FPO1-0001069.pdf

Marine_Panda_8000NE_CP_PMS_eng.R01 23.7.10

Fischer Panda GmbH

Power - wherever you are

Manual

Panda 8000 NE PMS with Mini VCSSuper silent technology

230V/400V - 50 Hz - 6,5 kW120V/240V - 60 Hz - 6,5 kW

Seite/Page 2 Marine_Panda_8000NE_CP_PMS_eng.R01 - Kapitel/Chapter A: 23.7.10

Current Revision Status

Erstellt durch / created byFischer Panda GmbH - Leiter Technische Dokumentation Otto-Hahn-Str. 32-34 33104 Paderborn - Germany Tel.: +49 (0) 5254-9202-0email: [email protected]: www.fischerpanda.deCopyrightDuplication 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 thebest of our knowledge. No liability is accepted for correctness. Technical modifications for improving the product wit-hout previous notice may be undertaken without notice. Before installation, it must be ensured that the pictures, dia-grams and related material are applicable to the genset supplied. Enquiries must be made in case of doubt.

DocumentActual: Marine_Panda_8000NE_CP_PMS_eng.R01_23.7.10Replaces:

Revision PageManual regenerated

23.7.10 Marine_Panda_8000NE_CP_PMS_eng.R01 - Inhalt/Contens Seite/Page 3

Inhalt / ContensPanda 8000 NE PMS with Mini VCS ...................................................................................... 1

Current Revision Status......................................................................................................... 2

1 General References and Regulations .......................................................................... 9

1.1 Safety first symbols ....................................................................................................... 101.2 Tools ................................................................................................................................ 151.3 Manufacturer declaration in accordance with the machine guideline 98/37/EG ...... 171.4 Customer registration and guarantee .......................................................................... 17

1.4.1 Technical Support ............................................................................................................. 171.4.2 Attention, important directions regarding operation! .......................................................... 17

1.5 Safety instructions - Safety first! .................................................................................. 181.5.1 Safe operation ................................................................................................................... 181.5.2 Observe safety instructions ............................................................................................... 181.5.3 Wear personal protective equipment (PPE) ...................................................................... 181.5.4 Cleanness protect ............................................................................................................. 181.5.5 Safe handling of fuel and lubricants - Keep away from fire ............................................... 191.5.6 Exhaust gases and fire prevention .................................................................................... 191.5.7 Cautions against burns and battery explosion ............................................................... . 201.5.8 Keep hands away from rotating parts ................................................................................ 201.5.9 Anti-Freeze and disposal of fluids ..................................................................................... 201.5.10 Implementation of security and maintenance .................................................................. . 21

1.6 Warning and caution labels ........................................................................................... 211.6.1 Safety instructions concerning operating the generator .................................................... 21

1.6.1.1 Protective grounding and potential equalisation.........................................................................221.6.1.2 Ground wire............................................................................................................................... 221.6.1.3 Switch off all load when working on the generator .................................................................... 221.6.1.4 Safety instructions concerning the cables..................................................................................23

1.6.2 Recommended starter battery size ................................................................................... 231.6.3 Important Advice for Batteries - Starting batteries and Traction batteries ......................... 231.6.4 Safety Instructions for the Handling with Batteries ............................................................ 24

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

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

3 The Panda Generator................................................................................................... 29

3.1 Type plate at the Generator ........................................................................................... 293.2 Description of the Generator ......................................................................................... 30

3.2.1 Right Side View ................................................................................................................. 303.2.2 Left Side View ................................................................................................................. . 313.2.3 Font View ........................................................................................................................ . 323.2.4 Back View ........................................................................................................................ . 333.2.5 View from above .............................................................................................................. . 34

3.3 Details of functional units ............................................................................................. 353.3.1 Components of the Cooling System (Raw Water) ............................................................. 353.3.2 Components of the Cooling System (Fresh Water) ........................................................... 363.3.3 Components of Fuel System ........................................................................................... . 403.3.4 Components of Combustion Air ...................................................................................... . 423.3.5 Components of the Electrical System ............................................................................... 443.3.6 The Operation Surveillance System .................................................................................. 483.3.7 Components of the Oil Circuit ......................................................................................... . 50

3.4 Remote Control Panel - see separate Control Panel Manual ..................................... 51

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Inhalt / Contens3.4.1 Starting the Generator - see separate Control Panel Manual ............................................ 513.4.2 Stopping the Generator - see separate Control Panel Manual .......................................... 51

4 Installation Instructions ...............................................................................................53

4.1 Placement ........................................................................................................................ 534.1.1 Advice for optimal sound insulation ................................................................................... 53

4.2 Generator Connections .................................................................................................. 534.3 Cooling System Installation - Raw Water ..................................................................... 54

4.3.1 General Information ........................................................................................................... 544.3.2 Installation of the thru hull fitting in Yachts ........................................................................ 544.3.3 Quality of the Raw Water Sucking In Line ......................................................................... 544.3.4 Generator Installation above Waterline ........................................................................... . 554.3.5 Generator Installation below Water-Line ......................................................................... . 564.3.6 Generator Housing cooled by Raw Water ......................................................................... 574.3.7 Indirect Cooling of the Genset Housing (by the Heat Exchanger) ................................... . 58

4.4 The Freshwater Coolant Circuit .................................................................................... 584.4.1 Position of the external cooling water expansion tank ....................................................... 584.4.2 Ventilating at the first filling of the Internal Cooling Water Circuit ...................................... 594.4.3 Pressure Test for Controlling the Cooling Water Circuit .................................................... 604.4.4 Scheme for Freshwater Circuit at Two Circuit Cooling System ....................................... . 61

4.5 Water Cooled Exhaust System ...................................................................................... 624.5.1 Installation of the Standard Exhaust System ..................................................................... 624.5.2 .Installation of the water collector ...................................................................................... 624.5.3 Possible Cause: Exhaust duct ........................................................................................... 634.5.4 Possible Cause: Coolant duct ............................................................................................ 634.5.5 Installation area of exhaust water collector ........................................................................ 63

4.5.5.1 The volume of the exhaust water collector ............................................................................... 644.5.5.2 Position of the water collector.................................................................................................... 664.5.5.3 Example of the installation of the water collector off-center and possible effects:..................... 68

4.5.6 Exhaust / Water separator ................................................................................................. 704.5.7 Installation Exhaust-Water-Separator .............................................................................. . 72

4.6 Installation of the Fuel System ...................................................................................... 744.6.1 General References ........................................................................................................... 744.6.2 The Electrical Fuel Pump ................................................................................................... 744.6.3 Connection of the Fuel Lines at the Tank .......................................................................... 754.6.4 Position of the Pre-Filter with Water Separator ................................................................. 754.6.5 Ventilating Air from the Fuel System ................................................................................. 76

4.7 Generator 12 V DC System Installation ........................................................................ 764.7.1 Connection of the 12 V Starter Battery .............................................................................. 764.7.2 Connection of the remote control panel - see separate control panel manual .................. 78

4.8 Generator AC System Installation ................................................................................. 794.8.1 Installation with looped in AC-Control box ......................................................................... 794.8.2 Installation AC-Box / distribution panel separate connected ........................................... . 804.8.3 AC Control Box with VCS and ASB - not all models ....................................................... . 824.8.4 VCS Voltage Control ........................................................................................................ . 83

4.8.4.1 Alternative Mini VCS.................................................................................................................. 844.8.5 Jump Start at High Starting Current (Booster) ................................................................... 844.8.6 Insulation Test ................................................................................................................. . 85

5 Maintenance Instructions ............................................................................................87

5.1 Personal requirements ................................................................................................... 875.2 Safety instructions for this chapter .............................................................................. 875.3 Environmental protection .............................................................................................. 895.4 General maintenance instructions ................................................................................ 89

5.4.1 Checks before each start ................................................................................................... 89

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Inhalt / Contens5.4.2 Check of Hoses and Rubber Parts in the sound insulated capsule .................................. 89

5.5 Oil Change Intervals ....................................................................................................... 895.6 Checking and refilling engine oil .................................................................................. 90

5.6.1 Checking oil-level .............................................................................................................. 905.6.2 Refilling Oil ........................................................................................................................ 915.6.3 After the oil level check and refilling the oil ....................................................................... 91

5.7 Exchanging engine oil and engine oil filter ................................................................. 925.7.1 After the oil change ........................................................................................................... 94

5.8 Verifying the starter batterie and (if necessary) the battery bank ............................. 955.9 Grease lubricated generator backend bearing ............................................................ 95

5.9.1 Exchange of grease lubricated bearing ............................................................................. 955.9.1.1 Demounting the cooling disc (if existent)................................................................................... 965.9.1.2 Demounting the backend bearing ............................................................................................. 965.9.1.3 Installing the new backend bearing........................................................................................... 97

5.10 Checking the oil level of the generator end bearing at Fischer Panda generators 1015.10.1 Oil level check ................................................................................................................. 1015.10.2 Refilling oil ....................................................................................................................... 1025.10.3 Refiller-Set ....................................................................................................................... 1025.10.4 Screw plug ....................................................................................................................... 102

5.11 Replacement of the oil-cooled backend bearing ....................................................... 1035.11.1 Exchange oil-cooled bearing ........................................................................................... 1035.11.2 Demounting the bearing .................................................................................................. 103

5.12 Checking the water separator in the fuel supply ...................................................... 1165.12.1 Ventilating the Fuel System ............................................................................................. 1165.12.2 Exchange of the Fuel Filter ............................................................................................. 117

5.12.2.1 Optional fuel filter with sight glass........................................................................................... 1185.12.3 Exchange the Air Filter Mat ........................................................................................... . 119

5.12.3.1 Alternative exchange the Air Filter Mat with pull out holder .................................................... 1205.12.4 Ventilation of the Coolant Circuit / Freshwater .............................................................. . 1225.12.5 Exchange of the V-Belt for the Internal Cooling Water Pump ......................................... 124

5.13 The Seawater Circuit .................................................................................................... 1265.13.1 Cleaning the Seawater Filter ........................................................................................... 126

5.14 Reasons for Frequent Impeller Wear .......................................................................... 1265.14.1 Exchanging the Impeller ................................................................................................ . 127

5.15 Conservation of the Generator (long operation interruption) .................................. 1295.15.1 Measures for preparation of winter storage ..................................................................... 1295.15.2 Initiation during Spring ..................................................................................................... 130

6 Generator Faults ........................................................................................................ 131

6.1 Personal requirements ................................................................................................ 1316.2 Safety instructions for this chapter ............................................................................ 1316.3 Tools and Measuring Instruments .............................................................................. 1326.4 Troubleshooting Table and Flowchart ....................................................................... 133

6.4.1 Generator output voltage too low .................................................................................... 1336.4.2 Generator voltage too high (more than 240 V - 50 Hz ................................................... 1336.4.3 Generator voltage fluctuates ........................................................................................... 1336.4.4 Generator not able to start electric motor ........................................................................ 1336.4.5 Diesel motor fails to start ................................................................................................. 1336.4.6 Starter is turning motor, but fails to start ......................................................................... 1336.4.7 Motor does not achieve enough speed during starting process ...................................... 1346.4.8 Motor runs unsteady ........................................................................................................ 1346.4.9 Motor speed drops .......................................................................................................... 1346.4.10 Motor runs in off position ................................................................................................. 1346.4.11 Motor stops by itself ........................................................................................................ 1356.4.12 Sooty, black exhaust ....................................................................................................... 1356.4.13 Generator must be shut off immediately if: ...................................................................... 1356.4.14 Troubleshooting for the VCS-Voltage Control ................................................................. 135

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Inhalt / Contens6.4.15 Troubleshooting Flowcharts ........................................................................................... . 136

6.4.15.1 Details and explanations concerning the troubleshooting flowchart ....................................... 1386.5 Versions of the generator power terminal box .......................................................... 1426.6 Overloading the Generator .......................................................................................... 146

6.6.1 Monitoring the Generator Voltage .................................................................................. . 1476.6.2 Automatic Voltage Monitoring and Auto-Shut Down ........................................................ 147

6.7 Setting the Speed Governor of the Actuator .............................................................. 1486.7.1 Setting the maximum upper speed setting ...................................................................... 1486.7.2 Setting the normal speed settings ................................................................................... 1496.7.3 Greasing the trapezoidal thread spindle on the speed actuator .................................... . 1506.7.4 Consequences of a continual overloading of the Actuator ............................................ . 1516.7.5 Possible faults concerning the speed control VCS ........................................................ 1516.7.6 Steps to check the voltage control in case of a failure: ................................................... 151

6.7.6.1 ..........................................The following measures are necessary if the actuator is jammed: 1526.7.6.2 Checking the generator voltage limitation............................................................................... 152

6.8 Generator-Output Voltage is too low .......................................................................... 1536.8.1 Discharging the Capacitors .............................................................................................. 1536.8.2 Checking the Capacitors ................................................................................................ . 154

6.8.2.1 Checking the electrical connections to the capacitors ............................................................ 1546.8.3 Check the Generator Voltage .......................................................................................... 1546.8.4 Measuring the Ohm Resistance of the Generator Windings ........................................... 1556.8.5 Check the Windings for Short Circuiting .......................................................................... 1556.8.6 Measuring the Inductive Resistance .............................................................................. . 156

6.9 Generator provides no voltage .................................................................................... 1566.9.1 Rotor Magnetism Loss and "Re-magnetising" ................................................................. 156

6.10 Engine Starting Problems ............................................................................................ 1576.10.1 Electric Fuel Solenoid Valve ........................................................................................... 1576.10.2 Re-start with Failure Bypass Switch ................................................................................ 1576.10.3 Lifting solenoid for motor stop - optional .......................................................................... 1586.10.4 Troubleshooting Table ..................................................................................................... 159

7 Tables ..........................................................................................................................161

7.1 Resistor & Inductance of the generator coil .............................................................. 1617.2 Voltage values stator coil ............................................................................................ 1627.3 Diameter of conduits .................................................................................................... 1627.4 Rated current ................................................................................................................ 1637.5 Cable cross section ...................................................................................................... 1637.6 Technical Data .............................................................................................................. 1647.7 Engine oil ....................................................................................................................... 165

7.7.1 Engine oil classification .................................................................................................... 1657.7.1.1 Operating range:..................................................................................................................... 1657.7.1.2 Quality of oil: ........................................................................................................................... 165

7.8 Coolant specifications ................................................................................................. 1667.8.1 Coolant mixture ratio ........................................................................................................ 166

7.9 Types of coil .................................................................................................................. 1677.9.1 HP1 - 230V / 50 Hz ......................................................................................................... 1677.9.2 HP1 - 120V / 60 Hz ......................................................................................................... 1677.9.3 HP3 - 400V / 50 Hz ........................................................................................................ . 1687.9.4 HP3 - 120V / 60 Hz .......................................................................................................... 1687.9.5 DVS - 400V / 50 Hz ......................................................................................................... 1687.9.6 DVS - 120V 240V / 60 Hz ............................................................................................. . 169

Generator Control Panel P6+ .............................................................................................171

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Current revision status ...................................................................................................... 172

8 General operation ...................................................................................................... 173

8.1 Panel Generator Control .............................................................................................. 1738.2 Rear view 12V-version ................................................................................................. 1748.3 Rear view 24V-version ................................................................................................. 175

8.3.1 Terminal connections ...................................................................................................... 1768.3.2 Function of the jumpers ................................................................................................... 1778.3.3 Configuration and adjustment ......................................................................................... 178

8.3.3.1 Configuration and setting sheet KE01..................................................................................... 1788.3.3.2 Configuration and setting sheet KE02..................................................................................... 1798.3.3.3 Configuration and setting sheet KE03..................................................................................... 1808.3.3.4 Configuration and setting sheet KE04..................................................................................... 181

8.4 Starting preparation / Checks (daily) .......................................................................... 1828.4.1 Marine version ................................................................................................................. 1828.4.2 Vehicle version ................................................................................................................ 182

8.5 Starting and stopping the generators ........................................................................ 1838.5.1 Starting the generator ...................................................................................................... 1838.5.2 Stopping the generator .................................................................................................... 184

8.6 Automatic adapter - optional ....................................................................................... 1858.6.1 Function: .......................................................................................................................... 1858.6.2 The mechanism entrance: ............................................................................................... 1858.6.3 Terminal connections ...................................................................................................... 187

8.7 Master-Slave adapter - optional .................................................................................. 1888.7.1 Fischer Panda Art. No. 21.02.02.015H 12V-version .............................................. 1888.7.2 Fischer Panda Art. No. 21.02.02.01H 24V-version ................................................ 1888.7.3 Terminal Connections: .................................................................................................... 1898.7.4 Fuse: ............................................................................................................................... 1898.7.5 Terminal connections ...................................................................................................... 189

8.7.5.1 Terminal X2 ( IN/OUT from view Master-Opearating-Panel)................................................... 1898.7.5.2 Terminal X3............................................................................................................................. 190

8.7.6 Configuration and adjustment ......................................................................................... 1918.7.6.1 Configuration and setting sheet KE05..................................................................................... 1918.7.6.2 Configuration and setting sheet KE06..................................................................................... 192

9 Measurements............................................................................................................ 193

9.1 Hole pattern .................................................................................................................. 193

Seite/Page 8 Marine_Panda_8000NE_CP_PMS_eng.R01 - Kapitel/Chapter 1: 23.7.10

General References and Regulations

23.7.10 General.R01.1 - Kapitel/Chapter 1: General References and Regulations Seite/Page 9

1. General References and Regulations

Fischer PandaFISCHER GENERATORS have been manufactured since 1978 and are a well-known brand for first class dieselgenerators with especially effective sound-insulation. Fischer has been one of the leading manufacturers for marinegenerators in respect of quality and know-how during this period. FISCHER, as the worldwide manufacturer ofmodern marine diesel generators, developed the Sailor-Silent series for example and produced a GFK sound-insu-lated capsule as early as 1979 and the basis for new generator technology.The companies Fischer and Icemaster amalgamated under the direction of Icemaster in 1988, in order to concen-trate on the development of new products. Production was moved to Paderborn.The amalgamation of the two quali-fied companies led to the development of a complete new programme within a short space of time. The generatorsdeveloped at that time set new technological standards worldwide.The generators became more efficient and powerful than other generators in the same nominal performance range,because of the improved cooling. Panda generator demonstrated its superiority in several tests by renowned institu-tes and magazines during the past years. The patented VCS (voltage Control System) means it can meet alldemands including motor speed. The start-booster (ASB) means Panda generators meet the highest demands inrespect of voltage stability and starting values. A water-cooled Fischer Panda generator, with the same drive motor, produces 15 % more effective output than themajority of conventional generators. This superiority in efficiency also ensures a fuel saving to the same extent.The Fischer Panda generators are currently manufactured in the performance range from 2 to 200 kW in variousversions. Fast running motors are preferred for performances up to approx. 30 kW (nominal speed 3000 resp. 3600rpm). The heavier slow runners are preferred for the higher range. The fast running generators have proved them-selves many times for many uses, that they meet the demands in quality of yachts and vehicles, and offer space andweight saving of 50 % compared to slow running generators.In addition to the Panda series, Fischer Panda also supply the super compact high-tech sound-insulated batterycharging generators from the DC/AC Panda AGT series, which is a very interesting solution for the production ofmobile power.The HTG-alternators ensure that a charging rate of 280 amps is achieved that was scarcely thought possible for thiscompact construction. This alternator replaces a separate shipboard generators (constant 230 volts AC with up to3.500 W from the main machine)

Icemaster GmbH Fischer MarineGenerators

Conclusion Fischer - Icemaster GmbH

100 % water cooled Panda generators

Panda Vehicle Generators

since 1977

since 1978

since 1988

since 1988

since 1988


Seite/Page 10 General.R01.1 - Kapitel/Chapter 1: General References and Regulations 23.7.10

1.1 Safety first symbols

These symbols are used throughout this manual and on labels on the machine itself to warn of the possibility of per-sonal injury. Read these instructions carefully. It is essential that you read the instructions and safety regulationsbefore you attempt to assemble or use unit.

Warning!: Toxic elementsThis danger symbol refers to toxic danger and draws attention to special warnings, instructions or procedures which, if not strictly observed, may result in severe personal injury or loss of life.

Attention!: Important AdviceThis warning symbol draws attention to special warnings, instructions or pro-cedures which, if not strictly observed, may result in damage or destruction of equipment

Warning!: Danger of fireThis warning symbol draws attention to special warnings, instructions or pro-cedures which, if not strictly observed, may result in damage or destruction of equipment

Prohibitation!: No SmokingDo not smoke in that area / do not smoke during the describes works

Prohibitation: Fire and open flames prohibitedFires and open light are ignition sources, which must be avoided.

Prohibitation: Turn on / start operation prohibitedDo not turn on or start operation. People are working at the generator and/or electrical system



Proscription!: Do not touch Berhren der entsprechenden Teile und Anlagen verboten

Warning!: Automatic start. Generator can be started by an external signal

Warning!: High voltage / danger by electricity -Danger for life

These symbols refer to electrical danger and points to special warnings, instructions and advices, which must be noticed. Otherwise an electrical shock with personal injury or death can be the consequence.

Warning!: Danger for life and/or equipment General Warning

Warning!: Harmful if accumulateSubstances can be harmful or lead to death, if accumulated or swallowed

Warning!: Electric shockWarning of live parts, which can cause electrical impacts during contact. Special danger for persons with heart problems and/or pace makers.

Warning!: Rotating partsDanger of injury by drawing into the machine. Injury by crushes and even-tually the separation of extremities. Danger of drawing during contact with extremities, loose clothes, scarf, ties etc.



Warning!: Risk of explosionWarning of materials, which can lead to explosions under certain conditions - e.g. heat or ignition sources

Warning!: Hot surfaceSurfaces and substances may be hot. Danger of burn / scalding

Warning!: Danger carrosive material - contermi-nation of persons possible

Warning of materials, which cause corrosive damage during contact. These materials can work contaminating when entering into the body.

Warning!: System can be under pressure!When opening the system the pressure can suddenly escape and drag along liquids. Danger of injury by parts flying around, danger of burn by liquids and gases.



Warning!: Hearing damage

Warning!: Magnetic field

Warning!: High pressure

Instruction!: Wear personal protective equip-ment (PPE)

Protective clothing is close fitting, with low resistance to tearing, with narrow sleeves and without protruding parts. It mainly provides protection against being entangled by moving machine parts.


Wear ear defenders to protect the ears against hearing damage.


Wear safety glasses to protect the eyes against parts flying around or squirts of fluids. Optical eyeglasses are not replacement for appropriate eye protec-tors.


Wearing protective gloves protects the hands against friction, graze, punctures or deep cuts as well as contact with hot surfaces.



Instruction!: Read the manual instructionsRead and consider the regulations, safety instructions and installation guide-lines of manual, in order to avoid dangers and accidents. You protect yours-elf and the generator.

Instruction!: Environmental protectionEnvironmental protection is the protection of our habitat. For you and your children



1.2 Tools

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

SpannersSW X = required size X mm

Hook wrench for oil filter

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

Multimeter, multimeter with capacitor measuring

Socket wrench set

Hexagon wrench keys

X



Current clamp (DC for synchron generators; AC for asynchron generators)

Drehmomentschlssel



1.3 Manufacturer declaration in accordance with the machine guideline 98/37/EG

Manufacturer declaration in accordance with the machine guideline 98/37/EGThe generator has been developed in such a way, that all assembly groups correspond to the CE guidelines. Ifmachine guideline 98/37/EG is applied, then it is forbidden to start the generator, until it has been ascertained thatthe system into which the generator is to be integrated, also corresponds to the machine guideline regulation 98/37/EG. This includes the exhaust system, cooling system and electrical installation.The evaluation of "protection against contact" must be carried out when installed, in conjunction with the respectivesystem. This includes correct electrical connections, a safe ground wire connection, foreign body and humidity pro-tection, protection against humidity due to excessive condensation, as well as overheating through appropriate andinappropriate use in its installed state. The responsibility lies with those who undertake installation of the generator inthe final system.

1.4 Customer registration and guarantee

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

1.4.1 Technical Support

Technical Support per Internet: [email protected]

1.4.2 Attention, important directions regarding operation!

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



1.5 Safety instructions - Safety first!

1.5.1 Safe operation

Careful operation is your best assurance against an accident. Read and understand this manualcarefully before operating the engine. All operators, no matter how much experience they mayhave, should read this and other related manuals befor operating the generator or any equipmentattached to it. It is the owners obnligation to provide all operators with this information and instructthem on safe operation.

1.5.2 Observe safety instructions

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

1.5.3 Wear personal protective equipment (PPE)

Do not wear loose, torn or bulky clothing around the maschine that may catch on working controlsand prejections or into fans, pulleys ond other moving parts causing personal injury.

Use additional safety items-PPE, e.g. safety protection, safety googles, gloves , etc.Do not operate the generator or any equipment attached to it while under the influence of alcohol,medication, or other drugs, or while fatigued.

Do not wear radio or music headphones while operating the generator.

1.5.4 Cleanness protect

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



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

Keep away open fire from fuels and lubricants.Always stop the generator before refueling and/or lubrivating and protect against unintentionalstarting. Do not smoke or allow flames or sparks in your work area. Fuel is extremely flammable and explo-sive under certain conditions.

Refuel at a well ventilated and open place. When fuel and/or lubrication are spilled, refuel afterletting the generator cool down. Do not mix gasoline or alkohol with diesel fuel. The mixture can couse a fire or severe generatordamage. Do not use unapproved containers e.g. buckets, bottles, jars. Use approved fuel starrage contai-ners and dispensers.

1.5.6 Exhaust gases and fire prevention

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

Exhaust gases of diesel engines and some components are carcinogen and can cause deformati-ons and other gene effects.

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.



1.5.7 Cautions against burns and battery explosion

To avoid burns, be cautious of hot components, e.g. muffler, muffler cover, radiator, hoses,engine body, coolants, engine oil, ect. during operation and after the engine has been shut down.

The Coolant system can be under pressure, Open the coolant system only, when the generatoris colled down. Wear Personal Protective Equipment.Be shure that the coolant system is closed and all hose clamps are tightend before operating thegenerator.

The battery (Starter battery and AGT battery bank) presents an explosive hazard. When the bat-tery is being charged, hydrogen and oxigen gasses are extremly explosive. Do not use or charge a battery if its fluid level is below the lower mark. Otherwise, the componentparts may deteriorate earlier than expected, which may shorten the the service life or cause anexplosion. Immediatly, add distilled water until the fluid level is between the lower and the uppermarks.

Keep sparks and open flames away from the battery, especially during charging. Do not strike amatch near the battery.Do not check the battery charge by placing a metal object across the terminals (danger of shortcircuit, battery damage and high danger of explosion). Use a Voltmeter or a hydrometer.Do not charge a frozen battery. There is a riosk of explosion. When frozen, warm the battery up toat least 16C.(61F).

1.5.8 Keep hands away from rotating parts

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

1.5.9 Anti-Freeze and disposal of fluids

Anti-freeze contains poison. Wear rubber gloves to avoid personal injury. In case of contact withskin, whash it off immideately. Do not mix different types of Anti-freeze. The mixture can producechemical reactioncausing harmful substances. Use approved or genuine Fischer Panda Anti-freeze.

Protect the environment. When draining fluids from the generator, place a siutable containerunderneath the generator body. Consider the relevant enviromental protection regulations whendisposing of oil, fuel, coolant, breakfluid, filters and batteries. Do not poor waste onto the ground,down a drain, or into any water source. Conducting safety checks and maintenance



1.5.10 Implementation of security and maintenance

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

1.6 Warning and caution labels

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

1.6.1 Safety instructions concerning operating the generator

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

The generator must not be taken into use with the cover removed.If the generator is being installed without a sound insulation capsule, make sure that all rotatingparts (belt-pulley, belts etc) are covered and protected so that there is no danger to life and body!If a sound insulation covering will be produced at the place of installation, then well-placed signsmust show that the generator can only be switched on with a closed capsule.All servicing-, maintenance or repair work may only carried out, when the motor is not running.Electrical voltages above 48 volts (battery chargers greater than 36 volts) are always dangerousto life). The rules of the respective regional authority must be adhered to. Only an electrician maycarry out installation of the electrical connections for safety reasons.



1.6.1.1 Protective grounding and potential equalisationIn the low voltage board for current supply of the consumers therefore a protective conductor is groundedand connected with electrically conductive objects. The connection with an outer conductor with theseobject then leads to the earth fault. This earth fault leads to the release of an over-current protection mecha-nism and thus to the disconnection of the voltage.

1.6.1.2 Ground wireThe generator, is "earthed" as series (centre and ground are connected together in the generatorterminal box by a bridge). This is an initial ground fuse, which offers protection, as long as no othermeasures are installed. Above all, it is conceived for the delivery and possible test run.This "neutralisation" (Protective Earthing Neutral - PEN) is only effective, if all parts of the electricalsystem are commonly "earthed" to a common potential. The bridges can be removed, if this isnecessary for technical reasons and another protective system has been setup.

There is full current in the AC control box when the generator is running. It must thereforebe ensured that the control box is closed and cannot be touched when the generator isrunning.The battery must always be disconnected, if work on the generator or electrical system isto be carried out, so that the generator cannot be unintentionally started.

1.6.1.3 Switch off all load when working on the generatorAll load must be disconnected, in order to avoid damages to the devices. In addition the semi conductors in the ACcontrol box must be disconnected in order to avoid the boat capacitors being activated. The minus pole of the batteryought to be removed.Capacitors are required to run the generator. These have two varying functions:A) The working capacitorsB) The (Booster) capacitorsBoth Groups are located in a separate AC-Control box.Capacitors are electrical stores. There could be a residual of high electrical current at the contactsfor a period disconnection from the circuit. The contacts may not be touched for safety reasons, Ifthe capacitors are to be exchanged or checked, and then a short circuit between the contactsshould be made so that the stored energy is discharged.If the generator is switched off in the normal manner, the working capacitors are automaticallydischarged by means of the windings. The booster capacitors are discharged by means of internaldischarge resistors.All capacitors must be short-circuited before work is carried out on the AC-Control box for safety reasons.Potential equalisation at Panda AGT DC generators. Further information for your generator see capture installation.



1.6.1.4 Safety instructions concerning the cables

Cable Type

It is recommended is that the cable used be UL 1426 (BC-5W2) compliant, with Type 3 stranding (ABYC Section E-11)

Cable Size

The cable size must be selected taking into account the amperage, voltage and conductor length (from the positivepower source connection to the electrical device and back to the negative power source connection.

Cable Installation

It is recommended that a self draining wire loom classified as V-2 or better in accordance with UL 94 be installed inthe section of the cable routed in the interior of the sound capsule. Care should be taken to avoid hot surfaces suchas the exhaust manifold or engine oil drain bolt and routed clear of any possible sources of chafing.

1.6.2 Recommended starter battery size

Only use batteries which are certified as starter battery by the manufacturer.Only use batteries with capacity recommended by the engine manufacturer.

1.6.3 Important Advice for Batteries - Starting batteries and Traction batteries

ATTENTION!!! Initial operation:Installation of battery lines. Consider the regulations and installation instructions of the battery manufacturer.

Consider ABYC regulation E11 AC and DC electrical systems on boats and/or EN ISO10133:2000 small watercrafts, electrical systems, low voltage (DC) systems !Ensure a professional battery installation.

The battery separation can be made mechanically or by an appropriate power relay.Consider the appropriate notes of the battery manufacturer concerning fire and explosion pre-vention.

Install a right sized fuse in the positive battery line as close as possible to the battery, but max.12 inch, 300mm from the battery.The length of the cable to the fuse, the cable must be protected by a sheath or conduit against damage of the insu-

Attention !! Check before installation if the starter battery voltage correspond with the genera-tor start system.

f.e. 12V starter battery for 12V start system

f.e. 24V starter battery for 24V start system



lation.

Use only cable with self retardant and self extinguishing insulation suitable for high temperatures up to 195F, 90C.Install battery lines in a safe way that the cable insulation will not be shaved or damaged.Battery poles must be protected against short circuits by error.Inside the capsule of the Fischer Panda Generator the battery positive line must be protectedagainst heat and vibration by a suitable conduit or sheath and must be routed that way it is nottouching any area that will get hot under normal operation like entire engine itself, exhaust elbowand exhaust manifold or exhaust lines or the V-belt and pulleys. The cable shall not be to tightotherwise damage will happen.Run the generator carefully after installation and double check, if there is any possibility fordamage of the battery cable. Correct if necessary.

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

1.6.4 Safety Instructions for the Handling with Batteries

These instructions must be noticed additionally to the instructions of the battery manufac-turer:

If the batteries are working, someone should be in your near area to help you in a case of emer-gency.

Water and soap must be hold ready if battery acid corrode your skin. Wear eye protection and protective clothing. During working with the batteries dont touch the

eyes. If you got a acid splash on your skin or clothing grow it with much water and soap out. If you got acid in your eyes rinse them immediately with clear water until no cauterization is no-

ticeable. Visit immediate a doctor.



Never smoke in the near of the batteries. Avoid naked flames or open fires. In the area of batte-ries exists danger of explosions.

Pay attention that no tools fall on the battery poles, if necessary cover them. During the installation dont wear a wrist watch or arm jewels, you can create under these cir-

cumstances a battery short-circuit. Burning of the skin could be the result. Protect every battery contact against unintentional touch. For battery banks: Use only cyclical profoundly dischargeable batteries. Starter batteries are not

appropriate. Lead-gel batteries are commended. They are maintenance-free, profoundly dischar-geable and not produce gas.

Do not charge a frozen battery. Avoid a batterie short-curcuit. Take care of a good ventilation of the battery to drain off developing gas. The battery connection terminals must be checked of a tight contact at least before operating. The battery connection cable must be carefully mounted and checked about incorrect heating at

operation with load. The vibrating devices must be regulary checked about scour points and flaw in the isolation.

Attention !! For battery charge generators (Fischer Panda AGT-DC)! Check before installation if the battery bank voltage correspond with the generator outputvoltage

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

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

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

First Aid in case of accidends by electrical shocks5 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 awooden pole, rope, or some nonconductive material.

Call an emergency doctor as soon as possible.

Immediately start necessary first aid procedures.

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

Seite/Page 28 - Kapitel/Chapter 2: In case of Emergency First Aid / Im Notfall - Erste Hilfe 23.7.10

2.1 WHEN AN ADULT STOPS BREATHING

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

1 Does the Person Respond? 2 Shout, "Help!"Tap or gently shake victim.Shout, "Are you OK?"

Call people who can phone for help.

3 Roll Person onto Back.Roll victim toward you by pullingslowly.

4 Open Airway. 5 Check for Breathing.Tilt head back, and lift chin.Shout, "Are you OK?"

Look, listen, and feel for breathing for3 to 5 seconds.

6 Give 2 Full Breaths.Keep head tilted back. Pinch nose shut.

Seal your lips tight around victim'smouth.

Give 2 full breaths for 1 to 1seconds each.

7 Check for Pulse at side of Neck. 8 Phone EMS for Help.Feel for pulse for 5 to 10 seconds. Send someone to call an ambulance.

9 Begin Rescue Breathing. 10 Recheck Pulse Every Minute.Keep head tilted back.Lift chin.Pinch nose shut.

Give 1 full breath every 5 seconds.Look, listen, and feel for breathingbetween breaths.

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

The Panda Generator

23.7.10 Marine_Panda_8000NE_CP_PMS_eng.R01 - Kapitel/Chapter 3: The Panda Generator Seite/Page 29

3. The Panda Generator

3.1 Type plate at the Generator

Fig. 3.1-1: Type plate at the generator

Fig. 3.1-2: Description type plate

The Panda Generator

Seite/Page 30 Marine_Panda_8000NE_CP_PMS_eng.R01 - Kapitel/Chapter 3: The Panda Generator 23.7.10

3.2 Description of the Generator

3.2.1 Right Side View

Fig. 3.2.1-1: Right Side View

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01. Water-cooled exhaust manifold / Heat exchanger (inside)02. 12 V DC-alternator03. V-belt for DC-alternator and cooling water pump04. Oil pressure switch05. Magnetic switch for starter motor06. Starter Motor07. Engine oil filter08. Generator power terminal box

09. Sound-cover base part10. Exhaust connection11. Connection for external cooling water expansion tank12. Raw water injection point13. Thermoswitch for cooling water injection14. Generator housing with winding15. Mini VCS

The Panda Generator


3.2.2 Left Side View

Fig. 3.2.2-1: Left Side View

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01) Charge control for DC-alternator02) Air suction housing with air filter03) Actuator for speed control04) Generator housing with winding05) Cooling water connection block06) Failure bypass switch07) Flat fuse08) Starter Relay Ks09) Pre-Glow Relay (Glow Plugs) K210) Starter Relay Fuel pump K3

11) Seawater inlet12) Fuel fine filter13) Oil dipstick14) Seawater pump15) Adjusting nut16) Ventilation screw fuel pump17) Internal cooling water pump18) Ventilation screw internal cooling water pump

The Panda Generator


3.2.3 Font View

Fig. 3.2.3-1: Front View

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01) Ventilation screw thermostat housing 02) Ventilation screw internal cooling water pump03) Internal cooling water pump04) Alternator 12 V 05) V-belt for DC-alternator and internal cooling water pump06) Engine oil filter07) Seawater pump08) Fuel fine filter 09) Seawater inlet 10) Fuel intake connection 11) Fuel backflow connection

12) Fuel pump cable (2x1,5mm)13) Oil drain hose14) Remote control panel cable (12x1mm)15) Electronic Voltage Control cable VCS (5x1mm)16) AC-Control box cable17) Electronic Voltage Control cable VCS (5x1mm)18) AC-Control box cable19) Main power20) Battery minus (-) 21) Battery plus (+)

The Panda Generator


3.2.4 Back View

Fig. 3.2.4-1: Back View

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01. Capacitor (boost)02) Air suction housing with air filter03) Capacitor (excitation)04) Generator front plate05) Cooling plate

06) Cooling water connection block07) Intake external cooling water expansion tank08) Backflow external cooling water expansion tank09) External ventilation valve connection

The Panda Generator


3.2.5 View from above

Fig. 3.2.5-1: View from above

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01) Ventilation screw fuel02) Ventilation screw internal cooling water pump03) Ventilation screw thermostat housing04) Thermostat housing with thermostat set05) 12 V DC-alternator06) Oil filler neck

07) Water cooled exhaust manifold / Heat exchange (insde)08) Injection nozzle09) Cylinder head thermo-switch10) Air suction housing with air filter11) Charge control for DC-Alternator

The Panda Generator


3.3 Details of functional units

3.3.1 Components of the Cooling System (Raw Water)

Fig. 3.3.1-1: Raw water intake Raw water intake

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

Fig. 3.3.1-2: Raw water impeller pump Raw water impeller pump

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

Fig. 3.3.1-3: Heat ExchangerHeat exchanger (mounted inside)The heat exchanger separates the raw water system from the fresh water system, so that the generator components do not have contact with the raw water circulation system. The raw water is fed direct to the exhaust connec-tion piece at the heat exchanger outlet.

The Panda Generator


Fig. 3.3.1-4: Connection ventilation valveVentilation valve

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

Fig. 3.3.1-5: Raw Water InjectionRaw Water InjectionThe injection point for the marine generator water-cooled exhaust system is situated at the exhaust connection pieces The exhaust connections must be regularly checked for signs of corrosion.

3.3.2 Components of the Cooling System (Fresh Water)

Fig. 3.3.2-1: Freshwater backflowFreshwater backflow

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

The Panda Generator


Fig. 3.3.2-2: Ventilation pipeVentilation pipe

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

Fig. 3.3.2-3: External Expansion TankHose connection pieces for the external expansion tank

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

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

Fig. 3.3.2-4: Heat ExchangerHeat exchanger

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

The Panda Generator


Fig. 3.3.2-5: Cooling Water Connection Block Cooling Water Connection Block

The cooling water is fed to and from the double lined casing of the generator. The cooling water terminal block seals must be regularly checked for leaks.

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

Fig. 3.3.2-6: Internal Cooling Water PumpInternal Cooling Water Pump

The fresh water pump aids the ciculation of the fresh water.

The fresh water enters and leaves the engine at the fresh water pump.

Fig. 3.3.2-7: Cooling water intakeCooling water intake

A.) To the thermostat housing

B.) From the external expansion tank

The intake pipe from the external cooling water expansion tank is connected to the point shown with B".

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B

The Panda Generator


Fig. 3.3.2-8: Ventilation Screw Cooling Water PumpVentilation screw cooling water pump

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

Fig. 3.3.2-9: Ventilation Screw Thermostat HousingVentilation screw thermostat housing

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

Fig. 3.3.2-10: Water Cooled Exhaust ManifoldWater cooled exhaust manifold

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

The Panda Generator


3.3.3 Components of Fuel System

Fig. 3.3.3-1: External Electrical Fuel PumpExternal Electrical Fuel Pump

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

Fig. 3.3.3-2: Connection Pieces for the Fuel PipeConnecting Pieces for the Fuel Pipe

1. Fuel intake

2. Fuel backflow

Fig. 3.3.3-3: Fuel FilterFuel Filter

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

A fine filter, which is firmly attached to the inside of the sound insulation cap-sule for the marine version, is supplied on delivery, and loose for other makes. In all cases a further pre-filter with water separator must be installed. See directions for fuel filter installation.

Fig. 3.3.3-4: Kraftstoff-Magnetventil Fuel Ventilation Screw

All models that do not have a fuel solenoid valve are equiped with a fuel ven-tilation screw to ventilate the fuel system.

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The Panda Generator


Fig. 3.3.3-5: Injection nozzles Injection NozzlesIf the engine does not start after the ventilation, the fuel injection lines must be ventilated individually.

Fig. 3.3.3-6: Glow PlugsGlow plugs

The glow plugs serve the pre-chamber for the heating with cold start. The glow device must be operated, if the temperature of the generator is below 16 C. This is practically the case with each star t. The glow device and star-ter button are set in a way that neither may be used at the same time.

The Panda Generator


3.3.4 Components of Combustion Air

Fig. 3.3.4-1: Combustion air intakeAir Suction Openings at the Sound Insulated Capsule

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

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

Fig. 3.3.4-2: Drillings for Combustion AirDrillings for combustion air at the sound insulated capsule

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

Fig. 3.3.4-3: Air Suction HousingAir suction housing with 12 V DC charge control

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

If the cover is removed, the inside of the air suction housing becomes visible. In these air suction housings is a filter element. The filter for the marine ver-sion is normally changed. It should be checked once in a while. 1

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The Panda Generator


Fig. 3.3.4-4: Air FilterAir Suction Housing with Air Filter Set

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

Fig. 3.3.4-5: Combustion Chamber Intake ElbowCombustion chamber intake elbow

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

Fig. 3.3.4-6: Exhaust ElbowWater-cooled Exhaust Elbow

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

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

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

The Panda Generator


Fig. 3.3.4-7: Exhaust ConnectionExhaust connection at the exhaust elbow

Seawater from the external cooling circle is fed here.

Fig. 3.3.4-8: Exhaust OutletExhaust outlet

Connect the exhaust pipe with the water lock.

3.3.5 Components of the Electrical System

Fig. 3.3.5-1: Cable for Starter BatteryConnection starter battery

1. Cable for starter battery (minus)

2. Cable for starter battery (plus)

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

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The Panda Generator


Fig. 3.3.5-2: Main PowerMain Power

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

Fig. 3.3.5-3: Electrical ConnectionsElectrical connections for control

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

1. Fuel pump

2. Remote control panel

3. VCS

4. AC-Control-Box

Fig. 3.3.5-4: Starter MotorStarter motor

1. Starter motor and

2. Solenoid switch

The diesel engine is started electrically. The electrical starter with the sole-noid switch is located at the rear of the engine.

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The Panda Generator


Fig. 3.3.5-5: ActuatorActuator for speed regulation

The generator voltage is determined by progressive speed control through "VCS" in conjunction with the speed actuator. Speed increases with increa-sing load.

Fig. 3.3.5-6: Blind PlugBlind Plug for Speed Sensor

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

Fig. 3.3.5-7: DC AlternatorDC Alternator

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

The 12 V charge system may be used only for the generator-own starter bat-tery.

The Panda Generator


Fig. 3.3.5-8: Charge ControlCharge control for DC alternator

The voltage regulator for the 12 V DC-alternator is located at the back of the air suction housing. The housing is streamlined for cooling purposes. The voltage regulator may not be externally covered. The surface must be acces-sible for cooling.

Fig. 3.3.5-9: Generator Power Terminal Box 230V/50HzGenerator Power Terminal Box 230V/50Hz

To locate the Terminalbox see Chapter A2.

In these terminal boxe there are the electrical connection points for the AC generator. Here is also the bridge for the protective grounding of the genera-tor. The cover may only be removed, if it is guaranteed that the generator cannot be inadvertently started.

Sample Picture

Fig. 3.3.5-10: Generator Power Terminal Box 400V/50HGenerator Power Terminal Box 400V/50Hz

To locate the Terminalbox see Chapter A2.

In these terminal boxe there are the electrical connection points for the AC generator. Here is also the bridge for the protective grounding of the genera-tor. The cover may only be removed, if it is guaranteed that the generator cannot be inadvertently started.

Sample Picture

LN L Z

L1 L3 NL2 PE

The Panda Generator


Fig. 3.3.5-11: Terminal BlockTerminal block for remote control cable with fuses and power relais

F1 fuse 15 A for DC wiring

F2 fuse 25 A for starter relay

Ks power relais for starter

K2 power relais for glow plugs

K3 power relais for fuel pump

3.3.6 The Operation Surveillance System

Fig. 3.3.6-1: Thermo-switch at Cylinder HeadThermo-switch at cylinder head

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

Fig. 3.3.6-2: Thermo-switch at exhaust connectionThermo-switch at exhaust connection

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

K2Ks K3

F1 F2

The Panda Generator


Fig. 3.3.6-3: Thermo-switch in the generator windingThermo-switch in the generator winding

1. Generator winding

2. Thermo-switch

3. Housing

Two thermo-switches inside the windings to protect the generator winding, which for safety reasons are installed independently in parallel.

Fig. 3.3.6-4: Oil Pressure SwitchOil pressure switch

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

Fig. 3.3.6-5: Failure Bypass switchFailure bypass switch

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

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The Panda Generator


3.3.7 Components of the Oil Circuit

Fig. 3.3.7-1: Oil filter neck with capOil filter neck with cap

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

Consider also the references to the engine oil specification.

Fig. 3.3.7-2: Oil dipstickOil dipstick

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

Fig. 3.3.7-3: Oil filterOil filter

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

The Panda Generator


Fig. 3.3.7-4: Oil Drain HoseOil Drain Hose

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

Note: Lubricating oil should be drained warm!

3.4 Remote Control Panel - see separate Control Panel Manual

3.4.1 Starting the Generator - see separate Control Panel Manual

3.4.2 Stopping the Generator - see separate Control Panel Manual

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The Panda Generator

Installation Instructions

23.7.10 Panda PMS 8.000 NE - 42 NE Manual.R05 - Kapitel/Chapter 4: Installation Instructions Seite/Page 53

4. Installation Instructions

4.1 Placement

Since Panda generators have extremely compact dimensions, they can be installed in tight locations. Attempts aresometimes made to install them in almost inaccessible places. Please consider that even almost maintenance-freemachinery 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 tobe checked regularly. The generator should not be placed in the proximity of light walls or floors, which can have resonance vibrationsbecause of airborne sounds. If this should be unavoidable, then it is recommended that this surface is lined with 1mm lead foil, which will change the mass and the vibration behaviour.You should avoid fixing the generator on a slippery surface with little mass (i.e.). This acts as an amplifier of airbornesounds in the most unreasonable case. An improvement can be achieved by reinforcing these surfaces with ribs. Inaddition, the breakthroughs, which interrupt these surfaces, should be sawed off. The lining of the surrounding wallswith a heavy layer (i.e lead) and foam additionally improve the conditions.The generator sucks its air from the surrounding engine room. Therefore it must be ensured that sufficient ventilationopenings are present, so that the generator cannot overheat. High temperature of the intake air decline the power of the generator and increases the coolant temperature. Airtemperatures of more than 40 C reduce the power by 2 % per temperature rise of 5 C. In order to keep th eseeffects as small as possible, the temperature in the engine room should not be higher than 15 C in rel ation to theoutside temperature.

4.1.1 Advice for optimal sound insulation

Fig. 4.1.1-1: Generator BaseThe convenient base consists of a stable framework, on which the generator is fastened by means of shock-mounts.

Since the aggregate is "free" downward, the combustion air can be sucked in unhindered.

In addition are void the vibrations, which would arise with a closed soil.

4.2 Generator Connections

Connect all electrical wires within the capsule tightly to the motor and the generator. This is also the case for fuellines and cooling water lines.The electrical connections MUST be carried out according to the respective valid regulations. This also concernsused cable materials. The cable supplied is meant for laying "protected" (i.e. in pipe) at a temperature up to a maxof. 70 C (160 F). The on-board circuit must also be fitted with all essential fuses.

Installation Instructions

Seite/Page 54 Panda PMS 8.000 NE - 42 NE Manual.R05 - Kapitel/Chapter 4: Installation Instructions 23.7.10

ATTENTION!

Before working (installatio

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