................................................................................ .... 83
8.11.3 Replacement of the air filter .......................... .... ... ... ... .... ... ... ... ... .... ... ... ... .... ... ... ... ... .... .... .... 84
8.12 De-aerating of the coolant circuit / freshwater ................................................................................ .... 85
8.13 The raw water circuit................................................................................................................... .... .... 85
8.13.1 Clean raw water filter ...................................................................................................... .... 85
8.13.2 Causes with frequent impeller waste .............................................................................. .... 85
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8.13.3 Replacement of the impeller ........................................................................................... .... 86
9 Generator Tables..................................................................................................................................... .....89
9.1 Cable cross section.... .......................................... ... ... .......................................... .... ... .................... .... 89
9.2 Diameter of conduits....................................................................................................................... .... 89
9.3 Technical Data................................................................................................................................ .... 89
9.4 Types of coil.................................................................................................................................... .... 90
9.5 Engine oil ........................................................................................................................................ .... 90
9.5.1 Engine oil classification ........... ... .... ... ... ... ... .... ... .......................................... ... ................. .... 90
9.5.1.1 Operating range: .............................................................................................. .... 90
9.5.1.2 Quality of oil:..................................................................................................... .... 90
9.6 Fuel................................................................................................................................................. .... 91
9.7 Coolant specifications..................................................................................................................... .... 91
9.7.1 Coolant mixture ratio ....................................................................................................... .... 93
9.8 Dimensions ..................................................................................................................................... .... 93
10 Tables....................................................................................................................................................... ..... 95
10.1 Troubleshooting .............................................................................................................................. .... 95
10.2 Technical data................................................................................................................................. .... 97
10.2.1 Technical Data Engine .................................................................................................... .... 97
10.3 Technical data................................................................................................................................. .... 97
10.4 Diameter of conduits....................................................................................................................... .... 98
10.5 Cable cross section........................... ... ... ... .......................................... .... ... ... ... ... .... ....................... .... 99
10.6 Engine oil ........................................................................................................................................ .... 99
10.6.1 Engine oil classification . .... .......................................... ... ... .............................................. .... 99
10.6.1.1 Operating range: .............................................................................................. .... 99
10.6.1.2 Quality of oil:..................................................................................................... .... 99
10.7 Coolant specifications..................................................................................................................... .. 100
10.7.1 Coolant mixture ratio ....................................................................................................... .. 101
10.8 Fuel................................................................................................................................................. .. 101
11 Inverter Panda PMGi .............................................................................................................................. ... 103
11.2 Type plate ............................................... ... .... ... ... ... ... .......................................... ........................... .. 104
11.3 Front side/connection side PMGi 230 V - representative picture.................................................... .. 105
11.4 Alternative front side/connection side PMGi 400 V - representative picture ................................... ..105
11.5 Alternative front side/connection side PMGi 120 V/240 V - representative picture........................ .. 106
11.5.1 Socket pins of the PMGi ................................................................................................. .. 106
11.5.1.1 PMGi AC out .................................................................................................... .. 106
11.5.1.2 PMGi input........................................................................................................ .. 107
11.5.1.3 Control.............................................................................................................. .. 108
11.5.1.4 External PE/N Bridge ............................................................................. .......... .. 108
11.6 Back side - Top side ..................... .... ... ... ... .... ... ... ... ... .... ... ... .......................................... ................. .. 109
11.7.1 Settings in the Victron VE Configure II Software - General ............................................ .. 110
11.7.1.1 Uninterrupted AC power (UPS function) ............................ ... .... ... ... ... .............. .. 110
11.7.1.2 Dynamic current limiter....... ... ... ... .... ... ... ... .... .......................................... ... ... .... .. 110
11.7.2 Settings in the Victron VE Configure II Software - Inverter ................................... ... ... .... .. 111
11.7.2.1 Assist current boost factor................................................................................ .. 111
11.8.1 Primary remarks / Winter operation ..................... ... .... .................................................... .. 112
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11.8.2 Load at the PMGi ........................................................................................................... .. 112
11.8.3 Automatic start ................................................................................................................ .. 112
11.9 Status LEDs.................................................................................................................................... .. 112
11.10 Cooling of the PMGi........................................................................................................................ .. 112
11.11.1 Cooling water connection schema - Vehicle Generator ................................................. .. 113
11.11.1.1Integration of a water cooled PMGi inverter into the cooling system. .............. .. 113
11.11.1.2Cooling water scheme if the Radiator is higher than the Generator /Inverter .. .. 114
11.11.1.3Cooling water scheme if the Radiator is on the same level or lower than the Generator /Inverter 114
11.11.1.4Cooling water scheme for PVK-UK iGenerators .............................................. .. 115
11.11.1.5Cooling water connection schema - Marine (PMS) Generator......................... .. 116
11.11.2 Electrical connection. ...................................................................................................... .. 117
11.11.2.1Connection to a system with RCD at PMGi with PEN jumper.. .... ... ... ... ... .... ... . .. 117
11.11.2.2Connection to a system with RCD at PMGi without PEN jumper..................... .. 117
11.11.2.3Connection to a system with isolation control at PMGi with PEN jumper ........ .. 118
11.11.2.4Connection to a system with isolation control at PMGi without PEN jumper ... .. 118
11.12 Technical Data................................................................................................................................ .. 118
11.12.1 General Data .................................................................................................................. .. 118
11.12.2 Generator Specification .................................................................................................. .. 118
11.13 PMGi protections............................................................................................................................ .. 125
11.13.1 Short circuit ..................................................................................................................... .. 125
Panda iControl2............................................................................................................................................ ... 127
Current revision status . ... ... .... .......................................... ... ... ... .... ... ... ........................................................ ... 128
Hardware....................................................................................................................................................... ... 128
12 Safety instructions for the Panda iControl2................................................. ... .... ... ... ... .... ... ... .............. ... 129
12.1 Personnel................................................................................................................................ ........ .. 129
12.2 Safety instructions .......................................................................................................................... .. 129
13 General operation ................................................................................................................................... ... 131
13.1 The Panda iControl2 panel..................................... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... .... .................... .. 131
13.2 Starting preparation / Checks (daily) .............................................................................................. .. 132
13.2.1 Marine version ................................................................................................................ .. 132
13.2.2 Vehicle version .......................... ... ... .......................................... .... ... .............................. .. 132
13.3 Operation........................................................................................................................................ .. 133
13.3.1 Switching the controller on and off ................................................................................. .. 133
13.3.2 The default display screen .............................................................................................. .. 133
13.3.3 Operating modes ............................................................................................................ .. 134
13.3.3.1 Stand-by mode............................ .......................................... ... .... ... ... ... ........... .. 134
13.3.3.2 Start-up mode ............................................. .... ... .......................................... ... . .. 135
13.3.3.3 Override mode ......................................... ... .... ... ... .......................................... . .. 136
13.3.3.4 Operation mode .............................................. ... ... ... ... .... ... ... ... .... ... ... ... ... ........ .. 136
13.3.3.5 Panda i-Generator with electro-magnet Clutch (optional)................................ .. 138
13.3.3.7 Autostart mode............................................................ .... ................................. . . 139
13.4.1 Set-up menu ................................................................................................................... .. 141
13.4.3 The configuration menu ("config") .................................................................................. .. 143
13.4.4 The network ID ............................................................................................................... .. 143
13.4.5 Saving settings and exiting the set-up menu ("Save & Exit") ......................................... .. 143
13.4.6 Activating/deactivating the autostart function ("Autostart") ............................................. .. 143
13.4.7 Resetting the service interval ("Service") ....................................................................... .. 145
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13.4.8 Priming the fuel system ("Prime Fuel") ........................................................................... .. 146
13.4.9 Selecting and saving a unit for the temperature value output ......................................... .. 146
13.5 iControl2-Emergency-Stop.............................................................................................................. .. 146
14 Installation ............................................................................................................................................... ... 149
14.1 Personnel........................................................................................................................................ .. 149
14.1.1 Hazard warnings for installation .................................. ... ... .............................................. .. 149
14.2 Disposal of the components............................................................................................................ .. 150
14.2.1 Panda iControl2 panel with installation housing ............................................................. .. 151
14.2.2 Terminal assignments on the Panda iControl2 panel ....................................... .... ... ... ... . .. 151
14.3 Dimensions ..................................................................................................................................... .. 152
14.4 Wiring of the Panda iControl2 controller ......................................................................................... .. 153
14.4.1 Terminal assignments on the Panda iControl2 controller ................................. .... ... ... ... . .. 154
14.4.1.1 Terminal assignment of 18-pin connector .... ... ... ... .... ... ... ... ... .... ... ... ................. .. 154
14.4.1.2 Fischer Panda standard bus ................................. .... ... ... ... ... ........................... .. 154
14.4.1.3 Fischer Panda CAN bus..... ... ... ... .... ... ... ........................................................... .. 154
14.5 Master and Slave Panels.................. ... ... .......................................... ... .... ....................................... .. 155
14.6 Start-up ........................................................................................................................................... .. 155
15 Maintenance ............................................................................................................................................ ...157
15.1 Maintenance of the iControl2 controller .......................................................................................... .. 157
15.1.1 Cleaning the iControl2 controller .................................................................................... .. 157
15.2 Maintenance of the iControl2 remote control panel ........................................................................ ..157
15.2.1 Cleaning the iControl2 controller .................................................................................... .. 157
16 Annex ....................................................................................................................................................... ... 159
16.1 Technical data................................................................................................................................. .. 159
16.1.1 Technical data for iControl2 control unit ........................................ ................................. .. 159
16.1.2 Technical data for iControl2 remote control panel .......................................................... .. 159
17 Warnings and error messages............................................................................................................... ... 161
17.1 Warnings......................................................................................................................................... .. 161
17.1.1 Examples of warnings on the display: ............................................................................ .. 161
17.2 Faults .............................................................................................................................................. .. 162
17.2.2 Warning and fault thresholds .......................................................................................... .. 163
17.2.3 Bus errors ....................................................................................................................... .. 164
17.3 The error memory of the iControl 2 Panel............ ... ... .... ... ... ........................................................... .. 164
17.3.1 How to get to the error memory of the iControl2 Panel? ................................................ .. 165
17.3.2 How are stored errors displayed? .............. ................................................. .................... .. 165
17.3.3 How do I exit the error memory after having read the entries? ....................................... .. 165
17.3.4 Can I delete the error memory? ...................................................................................... .. 165
17.3.5 Where are the errors stored? .......................................................................................... .. 165
17.3.6 In which language are the stored errors displayed? ....................................................... .. 165
17.3.7 Is it possible to upgrade an old iGenerator model by the error memory? ....................... .. 166
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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
14.7.16 Kapitel/Chapter 3: - Seite/Page 9
Page 10
General Instructions and Regulations

3. General Instructions and Regulations

3.1 Safety first!

These symbols are used throughout this manual and on labels on the machine itself to warn of the possibility of personal injury of lethal danger during certain maintenance work or operations. Read these instructions carefully.
WARNING: Hazardous materials Can cause acute or chronic health impairments or death even in very small quantities if inhaled, swallowed, or absorbed through the skin.
WARNING: Important information! This warning symbol draws attention to special warnings, instructions or procedures which, if not strictly observed, may result in damage or destruction of equipment.
ignition source (cigarettes, hot surfaces, sparks, etc.).
smoking is prohibited.
avoided.
is in progress.
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 3: General Instructions and Regulations 14.7.16
Page 11
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.
14.7.16 Kapitel/Chapter 3: General Instructions and Regulations - Seite/Page 11
Page 12
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.

3.2 Tools

These symbols are used throughout this manual to show which tool must be used for maintenance or installation.
Spanners W.A.F X = width across flats of X mm
Hook wrench for oil filter
Screw driver, for slotted head screws and for Phillips head screws
Multimeter, multimeter with capacitor measuring unit
Seite/Page 12 - Kaptitel/Chapter 3: General Instructions and Regulations 14.7.16
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
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General Instructions and Regulations
3.3 Manufacturer declaration in accordance with the Machinery Directive
2006/42/EC
Manufacturer declaration in accordance with the Machinery Directive 2006/42/EC The generator was designed in such a way that all assemblies correspond with the CE guidelines. If Machinery
Directive 2006/42/EC is applied, then it is forbidden to start the generator until it has been ascertained that the system into which the generator is to be integrated also complies with the Machinery Directive 2006/42/EC. This includes the exhaust system, cooling system and electrical installations.
The evaluation of “protection agai nst contact“ must be carried out when installed, in conjunction with the respective system. This also includes correct electrical connections, a safe ground wire connection, foreign body and humidity protection, protection against moisture due to excessive condensation, as well as overheating through appropriate and inappropriate use of the equipment in its installed state. The responsibility for implementing these measures lies with those who undertake the installation of the generator in the final system.

3.4 Customer registration and guarantee

Use the advantages of registering your product:
• you will receive a Guarantee Certificate after approval of your installation data
• you will receive extended product information that may be relevant to safety.
• You will receive free upgrades as necessary. Additional advantages: Based on your complete data record, Fischer Panda technicians can provide you with fast assistance, since 90 % of
the disturbances result from defects in the periphery. Problems due to installation errors can be recognized in advance.

3.4.1 Technical support

Technical Support via the Internet: [email protected]

3.4.2 Caution, important information for start-up!

1. The commissioning log shall be filled in immediately after initial operation and shall be confirmed by signature.
2. The commissioning log must be received by Fischer Panda GmbH at Paderborn within 4 weeks of initial
operation.
3. After receiving the commissioning log, Fischer Panda will make out the 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

3.5 Safety Instructions - Safety First!

3.5.1 Safe operation

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

3.5.2 Observe safety instructions!

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

3.5.3 Personal protective clothing (PPE)

For maintenance and repair work on the equipment, do not wear loose, torn, or ill-fitting clothing that may catch on protruding parts or come into 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.

3.5.4 Cleanliness ensures safety

Keep the generator and its environment clean. Before cleaning the generator, shut down the equipment and secure it against accidental start-up. Keep
the generator free from dirt, grease, and waste. Store flammable liquids in suitable containers only and ensure adequate distance to the generator. Check the lines regularly for leakage and eliminate leaks immediately as applicable.
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General Instructions and Regulations

3.5.5 Safe handling of fuels and lubricants

Keep fuels and lubricants away from naked fire. Before filling up the tank and/or applying lubricant, always shut down the generator and secure it against
accidental start-up. Do not smoke and avoid naked flame and sparking 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.

3.5.6 Exhaust fumes and fire protection

Engine fumes can be hazardous to your health if they accumulate. Ensure that the generator exhaust fumes are vented appropriately (leak-proof system), and that an 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

3.5.7 Safety precautions against burns and battery explosions

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

3.5.8 Protect your hands and body from rotating parts!

Always keep the capsule closed while operating the generator. To check the V-belt tension, always shut down the generator. Keep your hands and body away from rotating parts such as V-belt, fans, pulleys, and flywheel. Contact
can cause severe injury. Do not run the engine without the safety devices in place. Prior to start-up, mount all safety devices securely and
check for proper attachment and function.

3.5.9 Anti-freeze and disposal of fluids

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

3.5.10 Implementation of safety inspections and maintenance

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

3.6 Warning and instruction signs

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

3.6.1 Special instructions and hazards of generators

The electrical installations may only be carried out by trained and qualified personnel!
The generator must not be operated with the cover removed.
If the generator is being installed without a sound insulation capsule, it must be ensured that all rotating parts (belt-pulley, belts etc.) are covered and protected so that there is no danger to life and body!
If a sound insulation covering will be produced at the place of installation, then easily visible signs must show that the generator must only be switched on while the capsule is closed.
All servicing, maintenance, or repair work may only be carried out when the motor is not running. Electrical voltages above 60 volts are always dangerous to life. The rules of the respective regional
authority must be adhered to during installation. Fo r safety rea sons, only an elec tricia n ma y carry out the in stallation of the electrical connections of the generator.
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General Instructions and Regulations
3.6.1.1 Protective conductor and potential equalisation:
Electric voltage above 60 V may be life-threatening. Fort this reason systems are grounded with a protective conductor. In connection with a RCD the current supply will be disconnected in case of a failure.
Appropriate safety precautions like the RCD and corresponding fuses have to be provided by the customer to guarantee a save operation of the generator.
3.6.1.2 Protective conductor for Panda AC generators:
The generator is earthed“ as a standard (centre and gr ou nd are inte rcon nected in the generator ter mina l 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.
3.6.1.3 Switch off all loads while working on the generator
All loads must be disconnected prior to working on the generator to avoid damage to the devices. In addition, the semiconductor relays in the AC control box must be disconnected in order to avoid the booster capacitors being activated during set-up. The negative te rminal of the battery must be disconnected.
Capacitors are required to run the generator. These have two varying functions: A) The working capacitors B) The booster capacitors Both groups are located in a separate AC control box. Capacitors store electrical energy. High voltages may remain across the capacitor contacts even after th ey have
been disconnected from the mains. As a safety precaution, do not touch the contacts. If the capacitors must be replaced or inspected, the contacts shall be short-circuited by connecting an electrical conductor to discharge potentially remaining potential differences.
If the generator is switched off normally, the working capacitors are automatically discharged via the winding of the generator. The booster capacitors are discharged by means of internal discharge resistors.
For safety reasons, all capacitors must be discharged through short-circuiting before work is carried out on the AC control box.
3.6.1.4 Potential equalisation for Panda AGT DC generators
For further information specific to your generator, see the chapter installation.
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General Instructions and Regulations
3.6.1.5 Safety instructions concerning cables
Cable types
It is recommended to use cables that are in compliance with the standard UL 1426 (BC-5W2) with type 3 (ABYC section E-11).
Cable cross-section
The cable shall be selected taking into account the amperage, cable type, and conductor length (from the positive power source connection to the electrical device and back to the negative power source conn ection).
Cable installation
It is recommended to install a self-draining cable conduit classified as V-2 or higher in compliance with UL 94 in the area of the cable guide inside the capsule. It must be ensured that the cable guide is not routed along hot surfaces such as the exhaust manifold or the engine oil drain screw but instead is installed free from any influence due to friction and crushing.

3.6.2 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 ba tt er y.
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 n ot suitable. Lead-acid gel batteries
are recommended. They are maintenance-free, cycle stable, and do not release gases.
• Never charge a frozen battery.
• Avoid battery short-circuits.
• Ensure proper ventilation of the battery to vent gases that may be released.
• Battery connection terminals must be checked for proper seating before operation.
• Battery connection cables shall be installed with utmost care and shall be checked for excessive heating
under load. Check the battery near vibrating components regularly for chafing and insulation defects.
ATTENTION! For battery charger generators (Fischer Panda AGT- DC)! Prior to installation, verify that the voltage of the battery bank complies with the output voltage of
the generator.
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In case of Emergency First Aid / Im Notfall -
11
1
2
1
3
1
4
1
5
Erste Hilfe

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

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

Warning:DO NOT attempt to perform the rescue breathing techniques provided on this page, unless certified. Performance of these techniques by uncertified personnel could result in further injury or death to the
victim.
In case of Emergency First Aid / Im Notfall -
Erste Hilfe
Does the Person Respond?
1
Tap or gently shake victim. Shout, “Are you OK?“
Roll Person onto Back.
3
Roll victim towards you by pulling slowly.
Open Airway.
4
Tilt head back, and lift chin. Shout, “Are you OK?“
Give 2 Full Breaths.
6
Keep head tilted back. Pinch nose shut. Seal your lips tight around victim's mouth. Give 2 full breaths for 1 to 1½ seconds each.
Shout, “Help!“
2
Call people who can phone for help.
Check for Breathing.
5
Look, listen, and feel for breathing for 3 to 5 seconds.
Check for Pulse at side of Neck.
7
Feel for pulse for 5 to 10 seconds.
Begin Rescue Breathing.
9
Keep head tilted back. Lift chin. Pinch nose shut. Give 1 full breath every 5 seconds. Look, listen, and feel for breathing between breaths.
Phone EMS for Help.
8
Send someone to call an ambulance.
Recheck Pulse Every Minute.
10
Keep head tilted back. Feel for pulse for 5 to 10 seconds. If victim has pulse, not breathing, continue
rescue breathing. If no pulse, begin CPR.
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Basics

5. Basics

5.1 Intended use of the machine

The Fischer Panda generator is made to produce electrical energy out of diesel fuel. The diesel fuel is converted to mechanical energy by the diesel engine. This mechanical energy drives the
generator. In the genset, the mechanical energy is converted to electrical energy. This process is controlled by (sometimes external) components, the remote control panel and the VCS (voltage control system).
Sufficient amount of fuel and combustion air is necessary for this process. Arising exhaust and heat must be conducted according to the specification.
If the electrical power is fed to a local net, the regulations and installation instructions of the system operator and the regional authorities with reference to the power network/shipboard power supply system must be respected. Safety applications and safety devices (including lightening conduc tor, personal protection switch, ect.) have to be installed.
Misapplication of the product can damage and destroy the product and the electrical net inclusive all load which is attached to the net, and contain hazards like short circuit, ect. It is not allowed to modify the product in any ca se. Never open the sound cover during operation! The safety and hazard notes of the manual must be respected !

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

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

5.2.1 Trained persons

Qualified persons for the mechanical components are motor mechanics or persons with similar qualification and training.
Trained persons for the electrical components are electricians or persons with similar qualification and training.
After the installation the trained person has to instruct the operator/owner about the operation and maintenance of the generator. This must include the hazards of the generator use.

5.2.2 Operator/Owner

The operator is responsible for the operation of the generator.
After the installation, the operator/owner must be instructed concerning the operation and maintenance of the generator. This has to include the hazards during operation of the generator, different operating conditions, and instructions for the maintenance.
The operator/owner must read and follow the manual and must respect the hazard notes and safety instructions.
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Basics

5.2.3 User

Users are persons, established by the operator/owner, to operate the generator.
The operator/owner has to ensure that the user has read and understood the manual and that all hazard notes and safety instructions are respe cted. The user must be instructed by the operator/owner regarding his activity at the generator, especially concerning the maintenance.

5.3 Components of the i-system

Fig. 5.3-1: Panda i generator1. Panda i-generator
Permanent magnet generator
generator
Fig. 5.3-2: iControl panel2. Panel Panda iControl with electronic board at the
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Basics
Fig. 5.3-3: PMGi inverter3. Panda PMGi inverter AC/AC
Fig. 5.3-4: Manual4. Fischer Panda manual
The Fischer Panda manual contains the following components:
• Transparent sheet with general information, guarantee
conditions, installation inspection, and service list.
• Generator manual
• Spare parts catalogue „Installation & Service Guide“
• Engine manual from the engine manufacturer
• Wirin g dia gr a m of the ge n er at or
Optional components Optional components could be for example:
• fuel pump
• installation kits

5.4 Panda transport box

5.4.1 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
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5.4.2 Fischer Panda transport box with metal t ab 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 at the bottom of the transport box
5. Remove the sidewalls
6. Open the generator attachment

5.5 Opening the MPL sound insulation capsule

Fig. 5.5-1: Sound insulation capsule, side partT o open the sound insulation cap sule, the clo sures must
be rotated roughly 180° counter-clockwise. Use a flat head screwdriver . Pull th e sidewalls out by g rip ping into the slots.
Basics
Fig. 5.5-2: Closure lockedClosure locked
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Basics

5.5.1 Opening the GFK sound insulation capsule

Fig. 5.5-3: Closure openClosure open
direction and lift the lash of the closure pin. After lifting off the lashes, the sound isolation cover upper part can be removed.
Fig. 5.5-1: Lash closuresGFK sound insulation capsule with lash closures
Fig. 5.5-2: Lash closuresTo open the lash closures pull the handle in arrow
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Basics

5.6 Transport and loading/unloading

5.6.1 Transporting the generator

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

5.6.2 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.
Fig. 5.6.2-1: Lifting yoke (example)An adequate lifting yoke shall be used for transport/
loading.
5.7 Special service instructions and measures for extended machine
downtimes and decommissioning
Note: The decommissioning and storage mu st be un de rtaken and
proved regarding the operation and storage situation.
Fischer Panda takes no responsibilty for damages through wrong decommissioning and storage.
Downtimes are categorised in the following groups:
• Short downtime (1 to 3 months)
• Medium term downtime / hibernation (3 to 6 months)
• Extended downtime / decommissioning (more than 6 months)
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Basics

5.7.1 Instructions for the starter battery for extended downtimes

Note: Information starter batteryStarter batteries
Self-discharge of batteries is a physical and chemica l process and cannot be avoided even if the battery is disconnected
• For extended downtimes, the battery shall be disconnected from the genset.
• Charge battery regularly. Observe instructions of the battery manufacturer. Depending on the battery type, check the acid level before charging and refill each cell up to the marking using
distilled water as necessary. Modern starter batteries are typically maintenanc e- fr ee .
Deep discharge will damage the battery and can render it unusable.
Keep battery clean and dry. Clean battery poles (+ and -) and terminals regularly and coat with acid-free and acid­resistant grease. During assembly, ensure good contact of the terminal connections.
General limits for lead-acid batteries:
2.1 V / cell corresponds with full battery (charged).
1.95 V / cell corresponds with empty battery - recharge. For a 12 V battery, the following applies:
- 11.7 V lower open-circuit voltage (battery empty), recharge battery.
- 12.6 V upper open-circuit voltage (full battery) - trickle charge full battery at 13.2 V. For a 24 V battery, the following applies:
- 23.4 V lower open-circuit voltage (battery empty), recharge battery.
- 25.2 V upper open-circuit voltage (full battery) - trickle charge full battery at 26.4 V.
These values are based on a battery temperature of 20-25°C. Observe the instructions from the battery manufacturer.
Note: Starter battery recommendationFischer Panda recommends:
• Install battery circuit breaker and switch to OFF on the machine. (Cutting the battery circuit.)
• Secure the battery plus terminal close to the battery.
• Regularly check contacts for corrosion.

5.7.2 Measures for short downtimes

Short downtime (1 to 3 months)
• Measure battery charge status based on open-circuit voltage.
• During downtimes >7 days, disconnect battery (e.g. battery main switch to position 0).
• Check the battery within 2 months and allow the engine to warm up for min. 10 min.
• Fill fuel tank to 100% (level to full).

5.7.3 Measures for medium term downtimes / hibernation

Medium term downtimes (3 to 6 months)
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Basics
5.7.3.1 Courses for preservation:
• Check battery charge status and recharge regularly, roughly every 2 months, as necessary. Observe instructions of the battery manufacturer.
• Check cooling water anti-freeze level and refill as necessary.
The anti-freeze agent must not be older than 2 years. The anti-freeze conte nt shall be between 40 % and 60 % to ensure corrosion protection of the cooling water circuit. Top off coolant if necessary.
If the cooling water is drained, e.g. after engine surface protection is applied, no water may remain inside the engine during the downtime. The control unit must be marked accordingly with a note specifying “NO COOLING WATER“.
• Drain engine oil as specified. Refill engine with preservative oil to the max. level on the oil dipstick.
• Drain diesel from tank and refill with a protective mixture (90 % diesel and 10 % preservative oil) (level to full).
Crank engine without start.
• Dismount V-belt as specified, wrap and store in a dry location. Protect against UV radiation.
Attention! Cover alternator apertures.
Cleaning fluids and preservatives must not enter the alternator. Risk of destroying the alternator.
• Clean engine as per manufacturer's instructions.
• Spray engine parts and V-belt disks with preservative.
• Clean air filter housing and spray with preservative (metal housing only).
• Close off intake and exhaust apertures (e.g. with tape or end caps).
Attention! Before recommissioning, remove preservatives and
protective measures.
5.7.3.2 Measures for removing surface protection after medium term downtimes (3 to 6
months).
• Check battery charge status and recharge if necessary. Observe instructions of the battery manufacturer.
• Check cooling water anti-freeze level and cooling water level and refill as necessary.
• Drain engine oil. Replace oil filter and engine oil as per the specification.
• Remove preservatives from the engine with petroleum spirit.
• Degrease V-belt disks and mount V-belt according to instructions. Check V-belt tension!
• If applicable, open turbocharger oil pressure line and fill clean engine oil into channel.
• Hold engine stop lever in zero delivery position and crank engine manually several times.
• Clean air filter housing with petroleum spirit, check air filter and replace if necessary.
• Remove covers from exhaust aperture and intake apertures.
• Connect battery. Close battery main switch.
• Hold stop lever on generator motor in neutral position and crank starter for approx. 10 seconds. Then, pause for 10 seconds. Repeat this procedure 2 times.
• Perform visual check of the generator similar to initial commissioning and start up generator.
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Basics

5.7.4 Measures for extended downtimes / decommissioning

Downtimes (more than 6 months)
5.7.4.1 Courses for preservation:
• Check battery charge status and recharge regularly, roughly every 3 months, as necessary. Observe instructions of the battery manufacturer.
• Check cooling water anti-freeze level and refill as necessary.
The anti-freeze agent must not be older than 2 years. The anti-free ze content shall be betwe en 40 % and 60 % to ensure corrosion protection of the cooling wa ter ci rcu it. Top off coolant if necessary.
If the cooling water is drained, e.g. after engine surface protec tion is applied, no water may rema in inside the engine during the downtime. The control unit must be marked accordingly with a note specifying “NO COOLING WATER“.
• Drain engine oil as specified. Refill engine with preservative oil to the max. level on the oil dipstick.
• Drain diesel from tank and refill with a protective mixture (90 % diesel and 10 % preservative oil) (level to full).
Crank engine without start.
• Dismount V-belt as specified, wrap and store in a dry location. Protect against UV radiation.
• Disconnect battery. Coat terminals with acid-free grease.
Attention! Cover alternator apertures.
Cleaning fluids and preservatives must not enter the alternator. Risk of destroying the alternator.
• Clean engine as per manufacturer's instructions.
• Spray engine parts and V-belt disks with preservative.
• Clean air filter housing and spray with preservative (metal housing only).
• Spray preservative on intake and exhaust side of exhaust turb ocharger (where applicable) and re connect the lines.
• Remove valve cover and spray inside of valve cover, valve stems, springs, rocker, etc. with preservative oil.
• Remove injection nozzle and coat cylinder surface with preservative oil. Hold stop lever in zero delivery position and crank engine manually several times. Refit injection nozzles with new seals (at an operation hour of min. 100 hours after the last change). Observe torque values.
• Spray radiator cover and tank cover or radiator cover on expansion tank lightly with preservative oil and refit.
• Close off intake and exhaust apertures (e.g. with tape or end caps).
Note: For storage for more than 12 months, the preservation measures shall be checked annually and supplemented as necessary.
Attention! Before recommissioning, remove preservatives and protective measures.
5.7.4.2 Measures for removing surface protection after extended downtimes /
recommissioning (over 6 months):
• Check battery charge status and recharge if necessary. Observe instructions of the battery manufacturer.
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Basics
• Check cooling water anti-freeze level and cooling water level and refill as necessary.
• Drain engine oil. Replace oil filter and oil as per the specification.
• Remove preservatives from the engine with petroleum spirit.
• Degrease V-belt disks and mount V-belt according to instructions. Check V-belt tension!
• If applicable, open turbocharger oil pressure line and fill clean engine oil into channel.
• Hold engine stop lever in zero delivery position and crank engine manually several times.
• Clean air filter housing with petroleum spirit, check air filter and replace if necessary.
• Remove covers from exhaust aperture and intake apertures.
• Connect battery. Close battery main switch.
• Hold stop lever on generator motor in neutral position and crank starter for approx. 10 seconds. Then, pause for 10 seconds. Repeat this procedure 2 times.
• Perform visual check of the generator similar to initial commissioning and start up generator.
Note: Fischer Panda recommends:
After extended downtimes, a full 150 h inspection as per the inspection list should be performed.
5.8
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Panda 5000i PMS generator

6. Panda 5000i PMS generator

6.1 Type plate at the generator

Fig. 6.1-1: Type plate
Fig. 6.1-2: Discription type plate
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Description of the Generator

01
03
04
06
10
05 09
11
08
07
02
01) Housing with iControl electronic board (DO NOT OPEN)
02) Coolant pipe, raw water pump - heat exchanger
03) Toothed belt
04) Raw water pump
05) Type Plate
06) Sound cover base part
07) Passage for battery cable (+)
08) Passage for battery cable (-)
09) Raw water inlet
10) Engine Kubota EA300
11) Generator housing with coil

6.1.1 Right Side View

Panda 5000i PMS generator
Fig. 6.1.1-1: Right side view
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Panda 5000i PMS generator
01
12
06
05
11
13
02
04
03
07
08 1009
01) Generator housing with coil
02) Water-cooled exhaust elbow
03) Raw water injection pipe
04) Coolant pipe, water tank - heat exchanger
05) Connection external ventilation valve
06) Sound cover base part
07) Engine Kubota EA300
08) Injection nozzle
09) Coolant pipe, water pump - engine
10) Coolant water pump
11) Suction port at air suction housing
12) Cooling water tank
13) Cooling water filler neck

6.1.2 Left Side View

Fig. 6.1.2-1: Left side view
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6.1.3 Front View

13
14
01
09
08
07
06
05
11
10
02
03
04
12
01) Solenoid switch for starter motor
02) Starter motor
03) Actuator
04) Housing with iControl electronic board „DO NOT OPEN“
05) Raw water pump
06) Pulley
07) Ground connection terminal
08) Oil dipstick
09) Engine oil filler neck
10) Oil drain hose
11) Fuel solenoid valve
12) Fuse 30A
13) Air suction housing with air filter inlet
14) Suction port
Panda 5000i PMS generator
Fig. 6.1.3-1: Front side view
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Panda 5000i PMS generator
19
16
15
14
10
13
12
07
06
05
04
03
02
01
11 091808
17
01) Housing with iControl electronic board „DO NOT OPEN“
02) Generator front cover
03) Generator housing with coil
04) Starter motor
05) Cooling water filler neck
06) Cooling water tank
07) Coolant pipe, water pump - engine
08) Connection external ventilation valve
09) Raw water injection nozzle
10) Exhaust outlet (through capsul bottem)
11) Exhaust elbow
12) Connection for fuel OUT
13) Connection for fuel IN
14) FP bus cable to PMGi
15) Cable for fuel pump
16) Cable for iControl
17) Cable for PMGi
18) Sound cover base part
19) Raw water inlet

6.1.4 Back View

Fig. 6.1.4-1: Back side view
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Page 38

6.1.5 View from Above

01
13 07 06
04 05
02
11
09
08
10
03
12
01) Cooling water filler neck
02) Connection external ventilation valve
03) Cooling water tank
04) Exhaust out (through capsul bottem)
05) Generator housing with coil
06) iControl electronic board under cover „DO NOT OPEN“
07) Pulley
08) Starter motor
09) Fuel solenoid valve
10) Solenoid switch for starter motor
11) Air suction housing with air filter inlet
12) Coolant overflow hose
13) Suction port
Panda 5000i PMS generator
Fig. 6.1.5-1: Top side view
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Panda 5000i PMS generator
Ex pans ions t ank wit h
fillercap
Heatex changer
Freshwat er s ide
elect . Waterpump
Engine K ubota E A 300
W atercooled exhaus telbow
Overflow hose
Overpress ure valve
in fillercap
Thermosens or
at Engine
Thermosens or
at exha us telbow
iControl elekt ronic board
cooled
side
hot
side
coolant
Heatexchanger
Seewater s ide
Seewater
Impellerpump
Seewater
external
ventilat ion valve
Ex hau st/ Water
out
Water injec.
in exhaus t hos e

6.2 Details of function units

6.2.1 Remote control panel - see iControl manual
6.2.2 Components of the Cooling System (Raw Water)
Fig. 6.2.2-1: Cooling System (Raw Water)
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Page 40
6.2.3 Components of the Cooling System (Fresh Water)
Ex pans ions t ank wit h
fillercap
Heatex changer
Freshwat er s ide
elect . Waterpump
Engine K ubota E A 300
W atercooled exhaus telbow
Overflow hose
Overpress ure valve
in fillercap
Thermosens or
at Engine
Thermosens or
at exha us telbow
iControl elekt ronic board
cooled
side
hot
side
coolant
Heatexchanger
Seewater s ide
Seewater
Impellerpump
Seewater
external
ventilat ion valve
Ex hau st/ Water
out
Water injec.
in exhaus t hos e
Fig. 6.2.3-1: Cooling System (Fresh Water)
Panda 5000i PMS generator
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Panda 5000i PMS generator
ext ernal Tank
ext ernal elec. fuelpump
fuel stop s olonoid
fuel injection noz z le
fuel
in
fuel
out
air filt er housing
engine
Kubot a EA 300
exhaus t elbow
glow
plug
automat ic venting
filler cap with strainer
inject ion pump
Fuel filter +
wat er se pe rat o r
fuel in
exhaust
out
combustion
air in
6.2.4 Components of the Fuel System
Fig. 6.2.4-1: Components of the Fuel System
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6.2.5 Components of Combustion Air
ext ernal Tank
ext ernal elec . fuelpum p
fuel stop solonoid
fuel injection nozz le
fuel
in
fuel
out
air filter housi ng
engine
Kubot a EA 300
exhaus t elbow
glow
plug
automat ic venting
filler cap with strainer
injection pump
Fuel filter +
water seperator
fuel in
exhaust
out
combustion
air in
Fig. 6.2.5-1: Components of Combustion Air
Panda 5000i PMS generator
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Panda 5000i PMS generator
6.2.6 Components of the Electrical System
Fig. 6.2.6-1: Components of the Electrical System
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6.2.7 Components of the Oil Circuit
oil filler cap
engine
Kubot a E A 300
oil s trainer
oil dipst ic k
oil
press ure
switch
oil drain hose
iControl elect ronic board
operator co ntrol
oil in
oil
out
Fig. 6.2.7-1: Components of the Oil Circuit
Panda 5000i PMS generator
6.2.8 Sensors and switches for operating surveillance
The thermo-switch at the engine is used for monitoring the engine temperature.
Fig. 6.2.8-1: Thermo.switch at engineThermo-switch at engine
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Panda 5000i PMS generator
1
2
3
If the impeller pump drops out and deliveres no more seawater, the exhaust connection becomes extremely hot.
Fig. 6.2.8-2: TThermo-switch at exhaust connectionThermo-switch at exhaust connection
Fig. 6.2.8-3: Thermo-switch coilThermo-switch coil
One thermo sensor is located in the stator winding
In order to be able to monitore the lubricating oil system, an oil pressure switch is built into the system.
Fig. 6.2.8-4: Oil pressure switchOil pressure switch
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Panda 5000i PMS generator

6.3 Operation Instructions - see separate control panel manual

6.3.1 Daily routine checks before starting - See iControl manual.
6.3.2 Starting Generator - See iControl manual.
6.3.3 Stopping the Generator - See iControl manual.
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Installation Instructions

7. Installation Instructions

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 should be 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.
Attention!: Adapt system correctly.All connections (hoses, wires etc.) and installation

7.1 Personal requirements

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

7.1.1 Hazard notes for the installation

Notice:Follow the general safety instruction at the front of this
manual.
.Warning!: Automatic startDANGER TO LIFE! - Incorrect handling may lead to
health damage and to death.
Always disconnect the battery bank (first negative terminal than positive terminal) before you work at the generator or the electric system of the generator so that the generator may not be started unintentionally.
Warning!: Risk of injuryImproper installation can result in severe personal
injuries or material damage. Therefore:
• Always undertake installation work when the generator is switched off.
• Ensure there is sufficient installation clearance before start working.
• Ensure tidiness and cleanliness at the workplace. Loose components and tools lying around or on top of each other are sources of accidents.
• Only perform installation work using commercially available tools and special tools. Incorrect or damaged tools can result injuries.
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Page 48
sources. Therefore:
• No open flames during work on the generator.
• Do not smoke.
• Remove oil and fuel residues from the generator and floor.
damage to health. Therefore:
• 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.
severe personal injury and death.
Installation Instructions
Warning!: Danger of fire Oil and fuel vapours can ignite at contact with ignition
Danger!: Danger of poisoningContact with engine oil, antifreeze and fuel can result in
Attention!: Danger to Life - High voltageDANGER TO LIFE! - Improper handling can result in
Electrical voltages above 60 volts (battery chargers greater than 36 volts) are always dangerous to life. The rules of the respective regional authority must be adhered to. Only an electrician may carry out installation of the electrical connections for safety reasons.
operation. Risk of severe burns!
During operation an over pressure in the cooling system may be established.
Improper handling can lead to heating of the batteries and bursts. Corrosive acids and bases may leak. Under bad conditions it may lead to an explosion.
Consider the instructions of the battery manufacturer.
During installation/maintenance personal protective equipment is required to minimize the health hazards:
• Protective clothing
• Safety boots
Warning!: Hot surface/materialGenerator, oil and antifreeze can be hot during/after
Warning: Danger of chemical burnsBatteries contain corrosive acids and bases.
Instruction!: Personal protective equipment necessary
• Protective gloves
• Ear defender
• Safety glasses
Attention!: Disconnect all load.Disconnect all load during the work at the generator to
avoid damages at the load.
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Installation Instructions

7.2 Place of installation

7.2.1 Preliminary remark

• There must be sufficient fresh air supply for the combustion air.
• It has to be ensured that the cooling air supply from underneath or sidewise is sufficient.
• During operation the sea cock has to be opened.
• The generator may only be opened by a technical trained person.
• The generator may only be operated by a trained person.

7.2.2 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. plywood). This acts as an amplifier of airborne sounds in the most unreasonable case. An improvement can be achieved by reinforcing these sur faces 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.
As the generator sucks in its combustion air via several drill holes in the capsule base, the capsule base must be installed with sufficient space to the basement so that the air supply is guaranteed (at least 12 mm/½“)
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.
The Power out of the generator based on the following data: Ambient temperature: 20°C Air pressure: 1000mbar (100m above normal Zero) Raw water temperature: 20°C Rel. áir moisture: 30% reg. the ambient temper a tur e Fuel temperature: bis zu 20°C Exhaust backpressure: 80mbar (at the exhaust out of the sound isolation cover) Any differents to this data, for example an ambient temperature of 40°C because of the build inside a maschine
room/vehicle with a bad ventilation, will cause in a lower Power out (Derating).
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Page 50

7.2.3 Advice for optimal sound insulation

1
2
3
4
5
6
7
8
9
10
11
1. Raw water intake
2. Fuel intake from tank to generator
3. Fuel return from generator to tank
4. Electrical line for fuel pump
5. Engine oil drain hose
6. Electrical line for remote control panel
7. Electrical cable for AC control box (VCS-control)
8. Electrical cable for AC control box (230V und 400V)
9. Generator AC-output
10. Generator starter battery negative cable (-)
11. Generator starter battery positive cable (+)
Example - see section 5.2 for detailed information
which the generator is fastened by means of shock­mounts. Since the aggregate is „free“ downwards, the combustion air can be sucked in unhindered. In addition the vibrations are void which would arise with a closed capsule base.
Installation Instructions
Fig. 7.2.3-1: Generator baseThe convenient base consists of a stable framework, on

7.3 Generator Connections

Sample for the connection at the Fischer Panda generator. See the description of the genera to r for the or iginal loca­tion.
All electrical wires are connected within the capsule tightly to the motor and the generator. This is also the case for fuel lines and cooling water lines.
The electrical connections MUST be carried out according to the respective valid regulations. This also concerns used cable materials. The cable supplied is meant for laying „protected“ (i.e. in pipe) at a temperature up to a max of. 70 °C (160 °F). The on-board circuit must also be fitted with all essential fuses.
ATTENTION! Before working (installation) on the System read the
section „Safety Instructions“ in this manual.
Fig. 7.3-1: Connection at the Generator - sample
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Installation Instructions
1
2
1) External cooling water expansion tank
2) External ventilation valve
Example - see section 5.2 for detailed information
Fig. 7.3-2: Connection at the Generator - sample

7.4 Installation of the cooling system - raw water

7.4.1 General information

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

7.4.2 Installation of the through hull fitting in Yachts - scheme

Fig. 7.4.2-1: Position of the through hull fitting 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 sa iling direction to induce more water intake for cooling.
For 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.

7.4.3 Quality of the raw water sucking in line

In order to keep the suction resistance in the line at a minimum, the raw water intake system must have an inner 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,
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Installation Instructions
as well as the necessary cross section of the coo ling water pipe s ee sect ion 9.7, “Diameter of conduits,” on page 117

7.4.4 Generator installation above waterline

The Panda is equipped with a water intake pump mounted 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 ho se should form a loop as near as possib le 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.With the installation of a non return valve in the raw water inlet line, which is under the waterline, this problem can be restricted.
When starting the generator you should always consider when raw water runs out of the exhaust system. If this takes longer than 5 seconds you should replace the impeller pump because it sucks in air for too long before it delivers raw water. The impeller has lost its effect and cannot suck in raw water anymore. This results to an overheating of the motor. If the impeller is not exchanged early enough the impeller blades may break into pieces and plugging the cooling water cycle. It is very important to exchange the impeller after a couple of months.
generator installed too high above the water line a electrical pump can be installed into the raw water line. In this case the impeller should be removed out of the impeller pump.
Contact Fischer Panda for further information.
exchanging the old pump. If the sealing ring is defective within the pump, raw water runs into the sound cover of the genset. A repair is then very expensive.
Replacement impeller and also a spare pump should always be on board. The old pump can be sent back to Fischer Panda for cost-effective repair.

7.4.5 Generator installation below waterline

above the waterline, a vent valve must be installed at the raw water line.
Possible heeling must be taken into consideration if installed at the "mid-ship line"! The water hose for the external vent valve is located at the back of the sound insulated capsule. 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, 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. If the valve jams the cool water line cannot be de-aerated after stopping the generator, the water column is not discontinued and water can penetrate into the combustion chamber of the engine. This will lead to damage the engine in a short term!
NOTE:If the raw water line is too long for the impeller pump or the
NOTE:Never change the impeller for many years, without
Fig. 7.4.5-1: Vent valveIf the generator cannot be attached at least 600 mm
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Installation Instructions
Fig. 7.4.5-2: Rubber hose for vent valve - example
The rubber hose for the external vent valve wi ll be cu t.. .
Both hose ends will be extended respectively with a hose and connected with a vent valve 600 mm over the waterline.
Example
Fig. 7.4.5-3: Split rubber hose for vent valve ...and bend upwards.
7.4.5.1 Raw water installation scheme
Fig. 7.4.5.1-1: Raw water installation schema
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7.5 Installation of the cooling system - fresh water

7.5.1 Position of the external cooling water expansion tank

Installation Instructions
Position of the external cooling water expansion tank
The Panda generator is normally supplied with an additional, external cooling water expansion tank. This tank must be installed in such a way that its lower edge is at least 500 mm more highly arranged than the upper edge of the sound cover.
If this 500 mm should be fallen below, i.e. the cooling water expansion tank is lower installed, very large problems can occur with filling and ventilating. Extend and displace the hose lines to the outside or possibly even up to the deck.
only up to the lower edge of the lower tension tape (see note „max“) in the maximum filling level in cold condi­tion.
Fig. 7.5.1-1: Position of the External Cooling Water Expansion
Tank
ATTENTION! The external cooling water expansion tank may be filled

7.5.2 De-aerating at the first filling of the internal cooling water circuit

1. For the preparation of filling the following steps are to
be undertaken:
a. Open the cooling water cap on the cooling water tank.
Fig. 7.5.2-1: Cooling water filler neck2. Filling the cooling water circle
a. Fill in the prepared mixture (cooling water with anti­freeze protection according to the intended mixture) at the filler neck at the cooling water tank slowly so long, until cooling water reach the max. level at the neck.
Anti-freeze
In the interest of safety, the freezing point of the closed circuit coolant should be checked on a regular basis. Be sure that the coolant/antifreeze mixture is good for at least -15°C (5°F) and if it is possible that your genset experiences lower temperatures, for example during storage or transportation, then the entire cooling system should be drained and purged. To purge the cooling system, compressed air at about 0.5 bar (7.5 psi) is sufficient.
Electric cooling water pump
Connect the cooling water pump to an external DC power supply and start the pump. Refill the the cooling water at the filler neck while the pump runs.
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Installation Instructions
3. De-aerating
The cooling water circuit of the generator is self de-aerating.
ATTENTION! During the de-aerating proc ess it must be checked ag ain and again if the cooling water is indeed circulating. If air bubbles established in the internal cooling water pump, it could be, that the cooling water circuit is n ot circ ulate . Then the generator would be warming very fast and switched off by overheating.
Anti-freeze In the interest of safety, the fre ezing point of the closed circuit co olant should be checked on a regular basis. Be sure
that the coolant/antifreeze mixture is good for at least -15°C (5 ° F) and if it is possible that your genset experiences lower temperatures, for example during storage or transportation, then the entire cooling system should be drained and purged

7.5.3 Pressure Test for Controlling the Cooling Water Circuit

Check if a temperature difference exists between cooling water in-flow and cooling water return flow by use of the hand.
Feel the cooling water in-flow line at the internal cooling water pump. Feel the cooling water return pipe either at the outlet of the water-cooled exhaust elbow union or at the side, where
this pipe exits at the heat exchanger. The temperature difference between in-flow and return should be approximately 10 degrees.
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Installation Instructions

7.6 Installation of the water cooled exhaust system

7.6.1 Installation of the standard exhaust system

The generator exhaust system must remain completely independent and separate from the exhaust system of any other unit(s) on board. The water lock must be installed at the lowest point of the exhaust system. An optional n o ise insulated water lock can also be installed. The exhaust hose descends from the capsule to the water lock. Then the hose rises via the „goose neck“ to the silencer (see drawing). The goose neck must be vertical and sit preferably along the ship's keel centre line. In order that the back pressure inside the exhaust is not to high, the total length of the exhaust system should not exceed 6,3 m.
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 9.2, “Diameter of conduits,” on page 89.
Fig. 7.6.1-1: Installation Scheme Standard Exhaust System

7.7 .Installation of the waterlock

Note!:Pay attention to the ri ght flow direction throught the
waterlock.
Unfortunately , it can occasionally occur that, becau se of an disadvant ageous mounting position of the waterlock, 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.
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Installation Instructions
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.

7.7.1 Possible cause for water in the exhaust hose

7.7.1.1 Possible cause: exhaust hose
If the cause is the exhaust hose itself, the following points are to be checked at the hose: a) Position of the waterlock is too high. The water reaches the exhaust hose. b) Position of the waterlock is too far awa y from the midd le o f the ge nerato r. The water reaches the exhaust hose in
tilted position. c) The waterlock is too small relating to the length of the exhaust hose.
7.7.1.2 Possible cause: cooling water hose
If the generator is not clearly installed 600 mm over the water line, the cooling water feed must be equipped with a „venting valve“ which is at least led out 600 mm over the water line. (This position must also be assured in every tilted position. Therefore, the venting valve should be located in the ships’ center line, so that it cannot move in tilte d position).
a) Position of the venting valve is too low. The water flows into the exhaust area when the ship is tilted. 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 „waterlock“ play a very decisive role:

7.7.2 Installation area of the waterlock

Concerning a water-cooled exhaust syst em, it must be regard ed that - unde r no circum stances - cooling wate r 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 eng ine.
In addition to that, one has to reckon with possible tilted positions of sailing yachts, which makes the position of the waterlock even more important. In general one could say that:
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Installation Instructions
1
The deeper the waterlock is located underneath the generator, the better the protection 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.

7.7.3 The volume of the waterlock

The waterlock must be measured so large, that it can take the entire amount of water flowing back from the exhaust 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. 7.7.3.0-1: Volume of the waterlock
If there are any doubts, a verifica tion can e asily be made by temporarily using a clear-sighted hose (1) as exhau st hose. In that way , the cooling wate r level can be checked very easily.
Fig. 7.7.3.0-2: Testing the cooling water level
7.7.3.1 Ideal position of the waterlock
Important Note!The ideal position of the waterlock would be in center
underneath the generator.
Only in this position it is assured that the water level cannot change drastically in tilted position by the waterlock moving out of the center line.
See the following pictures:
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Installation Instructions
underneath the generator.
When the ship tilts, the position of the waterlock related to the critical point at the exhaust hose, changes only slightly.
The distance from the exhaust elbow to the hydrostatic head has derated to 540 mm.
Fig. 7.7.3.1-1: Ideal position of the waterlockIn Fig. 7.7.3.1-1, the waterlock is mounted in center
Fig. 7.7.3.1-2: Tilted position 15 degreesTilted position 15 degrees - Fig. 7.7.3.1-2
The distance of the water level, even in ideal position, changes that only 458 mm distance remain. So the critica l distance is under-run already.
In this case the water level rise so high, that the distance constitutes only 325 mm.
Even when the water lock is mounted in the ideal spot, at an extremely tilted position of 45 degrees there is still the risk that water can get straight into the discharge stack area through strong rocking motions („sloshing“). This shows that the distance of 600 mm represents a minimum size at which, even when installed ideally, the water can slosh into the exhaust elbow when the ship is very tilted or rocks very hard.
Fig. 7.7.3.1-3: Tilted position 30 degreesTilted position 30 degrees - Fig. 7.7.3.1-3
Fig. 7.7.3.1-4: Tilted position 45 degreesTilted position 45 degrees - Fig. 7.7.3.1-4
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Installation Instructions
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.
7.7.3.2 Example of the installation of the waterlock off-center and possible effects:
The following pictures are primarily relevant for an installation of the generator with the waterlock on sailing yachts. A change in the mounting position caused by tilted position does not have to be reckoned concerning motor yachts. Here it is only necessary to regard that the volume of the waterlock is measured so large that it can take the entire amount of water flowing back, and at the same time, maintains the minimum distance of 600 mm.
A) Installation of the waterlock 500 mm next to the generator’s center line:
Fig. 7.7.3.2-1: waterlock, 500 mm next to the center lineInstallation of the waterlock 500 mm next to the
generator’s center line
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-programm ed .
Fig. 7.7.3.2-2: Tilted position 45 degreesTilted position 45 degrees - Fig. 7.7.3.2-2
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B) Installation distance between waterlock and the generator’s center line 1000 mm
Fig. 7.7.3.2-3: waterlock, 1000 mm next to center lineInstallation distance between waterlock and the
generator’s center line 1000 mm
Fig. 7.7.3.2-4: Tilted position 30 degreesTilted position 30 degrees - Fig. 7.7.3.2-4
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-program m ed .
Summary:
Concerning sailing yachts it must be regarded, that the waterlock is mounted in center underneath the generator, at least in reference to the ships’ center line. Thus the waterlock is prevented from „leaking“ very strongly when the ship is tilted.
The „leaking“ of the waterlock leads to a rise of the water level which then gets too close to the exhaust elbow’s critical point.

7.8 Exhaust / water separator

In order to reduce the noise level of the generator 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 emanating from the exterior of the yacht are strong ly decrea sed. Particu larly the „water splash“.
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Fig. 7.8.0-1: Installation Scheme exhaust / water separator
Installation Instructions

7.9 Installation exhaust water separator

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 through­hull outlet. For such long exhaust routes, the exhaust hose diameter should also be increased, f.e. from NW40mm to NW50mm in order to reduce the back-pressure. The exhaust may have a length of over 10 m (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 gooseneck too large
Fig. 7.9.0-1: Example for an unfavourable Installation

7.10 Fuel system installation

7.10.0.1 The following items need to be installed:

• Fuel supply pump (DC)
• Pre-filter with water separator (not part of the delivery)
• Fine particle fuel filter
• Return fuel line to fuel tank (unpressurized) The external Fuel pump should be installed near the tank
With the Fischer Panda generator is usually supplied an external, electrical fuel pump (DC). The fuel pump must be installed close at the fuel tank. The electrical connections is prepared at the generator.
Some generators (f.e. with Deutz diesel engine) has an engine driven internal fuel pump. At these generators the electrical fuel pump is optional.
Fig. 7.10.0-1: electrical fuel pumpElectrical fuel pump
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Fig. 7.10.0-2: Fuel system - schema
5
2
3
4
1
6
1. Fuel tank
2. external fuel pump
3. external fuel prefilter with water separator
4. Non return valve
5. Fuel fine filter
6. Generator
Installation Instructions
External fine filter
Fig. 7.10-3: externer Feinfilter
At generators with Kubota EA 300 or Farymann engines, the fine filter is delivered with the generator. This fine filter should be installed in the fuel feed line next to the generator.
representative picture

7.10.1 Connection of the fuel lines at the tank

tank at separate connection points.
Note:General fuel feed and return line must be connected to the
Connection of the return pipe to the tank
The return pipe connected to the tank must be dropped to the same depth as the suction pipe, if the generator is mounted higher than the tank, in order to prevent fuel running back into the tank after the motor has been switched off, which can lead to enormous problems, if the generator is switched off for a long period.
Non-return valve in the suction pipe
A non-return valve must be fitted to the suction pip e, which prevents the fuel flowing back after the generator has
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Installation Instructions
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.

7.10.2 Position of the pre-filter with water separator

Inside the generator capsule itself, th ere is the fuel filter inst alled (exce ption: Panda 4500). Additio nal fuel filters (with water separator) must be mounted outside the capsule in easily accessible places in the fuel lines between the tank intake fuel pump and the diesel motor's fuel pump.
Fig. 7.10.2-1: Pre-filter with water separatorAdditionally to the standard fine filter a pre-filter with
water separator must be installed outside of the sound insulation capsule in the fuel system line (not included in the delivery).
representative picture

7.11 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):
Start the fuel pump
Note:The external fuel pump can be started manual by an option in
the iControl2 panel. See iControl2 manual for details.
Ventilation Screw
4.) Open the ventilation screw located at the fuel solenoid valve. The „START“ 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 „START“ button be released.
5.) Switch the panel „OFF“.
This procedure must be repeated several times, unt il fuel (nonporously) withdraws perfectly at the ventilation screw.
Injection nozzles
Pressing the starter button can now start the machine. The machine should start after a short period.
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Installation Instructions
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.
Switch main switch "OFF"

7.12 Generator DC system installation

Note:The Panda 5000i has no DC alternator to charge the Starter batter y. The Starter battery must be charge d by an external device.
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.

7.12.1 Connection of the starter battery block

An own separate starter battery must be installed for the generator. The positive cable (+) of the battery is attached directly at the solenoid switch of the starter motor (position 1). The
negative cable (-) of the battery is attached underneath the starter motor at the engine mo un t (po sit ion 2).
NOTE:Panda Generators Panda 6000 and higher normally provided with an alternator/dynamo to charge the starter battery. At generators without alternator/dynamo it is needed to charge the starter battery with an external battery charger.
ATTENTION!Make sure that the voltage of the starter battery fits to the start system voltage
f.e. 12 V starter battery for a 12 V start system f.e. 24 V starter battery for a 24 V start system (2x12 V
batteries in a row)
NOTE:To avoid large voltage drops the battery should be installed as near as possible to the generator. The positive terminal of the battery is attached at the red cable, the negative pole at the blue cable.
It must be guaranteed that first the cables are att ached at the generator and then at the battery.
Battery connection
Attention!: Consider correct connection
sequence
Attention!: Right connection of the battery.
Wrong connection of the battery bank can cause a short­circuit and fire.
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Installation Instructions
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.
The positive (+) battery cable is connected directly to the solenoid switch of the starter.
The negative (-) battery cable is connected to the engine foot.
Note! The battery negative pole may not be connected with the boat ground or with the protective grounding of the 120 V installation!
Fig. 7.12.1-1: Positive Battery Cable Positive battery cable
Fig. 7.12.1-2: Negative Battery CableNegative battery cable
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All Panda generators are equipped with an independent DC
1
2
1. Generator
2. Battery block
3. Fuse
4. Battery main switch
starter motor.
1. Solenoid switch for starter motor
2. Starter motor
Fig. 7.12.1-4: Connection starterbattery 12V - schema
Installation Instructions
Fig. 7.12.1-3: DC Starter Motor DC Starter Motor
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Installation Instructions
1. Generator
2. Battery block
3. Fuse
4. Battery main switch
F1
Fig. 7.12.1-5: Connection starterbattery 24V - schema

7.12.2 Connection of the remote control panel - See Panda iControl panel manual

7.12.3 Fuse

Fig. 7.12.3-1: Terminal block AGT 5000 12VF1: Fuse 30 A for DC system
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7.12.4 Installation of the iControl panel - See iControl Manual

7.13 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. Required cable cross-sections
The following recommended electrical cable dimensions (cross sections) are the minimum required sizes for a safe installation (see “Cable cross section” on Page 89).
Installation Instructions
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Installation Instructions
1
2
3
4
5
1. Generator
2. Electrical fuel pump DC
3. PMGi 5000 inverter
4. iControl panel
5. Starter battery DC
Fig. 7.13-1: Electrical installation - example

7.13.1 Installation PMGi inverter - See separate PMGi 5000 inverter manual

All electrical safety installations have to be made on board.

7.13.2 Power source selector

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
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systems separate.
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
Installation Instructions
Fig. 7.13.2-1: 3-Way Cam Switch3-Way Cam Switch
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! The fuses must be of the slow type. A 3-way motor protection switch must be inst alled to protect the electrical motor.
Required fuses see Tabelle 9.1, “Cable cross section,” auf Seite 89
Required cable cross-sections
The following recommended electrical cable dimensions (cross sections) are the minimum required sizes for a safe installation. (siehe Tabelle 9.1, “Cable cross section,” auf Seite 89)
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Installation Instructions

7.14 Checking and filling of the oil circuit

Check oil and fill the oil circuit as described in the service chapter.

7.15 Isolation test

handover of the generator to the customer, an isolation test has to be accomplished as follows:
1. Switch off all electrical load.
2. Start the generator.
3. Measure the AC-voltage with a voltmeter (adjust to Volt/AC) between: a) generator housing and AC-Control box
ATTENTION!After installation, before bringing into service and
b) generator housing and ground. The measured voltage must not exceed 50 mV (millivolt).
4. Once the safety systems have been installed, they must be checked. If a leakage current relay (RCD) has been installed, it also has to be tested in order to ensure that all contacts are connected properly. The individual phases have to be checked against each other, and between phase and ground. An additional 4th phase (L1’) also needs to be checked at generators with DVS winding.
5. If the generator is protected by a ground connection, it h as to be ensured th at ALL electrical devices must also be connected to this „common“ ground (usually ground contacts are attached to the device’s metallic housing).
The electrical system installation must also comply with the hook-up requirements of the shore current grid. Generally a leakage current relay (RCD) is sufficient for safe electrical operation; how ewer, this must be confirmed by the electrical safety standard in the region where the system is attached to a main land power grid. The release current of the relay (RCD) has to meet the installation circumstances.

7.16 Initial operation

After successful installation an initial operation has to be performed. For this purpose the initial operation record has to be completely filled out by the installing expert. The filled record
has to be handed out to the owner. The owner has to be instructed regarding handling, servicing and risks of the generator. This applies to the service
steps and risks mentioned in the manual as well as further risks which may arise fr om the specific installation and the connected components.
Note:The original initial operation record has to be sent to Fischer Panda to receive the complete guarantee. Please make a copy for your own documentat ion.
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Leere Seite / Intentionally blank
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Maintenance Instructions

8. Maintenance Instructions

8.1 Personal requirements

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

8.2 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.

8.3 Hazard notes for the maintenance and failure

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.
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.
Notice!:Follow the general safety instruction at the front of this
Warning!: Automatic startDanger for life! - The generator can be equipped with a
Warning!: Risk of injuryWorking at a running generator can result in severe
Warning!: Risk of injuryImproper installation/maintenance can result in severe
• 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.
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.
Maintenance Instructions
Warning!: Danger of fire Oil and fuel vapours can ignite on contact with ignition
Danger!: Danger of poisoningContact with engine oil, antifreeze and fuel can result in
ATTENTION!: Danger to Life - High voltageDanger for Life. Improper handling, operation, installa-
Electrical voltages above 60 volts are always dangerous to life). The rules of the respective regional authority must be adhered to. Only an electrician may carry out installation of the electrical connections for safety reasons.
operation. Risk of severe burns.
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.
Warning!: Hot surface/materialGenerator, oil and antifreeze can be hot during/after
Instruction!: Personal protective equipment necessary.
Attention!: disconnect all loadDisconnect all load during the work at the generator to
Warning!:Batteries contains acid or alkalis.
Improper handling can result in battery explosion and leakage. Acid or alkalis can run out. An explosion of the battery is possible.
See the operation and safety instruction from your battery manufacturer.
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.
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Maintenance Instructions
Observe the instructions from your battery manufacturer.

8.4 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.
Environmental protection.Danger to the environment due to mishandling!

8.5 General maintenance instructions

8.5.1 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 seperate datasheet

8.6 Maintenance interval

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.

8.6.1 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
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Maintenance Instructions
Oil Max.
Oil Min.
2/3 Suggestion
be accomplished for marine generators, such as control of the sacrificia l anode (cooling water connection blo ck) and the front seal cover at the generator.

8.7 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.

8.8 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 gene r ato r casin g.
• 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. 8.8-1: Oil dipstickOil dipstick EA 300 Engine
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 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. 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 Panda se rvice
point immediately.

8.8.1 Refilling Oil

You require:
Engine oil
1. Check oil-level as described under section 8.8, “Checking oil-level,” on page 78.
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 8.8, “Checking oil-level,” on page 78. If oil-level is still too low (under 2/3): repeat steps 4-6.

8.8.2 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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8.9 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 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. 8.9-1: Oil filling cap2. Loosen oil filling cap
Fig. 8.9-2: Oil drain hose3. Open oil drain screw.
4. Discharge used oil.
Let the entire amount of oil drain out of the engine. This can take several minutes.
Fig. 8.9-3: Oil screenOil screen with generators with EA300 engines
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
5. 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.
6. Check proper filling level. See section 8.8, “Checking oil-level,” on page 78.
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.
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Maintenance Instructions
7. Clean up Wipe off all oil splashes from the generator and make sure that the drai n scr ew ha s no leak .

8.9.1 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).

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

Check the condition of the battery. Proceed here as prescribed by the battery manufactu re r.
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Maintenance Instructions

8.11 Checking the water separator in the fuel supply

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
Fig. 8.11-1: Pre-filter with water separatorThe pre-filter with water separator has a co ck underneath , by

8.11.1 Exchange of the Fuel Filter

Fig. 8.11.1-1: Fuel FilterExchanging the filter, depending upon fuel contamination,
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.

8.11.2 De-aerating the fuel system

Normally, the fuel system is designed to bleed out 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 bleed the system as follows prior to the first operation (as all hoses are empty):
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out fuel to catch.
8
2. Switch the panel „ON“.
3. Activate the the fuel pump prime function in the panel menue.
4. Let the pump run till the fuel runs bleed free out of the return line. (about three times activation of the fuel pump prime function)
Maintenance Instructions
Fig. 8.11.2-1: Fuel return pippe1. Put a container under the fuel return pipe to catch running
(nonporously) withdraws perfectly at the fuel return pipe.
5. Switch the panel „OFF“.

8.11.3 Replacement of the air filter

head screws on the frame cover.
Fig. 8.11.2-2: iControlThis procedure must be repeated several times, until fuel
Fig. 8.11.3-1: Air filterOpen the air suctin housing by loosen the six hexagon
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Maintenance Instructions

8.12 De-aerating of the coolant circuit / freshwater

Fig. 8.11.3-2: Air filter matChange the air filter mat and close the cover again.
The Panda 5000i PMS is self de-aerating.

8.13 The raw water circuit

8.13.1 Clean raw water filter

The raw water filter should be released regularly from arrears. In each case the water cock must be closed before. It is mostly sufficient to beat the filter punnet.
If water should seep through the cover of the raw water filter, this may be sealed in no case with adhesive or sealant. Rather must be searched for the cause for the leakage. In the simplest case the sealing ring between caps and filter holders must be exchang ed .
Fig. 8.13.1-1: Raw water filter

8.13.2 Causes with frequent impeller waste

The impeller of the cooling water pump must be regarded as wearing part. The life span of the impeller can be extremely different and exclusively depends on the operating conditions. The cooling w ater pumps of the PANDA generators are laid out in such a way that the number of revolutions of the pump lies low compared with other aggregates. This is for the life span of the pump a positive effect.
Unfavorably affects the life span of the impeller, if the cooling water sucking in way is relatively long or the supply is handicapped, so that the cooling water sucking in range develops a negative pressure. This can reduce first of all the power of the cooling water pump extremely that the wings of the impeller are exposed to very strong loads. This
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Maintenance Instructions
can shorten the life span extremely. Further the operation of the impeller pump loaded in waters with a high portion of suspended matters. The use of the
impeller pump is particularly critical in coral waterbodies. Cases are well-known, which a impeller pump had so strongly run after 100 hours already that the lip seal on the wave was ground in. In these cases sharp crystal parts of the coral sand assess in the rubber seal and a f fect like an abra sive the h igh-grade stee l shank of the impeller pump.
If the generator were moun ted ov er the water level it is particularly unfavorable for the impeller pump. After the first start some seconds will pass by, until the impeller can suck in cooling water. This short unlubricated operation time damages the impeller. The increased wear can lead after shor t time to the loss. (see special notes: "E ffects on the impeller pump, if the generator is mounted over the waterline").

8.13.3 Replacement of the impeller

Fig. 8.13.3-1: Raw water stop cockClose the raw water stop cock.
Fig. 8.13.3-2: Raw water pumpRaw water pump on the front side of the genset.
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Maintenance Instructions
wing screws from the housing.
Fig. 8.13.3-3: Raw water pumpRemove the cover of the raw water pump by loosen the
Fig. 8.13.3-4: ImpellerPull to the impeller with a multigrip pliers of the wave.
Mark the impeller, to make sure that these is used in the correct position at re-installation.
necessary.
Before the reinsertion into the housing the impeller should have been lubricated with glycerin or with a non-mineral oil based lubricant e.g. silicone spray.
impeller is used, pay attention to the before attached marking).
Fig. 8.13.3-5: ImpellerCheck to the impeller for damage and replace it if
Fig. 8.13.3-6: TImpeller sealhe impeller is attached to the pump wave (if the old
Fastening the cover and use a new seal.
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Maintenance Instructions
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Generator Tables

9. Generator Tables

9.1 Cable cross section

Fig. 9.1.0-1: Kabelquerschnitte/Cable cross sectiion
Länge/length 1 - 3 m 4 - 6 m 7 - 10 m 11 - 15 m 16 - 20 m 2,5 mm² 4 mm² 6mm² 10mm² 16 mm² 70 A 63 A 55 A 48 A 42 A 25mm² 112 A 100 A 88 A 75 A 63 A 35mm² 145 A 130 110 100 A 90 A 50mm² 225 A 200 A 175 A 150 A 125 A 70mm² 275 A 250 A 225 A 195 A 170 A 95mm² 340 A 300 A 280 A 260 A 220 A

9.2 Diameter of conduits

Fig. 9.2-1: Diameter of conduits
Generator type Ø Cooling water pipe Ø Exhaust hose
Fresh water [mm]
Panda 5000i PMS 20 20 30 8 8
Raw water [mm]
[mm]
Ø Fuel hose Supply
[mm]
Return [mm]

9.3 Technical Data

Fig. 9.3-1: Technical Data generator
Panda 5000i PMS Panda 5000i PMS with Tier 4
Type EA 300 EA330 Govenour Servo Servo Cylinder 11 Bore 75mm 77 Stroke 70mm 70 Stroke volume 309cm max. Power (DIN 6270-NB) at 3000rpm 5,1kW 5,15kW Rated speed 3000rpm 3000 Idle speed running Valve clearance (engine cold) 0,16 - 0,20mm 0,16-0,20 Cylinder head torque 58,8 - 63,7Nm 58,8 - 63,7Nm Lubrication oil capacity 1,3l 1,3l Fuel consumption
a
b
3
2900rpm 2900
approx. 0,42 - 1,12 l approx. 0,42 - 1,12 l
a. progressive speed by VCS b. 0,35l/kW electrical power, the randomized values between 30% and 80% of the nominal power
325cm³
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9.4 Types of coil

HP3 delta connection
Generator Tables
Fig. 9.4-1: HP3 delta connection

9.5 Engine oil

9.5.1 Engine oil classification

9.5.1.1 Operating range:
The operating range of an engine oil is determined by SAE class. „SAE“ is for the union of American auto engineers (Society of Automotives Engineers).
The SAE class of an engine oil only infor ms over the viscosity of the oil (larger number = more viscous, smaller number = more highly liquidly) e.g. to 0W, 10W, 15W, 20, 30, 40. The first number shows the liquid of the oil with cold weather, the second number refers to the fluidity with heat. Complete yearly oils have usually SAE classes of SAE 10W-40, SAE 15W-40 etc.
9.5.1.2 Quality of oil:
The quality of an engine oil is specified by the API standard („American Petroleum Institutes“). The API designation is to be found on each engine oil bundle. The first letter is always a C.
API C for diesel engines
The second letter is for the quality of the oil. The more highly the letter in the alphabet, the better the quality. API C for diesel engine Examples for diesel engine oil: API CC Engine oil for small demands API CD Engine oil for suction- and turbo diesel engine
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Generator Tables
API CF Replace the specification API CD since 1994 API CG Engine oil for highest demands, turbo-tested
Engine oil type over 25 °C SAE30 or SAE10W-30; SAE10W-40 0 °C to 25 °C SAE20 or SAE10W-30; SAE10W-40 below 0 °C SAE10W or SAE10W-30; SAE10W-40
Fig. 9.5.1-2: Temp. range of the SAE classes
Notice!:See technical data for the specificated engine oil
Fig. 9.5.1.2-1: Engine oil type.

9.6 Fuel

Use a clean Diesel fuel oil according to DIN590:1999 or better. For Generators with common rail or particle filter use DIN590:2009 or better.
Do not use alternative fuel, because its quality is unknown or it may be inferior in quality. Kerosene, which is very low in cetane rating, adversely effects the engine.

9.7 Coolant specifications

Use a mixture of water and antifreeze. The antifreeze needs to be suitable for aluminium. The antifreeze concentration must be regularly checked in the interests of safety.
Fischer Panda recommend to use the product: GLYSANTIN PROTECT PLUS/G 48
Engine coolant automotive industry Product description Product name GLYSANTIN ® PROTECT PLUS / G48 Chemical nature Monoethylenglycol with inhibitors Physical form Liquid
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Chemical and physical properties Reserve alkalinity of 10ml ASTM D 1121 13 – 15 ml HCl 01 mol/l Density, 20°C DIN 51 757 procedure 4 1,121 – 1,123 g/cm Water content DIN 51 777 part 1 max. 3,5 % pH-value undiluted 7,1 – 7,3
3
Generator Tables
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Generator Tables

9.7.1 Coolant mixture ratio

Water/antifreeze Temperature
70:30 -20 °C 65:35 -25 °C 60:40 -30 °C 55:45 -35 °C 50:50 -40 °C

9.8 Dimensions

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Fig. 9.8-1: Diamensions
Generator Tables
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Tables

10.Tables

10.1 Troubleshooting

GENERATOR OUTPUT VOLTAGE TOO LOW If the generator delivers less than 24V current („undervoltage“), there can be various reasons for this:
Cause Solution
PGMi is overloaded. Reduce the electrical load. (Switch off load) Motor is not reaching the rated rpm. Refer to „motor faults“ section.
MOTOR DOES NOT TURN OVER WHEN STARTING Cause Solution
Battery main switch is switched off. Check the position of the battery main switch, if necessary switch on. Battery voltage not sufficient. Check that connection is firm and whether corrosion has occurred. Starting current fault. The voltage of full batteries fall to a maximum of 11V. The wiring is
severed if the voltage does not drop. The battery is discharged if the voltage drops further.
MOTOR TURNS OVER BUT DOES NOT START Cause Solution
Stop solenoid valve not opening. Check wire connections and circuitry to solenoid valve. (ref. DC wiring
diagram: Relay K2, Fuse) Fuel pump does not operate. Check fuel-filter and pump: clean if necessary. Lack of fuel. Check fuel supply. Glow-plugs not working correctly. Check glow plugs and heating time. Too much air in fuel lines. Test fuel system for leakage. Bleed air from fuel system (refer to section
„Air-bleeding of the Fuel System“). Fuel filter blocked. Replace fuel filter. Low compression pressure. See Kubota motor-manual.
MOTOR DOES NOT TURN OVER AT THE NORMAL SPEED DURING THE STARTING PROCESS Cause Solution
Starter battery voltage insufficient. Check battery. Damaged bearing(s) piston (seized). Repairs need to be carried out by Kubota-Service. (refer to Kubota
Cooling water in combustion chamber. 1. Turn generator „OFF“ at control panel.
motor-manual)
2. Remove the glow plug (see Kubota-manual).
3. Rotate the motor by hand carefully.
4. Check if there is water in the oil and change both oil and filter if
necessary.
5. Determine cause for excess water in the combustion chamber. The
excess water can be caused by a defective air vent in the cooling water
system, which should be checked and cleaned, or replaced if faulty.
MOTOR RUNS IRREGULARLY Cause Solution
Faulty centrifugal injector governor. Have the centrifugal governor inspected by a Kubota-Service
technician. Too much air in fuel lines. Bleed air from fuel system.
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Tables
DROP IN THE SPEED OF THE MOTOR Cause Solution
Too much oil. Drain oil. Lack of fuel. Check fuel supply system:
- fuel filter, renew if necessary
- check fuel pump
- check fuel lines (bleed if necessary)
Lack of intake air. Check air intake paths.
Check and clean air filter (and intake muffler if installed). Generator overloaded by too many load. Reduce the electrical load (switch off load). Defective generator (windings, bearings, or other). Generator must be sent to manufacturer for repair of damaged bearings
or winding. Damaged engine. Repair of bearing damage, etc., by Kubota-Service.
MOTOR SWITCHES ITSELF OFF Cause Solution
Fuel solenoid valve or throttle shut solenoid is not switching off. Check wire connections to solenoid. Check valve functions as in the
„Inlet Fuel Solenoid Valve“ or in the throttle shut off solenoid sections.
Replace if necessary.
MOTOR STOPS BY ITSELF Cause Solution
Lack of fuel. Check fuel supply system. Excess heat in cooling system (thermo switch tripped)- lack of cooling
water. Is indicated on the remote control panel. Lack of oil (oil pressure sensor tripped). Check oil-level and if necessary top up.
SOOTY, BLACK EXHAUST Cause Solution
Generator is overloaded. Check electrical load and switch off unnecessary load. Insufficient intake air. Check intake air filter; clean if necessary. Fuel injector nozzles faulty. Replace injector nozzles. Valve clearance incorrect. Readjust valve clearance to correct value (refer to Kubota-manual). Poor fuel quality. Use better quality diesel (recommended: 2-D Diesel). Poor combustion. Incorrect AFR (air/fuel ratio) due to motor timing adjustment. Have motor
Low compression pressure. See Kubota motor manual.
GENERATOR MUST BE SHUT OFF IMMEDIATELY IF: Cause Solution
- motor rpm suddenly rises or drops
- unusual noise comes from genset
- exhaust colour suddenly becomes dark
- motor overheats
- oil pressure drops, oil light suddenly flashes
Check cooling water system flow: water pump, inlet water filter, extra
heat exchanger coolant flow.
Check motor's oil-pressure and have repaired by Kubota-Service if
necessary.
serviced by Kubota.
Refer to respective section of manual and if necessary, have repaired by
Kubota-Service, or Panda representative.
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Tables

10.2 Technical data

10.2.1 Technical Data Engine

10.3 Technical data

Fig. 10.3-1: Technical data igenerators
Panda 4800i Panda 5000i Panda 8000i Panda 10000i Panda 15000i
Type Faryman 18W430 EA300 Z482 Z602 D902 Governor iControl2 iControl2 iControl2 iControl2 iControl2 Automatic start booster no no no no no Cylinder 11223 Bore 82 mm 75 mm 67 mm 72 mm 72 mm Stroke 55 mm 70 mm 68 mm 73,6 mm 73,6 mm Stroke volume 290 cm³ 309 cm³ 479 cm³ 599 cm³ 898 cm³ Max. power (DIN 6271-NB) at 3000 rpm 5,7 kW 5,1 kW 9,32 kW 11,6 kW 17,5 kW Rated speed 3600 rpm 3000 rpm 3000 rpm 3000 rpm 3000 rpm Idle running speed 3690 rpm 2900 rpm 2900 rpm 3100 rpm 2900 rpm Valve clearance (engine cold) 0,20 mm 0,16 - 0,20 mm 0,2 mm 0,2 mm 0,2 mm Cylinder head nut torque 30-33 Nm 58,8 - 63,7 Nm 42 Nm 42 Nm 42 mm Compression ratio 20:1 -- 23:1 24:1 24:1 Lubrication oil capacity 1,25 l 1,3 l 2,8 l 2,8 l 3,7 l Fuel consumption ³ approx. 0,42 -
1,12 l
Oil consumption -- max. 1 % of fuel consumption Oil specification API CF API CF API CF API CF API CF Cooling water requirement for seawater
circuit (Marine generators only) Permissible max. permanent tilt of engine -- a) 25° crosswise to the longitudinal axis
Recommend starter battery size 12 V 28 Ah
Recommend cable cross size starter battery cable
Length 4 meter max.
Max. exhaust back pressure -- -- 9,3 kPa
³ 0,35 l/kW electrical power, the randomized values between 30 % and 80 % of the rated speed
-- -- 16-28 l/min 16-28 l/min 16-28 l/min
equivalent 25 mm² 25 mm² 25mm² 25 mm² 25 mm²
approx. 0,42 ­1,12 l
b) 20° in longitudinal direction 12 V 28 Ah
equivalent
approx. 0,7-1,8 l approx. 1,0-2,66 l approx. 1,3-3,6 l
12 V 28 Ah equivalent
93 Millibar²
12 V 36 Ah equivalent
9,3 kPa 93 Millibar
12 V 52 Ah equivalent
9,3 kPa 93 Millibar
Fig. 10.3-2: Technical data igenerators
Panda 25i Panda 45i
Type Kubota V1505 Kubota V2403 Governor iControl2 iControl2 Automatic start booster no n o Cylinder 44 Bore 78 mm 87 mm Stroke 78,4 mm 102,4 mm Stroke volume 1498 cm Max. power (DIN 6271-NB) at 3000 rpm 23,3 kW 31,1 kW
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3
2434 cm³
Page 98
Panda 25i Panda 45i
Rated speed 1500 rpm 2700 rpm Idle running speed 1800 rpm 1600rpm Valve clearance (engine cold) 0,2 mm 0,18 - 0,22 mm Cylinder head nut torque 68 Nm 93,1 - 98 Nm Compression ratio 22:1 Lubrication oil capacity 6,0 l 9,5 l Fuel consumption ³ approx. 1,20-
Oil consumption max. 1 % of fuel consumption Oil specification API CF API CF Cooling water requirement for seawater
circuit (Marine generators only) Permissible max. permanent tilt of engine a) 25° crosswise to the longitudinal axis
Recommend starter battery size 12 V 70 Ah
Recommend cable cross size starter battery cable
Length 4 meter max.
Max. exhaust back pressure 10,7 kPa
³ 0,35 l/kW electrical power, the randomized values between 30 % and 80 % of the rated speed
3,36 l
28-40 l/min 55-80 l/min
b) 20° in longitudinal direction
equivalent 25 mm² 70 mm²
107 Millibar
approx. 1,95 ­5,2 l
12 V 136 Ah equivalent
10,7 kPa 107 Millibar
Tables

10.4 Diameter of conduits

Fig. 10.4-1: Diameter of conduits
Generator type Ø Cooling water conduit Ø Exhaust conduit
Freshwater [mm]
Panda PMS 3,8 ND 12 12 30 8 8 Panda PMS 4,5 ND 12 12 30 8 8 Panda PMS 4500 SCB 12 12 30 8 8 Panda PMS 5000 SCE 12 12 30 8 8 Panda PMS 4500 FCB 12 12 30 8 8 Panda PMS 5000 LPE 16 16 30 8 8 Panda PMS 6000 ND 20 20 40 8 8 Panda PMS 8000 NE (8 mini
Digital) Panda PMS 9000 ND 20 20 40 8 8 Panda PMS 12000 NE (12 mini
Digital) 15 mini Digital 20 20 40 8 8 Panda PMS 14000 NE 20 20 40 8 8 Panda PMS 18 NE (16 Digital) 25 20 50 8 8 Panda PMS 24 NE (22/25 Digital) 25 20 50 8 8 Panda PMS 30 NE 25 20 50 8 8 Panda PMS 33 KU 30 25 50 8 8 Panda PMS 42 KU 30 30 50 8 8 Panda PMS 32 YA 30 30 50 8 8 Panda PMS 50 YA 30 30 60 8 8 Panda PMS 60 YA --60 88
20 20 40 8 8
20 20 40 8 8
Seawater [mm]
[mm]
Ø Fuel conduit Supply
[mm]
Return [mm]
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Tables
Generator type Ø Cooling water conduit Ø Exhaust conduit
Freshwater [mm]
Panda PMS 50 MB 40 30 60 8 8 Panda PMS 60 MB 40 40 60 8 8 Panda PMS 75 MB 40 30 60 8 8
Panda PMS-HD 7,5-4 KU 25 20 40 8 8 Panda PMS-HD 09-4 KU 25 20 50 8 8 Panda PMS-HD 12-4 KU 25 20 50 8 8 Panda PMS-HD 17-4 KU 25 25 60 8 8 Panda PMS-HD 22-4 KU 30 30 60 8 8 Panda PMS-HD 30-4 KU 30 30 60 8 8 Panda PMS-HD 40-4 KU 30 30 60 8 8 Panda PMS-HD 60-4 DZ --- -­Panda PMS-HD 70-4 DZ --- -­Panda PMS-HD 85-4 DZ --- -­Panda PMS-HD 110-4 DZ --- -­Panda PMS-HD 130-4 DZ --- --
Seawater [mm]
[mm]
Ø Fuel conduit Supply
[mm]
Return [mm]

10.5 Cable cross section

Fig. 10.5.0-1: Cable cross section
length 1 - 3 m 4 - 6 m 7 - 10 m 11 - 15 m 16 - 20 m 16 mm² 70 A 63 A 55 A 48 A 42 A 25mm² 112 A 100 A 88 A 75 A 63 A 35mm² 145 A 130 110 100 A 90 A 50mm² 225 A 200 A 175 A 150 A 125 A 70mm² 275 A 250 A 225 A 195 A 170 A 95mm² 340 A 300 A 280 A 260 A 220 A

10.6 Engine oil

10.6.1 Engine oil classification

10.6.1.1 Operating range:
The operating range of an engine oil is determined by SAE class. „SAE“ is for the union of American auto engineers (Society of Automotives Engineers).
The SAE class of an engine oil only informs over the viscosity of the oil (larger number = more viscous, smaller number = more highly liquidly) e.g. to 0W, 10W, 15W, 20, 30, 40. The first number shows the liquid of the oil with cold weather, the second number refers to the fluidity with heat. Complete yearly oils have usually SAE classes of SAE 10W-40, SAE 15W-40 etc.
10.6.1.2 Quality of oil:
The quality of an engine oil is specified by the API standard („American Petroleum Institutes“). The API designation is to be found on each engine oil bundle. The first letter is always a C.
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API C for diesel engines
The second letter is for the quality of the oil. The more highly the letter in the alphabet, the better the quality. API C for diesel engine Examples for diesel engine oil: API CC Engine oil for small demands API CD Engine oil for suction- and turbo diesel engine API CF Replace the specification API CD since 1994 API CG Engine oil for highest demands, turbo-tested
Notice!:See technical data for the specificated engine oil
Fig. 10.6.1.2-1: Engine oil type.
Engine oil type over 25 °C SAE30 or SAE10W-30; SAE10W-40 0 °C to 25 °C SAE20 or SAE10W-30; SAE10W-40 below 0 °C SAE10W or SAE10W-30; SAE10W-40
Tables
Fig. 10.6.1-2: Temp. range of the SAE classes

10.7 Coolant specifications

Use a mixture of water and antifreeze. The antifreeze needs to be suitable for aluminium. The antifreeze concentration must be regularly checked in the interests of safety.
Fischer Panda recommend to use the product: GLYSANTIN PROTECT PLUS/G 48
Engine coolant automotive industry Product description Product name GLYSANTIN ® PROTECT PLUS / G48 Chemical nature Monoethylenglycol with inhibitors Physical form Liquid
Seite/Page 100 - Kaptitel/Chapter 10: Tables 14.7.16
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