Fischer Panda Panda 14.000 NE PVK-U User manual

Generator type:
Panda 14.000 NE PVK-U
400V - 50 Hz / 12kW
Icemaster Fischer Panda

ii
Fischer Panda
FISCHER GENERATORS have been manufactured since 1978 and are a well-known brand for first class diesel gene-
rators with especially effective sound-insulation.
Fischer has been one of the leading manufacturers in respect of quality and know-how during this period.
FISCHER, as the worldwide manufacturer of modern marine diesel generators, developed the Sailor-Silent series for
example and produced a GFK sound-insulated capsule as early as 1979 and the basis for new generator technology.
The companies Fischer and Icemaster amalgamated under the direction of Icemaster in 1988, in order to concentrate
on the development of new products. Production was moved to Paderborn.
The amalgamation of the two qualified companies led to the development of a complete new programme within a short
space of time. The gensets developed at that time set new technological standards worldwide.
The gensets became more efficient and powerful than other gensets in the same nominal performance range, because
of the improved cooling. Panda generator demonstrated its superiority in several tests by renowned institutes and
magazines during the past years. The patented VCS (voltage Control System) means it can meet all demands including
motor speed. The start-booster (ASB) means Panda generators meet the highest demands in respect of voltage stabi-
lity and starting values A Panda generator, with the same drive motor, produces 15% more effective output than the
majority of conventional generators. This superiority in efficiency also ensures a fuel saving to the same extent.
The 100% water-cooled Panda genset are currently manufactured in the performance range from 2 to 100 kW in
various versions. Fast running motors are preferred for performances up to approx 30 kW (Nominal speed 3000 rpm).
The heavier slow runners are preferred for the higher range. The fast running gensets have proved themselves many
times for many uses, that they meet the demands in quality of yachts and vehicles, and offer space and weight saving
of 50% compared to slow running generators.
In addition to the Panda series, Icemaster also supply the super compact high-tech sound-insulated battery charging
genset from the DC/AC Panda AGT series, which is a very interesting solution for the production of mobile power.
The new HTG-alternators ensure that a charging rate of 285 amps is achieved that was scarcely thought possible for
this compact construction. This alternator replaces a separate shipboard generators (constant 230 volts AC with up to
3500 kW from the main machine)
ICEMASTER 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 pre-
vious 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 o doubt.
since 1972
Established in the
Marine technology
since 1978
Fischer Marine
Generators
since 1988
Conclusion Fischer -
Icemaster GmbH
since 1988
100 % water cooled Pan-
da generators
since 1988
Panda Vehicle Genera-
tors
30 20 10 10 10

iii
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.
The electrical Installations may only be carried out be trained and
tested personnel!
Manufacturer declaration in terms of the machine guideline 98/37/EG .
The generator is in such a way developed that all assembly groups correspond to the CE guidelines. If machine gui-
deline 98/37/EG is applicable, then it is forbidden to bring the generator into operation until it has been determined
that the system into which the generator is to be installed in also corresponds to the regulations of the machine gui-
deline 98/37/EG. This concerns among other things the exhaust system, cooling system and the electrical installa-
tion.
The evaluation of the "protection against contact" can only be accomplished in connection with the respective
system. Likewise among other things responsibility for correct electrical connections, a safe ground wire connection,
foreign body and humidity protection, protection against humidity due to excessive condensation as well as the over-
heating through appropriate and inappropriate use in its installed state on the respective machine lies within the
responsibility of those who undertake installation of the generator in the system.
Technical Support per Internet: [email protected]

iv
Safety Instructions
The electrical Installations may only be carried out be trained and
tested personnel!
The generator may not be taken into use with the cover removed.
The rotating parts (belt-pulley, belts, etc) must be so covered and protected do that there is no danger to life and
body!
If a sound insulation covering must be produced at the place of installation, then well-placed signs must show that
the generator can only be switched on with a closed capsule.
All servicing-, maintenance or repair work may only carried out, when the motor is not running.
Electrical voltages above 48 volts (battery chargers greater than 36 volts) are always dangerous to life). The rules of
the respective regional authority must be adhered to. Only an electrician may carry out installation of the electrical
connections for safety reasons.
Protective Conductor:
The generator is „earthed " as standard (The centre and earth are connected by means of a bridge in the generator
terminal box). This is a basic safety function, which offers basic safety as long as no other component has been
installed. It is, above all, conceived for supply and an eventual test run.
This "earth" (PEN) is only effective, if all parts of the electrical system is earthed, and has a common “potential”. The
bridges can be removed, if this is required for technical reasons and another protection system has been installed.
The full voltage is exploited at the AC-control box, when the generator is run. It must therefore be ensured
that the control box is closed and cannot be tampered with, if the generator is running.
The battery must always be disconnected, if work on the generator or electrical system is to be carried out,
so that the generator cannot be unintentionally started.
Switch off all load when working on the generator
All load must be disconnected, in order to avoid damages to the devices. In addition the semi conductors in the AC
control box must be disconnected in order to avoid the boat capacitors being activated. The minus pole of the battery
ought to be removed.
Capacitors are required to run the generator. These have two varying functions:
A) The working capacitors
B) The (Booster) capacitors
Both Groups are located in a separate AC-control box.
Capacitors are electrical stores. There could be a residual of high electrical current at the contacts for a period dis-
connection from the circuit. The contacts my not be touched for safety reasons, If the capacitors are to be exchanged
or checked, then a short circuit between the contacts should be made so that the stored energy is discharged.
If the generator is switched off in the normal manner, the working capacitors are automatically discharged by means
of the windings. The booster capacitors are discharged by means of internal discharge resistors.
All capacitors must be short-circuited before work is carried out on the AC control box for safety reasons.

Panda 14000 NE PVK-U S00420 - Table of contents - Page 1
Table of Contents
AThe Panda Generator .........................................................................................................3
A.1 Description of the genset .....................................................................................................3
A.1.1 Front View.................................................................................................................................3
A.1.2 Back View.................................................................................................................................. 4
A.1.3 Right Side View......................................................................................................................... 5
A.1.4 View from above........................................................................................................................ 6
A.2 Detais of functional units .....................................................................................................7
A.2.1 Remote control panel ................................................................................................................ 7
A.2.2 Components of coolant system................................................................................................. 8
A.2.3 Components of fuel system.................................................................................................... 12
A.2.4 Components of combustion air................................................................................................ 14
A.2.5 Components of electrical system ............................................................................................ 16
A.2.6 Sensors and switches for operating surveillance .................................................................... 19
A.2.7 Components of oil curcuit........................................................................................................ 21
A.2.8 Ecternal components............................................................................................................... 23
BGenerator Operating Instructions ..................................................................................25
B.1 Safety Instructions .............................................................................................................. 25
B.1.1 Protection Conductor:.............................................................................................................. 25
B.1.2 Instructions for Capacitors....................................................................................................... 25
B.2 Operating Instructions ........................................................................................................ 26
B.2.1 Routine „Pre-Start“ Checks (daily) .......................................................................................... 26
B.2.2 Preliminary remarks ................................................................................................................ 26
B.2.3 Overloading of Engine during longer Operation...................................................................... 28
B.2.4 Starting Generator................................................................................................................... 28
B.2.5 Stopping the Generator........................................................................................................... 29
B.2.6 Starting the Generator when overheated by a "Failure Bypass Switch“.................................. 29
B.2.7 Operating Control System on the Panda Generator ............................................................... 30
CMaintenance Instructions ................................................................................................33
C.1 Maintenance Requirements ................................................................................................33
C.2 Oil Circuit Maintenance ...................................................................................................... 33
C.3 De-aerating of the coolant circuit ...................................................................................... 36
C.4 Air-bleeding of the Fuel System ........................................................................................ 38
C.4.1 Exchange of the fuel filter........................................................................................................ 39
C.5 Exchange the air filter ......................................................................................................... 40
C.6 Exchange of the V-belt ........................................................................................................ 41
DGenerator Failure .............................................................................................................43
D.1 Overloading the Generator ................................................................................................. 43
D.1.1 Generator Voltage Fluctuations and Monitoring...................................................................... 44
D.1.2 Automatic Voltage Monitoring and Auto-Shut Down ............................................................... 44
D.1.3 Adjusting Instructions for the Spindle of the actuator.............................................................. 44
D.1.4 Adjustment of the maximum upper revolution:........................................................................ 45
D.1.5 Adjustment of the normal rev limitation ................................................................................... 46
D.1.6 Lubrication of the spiral thread spindle.................................................................................... 47
D.1.7 Effects of a overload to the actuator........................................................................................ 47
D.1.8 Low Generator Output Voltage................................................................................................ 49

Page 2 Panda 14000 NE PVK-U S00420 - Table of contents
D.1.9 Checking the Generator Voltage ........................................................................................... 50
D.1.10 Checking the Capacitors ........................................................................................................ 51
D.2 Testing Generator Stator Winding for "Shorts" to Ground .............................................53
D.3 Coil Resistance Measurements in Stator Windings .........................................................53
D.3.1 Measuring the Coil Inductive Resistance ............................................................................... 54
D.3.2 Rotor Magnetism Loss and "Re-magnetizing"........................................................................ 55
D.4 Starting Problems ................................................................................................................56
D.4.1 Fuel Solenoid Valve................................................................................................................ 56
D.4.2 Failure Bypass Switch ............................................................................................................ 57
D.5 Troubleshooting Table ........................................................................................................57
EInstallation Instructions ..................................................................................................59
E.1 Generator Connections .......................................................................................................59
E.1.1 General Instructions ............................................................................................................... 59
E.1.2 Connections............................................................................................................................ 59
E.1.3 Fuel System Installation ......................................................................................................... 60
E.1.4 Connection to 12V Starter Battery-Block................................................................................ 61
E.1.5 Connection of electrical components...................................................................................... 62
E.1.6 Connection of the external radiator ........................................................................................ 63
E.2 AC-Control box ....................................................................................................................64
E.2.1 Voltage control system ........................................................................................................... 65
E.3 The fan control .....................................................................................................................66
E.4 Cooling system ....................................................................................................................67
E.5 Exhaust installation .............................................................................................................80
FAppendix .............................................................................................................................I
F.1 Maintenance intervalls ...........................................................................................................I
F.2 Engine oil ...............................................................................................................................II
F.3 Coolant specifications .........................................................................................................III
F.4 Troubleshooting .................................................................................................................. IV
F.5 Technical Data Engine ........................................................................................................ IX
F.6 Technical Data Generator ................................................................................................... IX
F.7 Measurements ...................................................................................................................... X
F.8 Wiring diagram control panel ............................................................................................. XI

The Panda Generator
Panda 14.000 NE PVK-U S00420 - Chapter A: The Panda Generator Page 3
A. The Panda Generator
A.1 Description of the genset
A.1.1 Front View
22
01 03
21 20
02 04 06 07 08
13
19
14
18
09 10
11
17 16
05
12
15
01. Watercooled pre-silencer
02. De-aerating screw at the pre-silencer
03. Thermo-switch at the pre-silencer
04. Oil filter
05. Charge controler for DC-alternator
06. Air suction housing with air filter
07. Air suction tube, housing - induction elbow
08. Fuel solenoid valve
09. Thermostat housing
10. Pulley for internal cooling water pump and DC-alternator
11. Actuator for rpm-regulation
12. Oil dipstick
13. Alternative oil filler neck
14. Fuel filter
15. Failure bypass switch
16. Power relay K3
17. Power relay K2
18. Passage oil drain hose
19. Power relay Ks
20. Electrical fuses
21. Plug for rpm-sensor
22. Cooling water connection block

The Panda Generator
Page 4 Panda 14.000 NE PVK-U S00420 - Chapter A: The Panda Generator
A.1.2 Back View
02
09 10
08
12
03 04 05
07
06
01
11
01. Service- and inspektion hatch
02. Cooling water intake, radiator - generator
03. Cooling water output, generator - radiator
04. Exhaust output
05. Return pipe expansion tank
06. DC-Alternator
07. Watercooled exhaust manifold
08. Compensator under heat isolation
09. Oil pressure switch
10. Generator power terminal box
11. Starter motor
12. Generator housing with coil

The Panda Generator
Panda 14.000 NE PVK-U S00420 - Chapter A: The Panda Generator Page 5
A.1.3 Right Side View
1406 07 08 09 10 13 11 12
15
02
01
03
04
05
01. De-aersting screw internal cooling water pump
02. De-aerating screw thermostat housing
03. Pulley for internal cooling water pump and DC-alternator
04. V-belt
05. Alternative oil filler neck
06. Connection fuel in
07. Connection fuel out
08. Cable for fuel pump
09. Cable for remote control panel
10. Cable for VCS
11. Load
12. Cable for AC-Control box
13. Battery minus (-)
14. Battery plus (+)
15. Air suction intake

The Panda Generator
Page 6 Panda 14.000 NE PVK-U S00420 - Chapter A: The Panda Generator
A.1.4 View from above
02
01
06
08
11
03
14 13 12 10 09
07
04 05
01. Watercooled pre-silencer
02. Compensator under heat isolation
03. Cooling water tube
04. Watercooled exhaust manifold
05. Oil filler neck
06. DC-alternator 12V
07. De-aerating screw at the thermostat housing
08. De-aerating screw at the internal cooling water pump
09. Fuel solenoid valve
10. Air suction tube, housing - unduction elbow
11. Thermo-switch at the cylinder head
12. Air suction housing with air filter
13. Thermo-switch at the silencer
14. De-aerating screw at the silencer

The Panda Generator
Panda 14.000 NE PVK-U S00420 - Chapter A: The Panda Generator Page 7
A.2 Detais of functional units
A.2.1 Remote control panel
The remote control panel is equipped with some new monitoring functions, which increases the
operational safety of the generator. A failure message is shown over contacts which are normaly
closed. If a connection is intermitted triggers this a failure message.
Fig. A.1: Remote control panel
Automatic Start Option
An automatic start option is available as an accessory. This includes a separate control board,
which is connected to the main remote control board panel. The Automatic Start Option allows
the generator to be started by means of an external signal (i.e Battery Monitor). A speed gauge
and a sensor for speed pick-up are additionally necessary in addition to the automatic start
option. (See Component Automatic Start)
01 02 03 04 05
08
09 10
11
15 12 13
14
06 07
01. Warning light for coolant temperature
02. Warning light for water leak (sensor optional)
03. Warning light für AC-fault
04. AC-power indicator light
05. Warning light for coil temperature
06. Warning light for oil pressure
07. Battery charge voltage 12V-DC control light
08. Glow plug pre-heat indicator light
09. Glow plug pre-heat button
10. System „START“-button
11. System „START“ light
12. Main power switch „OFF“
13. Main power switch „ON“
14. Indicator light Generator „STAND BY“
15. Hours of operation counter

The Panda Generator
Page 8 Panda 14.000 NE PVK-U S00420 - Chapter A: The Panda Generator
A.2.2 Components of coolant system
This connection mst be connected with
the external radiator. From here the cool
water flows first into the cooling water
connection block, thus into the generator
coil.
Fig. A.2: Coolant in-flow
Cooling water connection block
The cooling water is fed to the generator
and drained via the cooling water connec-
tion block. The cooling water connection
block consists of an aluminium alloy,
which can behave like a sacrificial anode.
Fig. A.3: Cooling water connection block
Cooling water pipe
From the cooling water connection block
the water leads to the internal cooling
water pump.
Fig. A.4: Coolant flow

The Panda Generator
Panda 14.000 NE PVK-U S00420 - Chapter A: The Panda Generator Page 9
Internal cooling water pump
The diesel motor cooling water pump (see
arrow) aids the circulation of the internal
freshwater system.
Fig. A.5: Internal cooling water pump
De-aerating screw cooling water pump
The de-aerating screw above the cooling
water pump casing may not be opened,
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. A.6: De-aerating screw internal cooling water pump
De-aerating screw thermostat housing
The de-aerating screw on the thermostat
housing should occasionally be opened
for control purposes. Standing machinery
should principally carry out ventilating.
Fig. A.7: De-aerating screw thermostat housing

The Panda Generator
Page 10 Panda 14.000 NE PVK-U S00420 - Chapter A: The Panda Generator
Watercooled exhaust manifold
The exhaust elbow union is cooled by the
water withdrawing from the cylinder head.
Fig. A.8: Watercooled exhaust manifold
Cooling water pipe
Cooling water pipe from the water-cooled
exhaust elbow union to the water-cooled
pre-silencer.
Fig. A.9: Cooling water pipe
Watercooled pre-silencer
Fig. A.10: Watercooled pre-silencer

The Panda Generator
Panda 14.000 NE PVK-U S00420 - Chapter A: The Panda Generator Page 11
Cooling water return flow
From here the cooling water heated up
flows into the radiator.
Fig. A.11: Cooling water return flow
De-aerating screw
The de-aerating screw at the water-cooled
pre-silencer is used at first time filling or
after repair work.
Fig. A.12: de-aerating screw
Return flow expansion tank
The breather pipe at the water-cooled pre-
silencer leads to the external expansion
tank.
Fig. A.13: Return flow

The Panda Generator
Page 12 Panda 14.000 NE PVK-U S00420 - Chapter A: The Panda Generator
A.2.3 Components of fuel system
Electrical fuel pump
The Panda generator is always supplied
with an external, electrical (12 V of DC) fuel
pump. The fuel pump must be always
installed in the proximity of the tank. The
electrical connections with the lead plan-
ned for it are before-installed at the gene-
rator. 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. A.14: Electrical fuel pump
Connecting pieces for the fuel pipe
1. Fuel intake
2. Fuel backflow
Fig. A.15: Fuel connections
Fuel filter
A consequential filtering of fuel is especi-
ally important for all marine systems. A fine
filter, which is firmly attached to the inside
of the sound insulation capsule 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 instal-
lation.
Fig. A.16: Fuel filter
12

The Panda Generator
Panda 14.000 NE PVK-U S00420 - Chapter A: The Panda Generator Page 13
Fuel solenoid valve
The fuel solenoid valve opens automati-
cally if „START“ is pressed on the remote
control panel“. The solenoid closes, if the
generator is switched to „OFF“ position. It
takes a few seconds before the generator
stops. If the generator does not start or
does not run smoothly (i.e. stutters), or
does not attain full speed, then the cause is
fore-mostly the solenoid.
1) Fuel solenoid valve
2) Ventilation screw solenoid valve
3) Magnetic coil
Fig. A.17: Fuel solenoid valve
Injection nozzles
Fig. A.18: Injection nozzles
Glow plugs
Glow plugs heat the pre-chamber up
Fig. A.19: Glow plugs
2
1
3

The Panda Generator
Page 14 Panda 14.000 NE PVK-U S00420 - Chapter A: The Panda Generator
A.2.4 Components of combustion air
Suction air intake at sound cover
Do not cover!
Fig. A.20: Suction ait intake
Air suction housing
The air suction housing sucks in fresh air
from the sound cover.
Fig. A.21: Air suction housing
Air suction housing with air filter
Fig. A.22: Air filter

The Panda Generator
Panda 14.000 NE PVK-U S00420 - Chapter A: The Panda Generator Page 15
Induction elbow
Fig. A.23: Induction elbow
Watercooled exhaust manifold
Fig. A.24: Watercooled exhaust manifold
Compensator under heat isolation
This part is flexible by the internal struc-
ture and compensates vibrations.
Fig. A.25: Compensator

The Panda Generator
Page 16 Panda 14.000 NE PVK-U S00420 - Chapter A: The Panda Generator
Exhaust outlet
The silencer must be attached here.
Fig. A.26: Exhaust outlet
A.2.5 Components of electrical system
Connection starter battery
1. Cable for starter battery (minus)
2. Cable for starter battery (plus)
Fig. A.27: Cable for starter battery
Connection for load
Fig. A.28: Connection for load
1 2
1