Fischer Panda 4000s PMS SCB User manual

Panda_4000s_PMS_SCB_FCB_eng.R02 31.7.09
Description of the generator and operation manual
Marine Generator
Panda 4000s PMS SCB
Panda 4000s PMS FCB
230 V - 50 Hz / 3,8 kW
Super silent technology
Fischer Panda GmbH
Manual

2
Current Revison Status
Document
Actual: Panda_4000s_PMS_SCB_FCB_eng.R02_31.7.09
Replace: Panda_4000s PMS_SCB_eng.R01
Revision Page
Panda 4000s FCB added
Copyright
Duplication and change of the manual is permitted only with consultation with the manufacturer!
Fischer Panda GmbH, 33104 Paderborn, reserves all rights regarding text and graphics. Details are given to
the best of our knowledge. No liability is accepted for correctness. Technical modifications for improving
the product without previous notice may be undertaken without notice. Before installation, it must be ensu-
red that the pictures, diagrams and related material are applicable to the genset supplied. Enquiries must be
made in case o doubt.

31.7.09 Panda_4000s_PMS_SCB_FCB_eng.R02 - Table of contents Page 1
Table of contents
Current Revison Status.......................................................................................................... 2
Safety first symbols ............................................................................................................... 6
Tools........................................................................................................................................ 9
Safety instructions - Safety first!........................................................................................ 11
5 Safety steps to follow if someone is the victim of electrical shock ............................. 19
WHEN AN ADULT STOPS BREATHING.............................................................................. 20
A The Panda Generator................................................................................................... 21
A.1 Type plate at the Generator ........................................................................................... 21
A.2 Description of the Generator 4000s SCB PMS ............................................................ 22
A.2.1 Right Side View 4000s SCB PMS ..................................................................................... 22
A.2.2 Left Side View 4000s SCB PMS ....................................................................................... 23
A.2.3 Front View 4000s SCB PMS ............................................................................................. 24
A.2.4 Back View 4000s SCB PMS .............................................................................................. 25
A.2.5 View from above 4000s SCB PMS .................................................................................... 26
A.3 Description of the Generator 4000s FCB PMS ............................................................ 27
A.3.1 Right Side View 4000s FCB PMS ..................................................................................... 27
A.3.2 Left Side View 4000s FCB PMS ........................................................................................ 28
A.3.3 Front View 4000s 4000s FCB PMS ................................................................................... 29
A.3.4 Back View 4000s FCB PMS .............................................................................................. 30
A.3.5 View from above 4000s FCB PMS .................................................................................... 31
A.4 Details of Functional Units ............................................................................................ 32
A.4.1 Remote Control Panel - see Remote Control Panel Datasheet ........................................ 32
A.4.2 Components of Cooling System (Raw water) 4000s SCB ................................................ 33
A.4.3 Components of Cooling System (Raw water + Fresh water) 4000s FCB ......................... 37
A.4.3.1 Components of Cooling System (Raw water) 4000s FCB ........................................................ 38
A.4.3.2 Components of Cooling System (Fresh water)4000s FCB ....................................................... 40
A.4.4 Components of conbustion air 4000s SCB + 4000s FCB ................................................. 43
A.4.5 Components of the Fuel System 4000s SCB + 4000s FCB .............................................. 46
A.4.6 Components of Electrical System 4000s SCB + 4000s FCB ............................................ 48
A.4.7 Sensors and Switches for Operation Surveillance ............................................................ 51
A.4.8 Components of Oil Circuit 4000s SCB + 4000s FCB ........................................................ 52
A.5 Operation manual ........................................................................................................... 54
A.5.1 Preliminary remarks .......................................................................................................... 54
A.5.2 Daily routine checks before starting .................................................................................. 54
A.5.3 Starting Generator - see remote control panel datasheet ................................................. 55
A.5.4 Stopping Generator - see remote control panel datasheet .............................................. 55
B Installation Instructions .............................................................................................. 57
B.1 Placement ....................................................................................................................... 57
B.1.1 Placement and Basemount ............................................................................................... 57
B.1.2 Advice for optimal sound insulation ................................................................................... 57
B.2 Generator Connections - Scheme ................................................................................ 58
B.3 Cooling System Installation - Raw water ..................................................................... 59
B.3.1 General References .......................................................................................................... 59
B.3.2 Installation of the thru-vessel fitting in Yachts ................................................................... 60
B.3.3 Quality of the raw water sucking in line ............................................................................. 60
B.3.4 Installation above waterline ............................................................................................... 61

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Table of contents
B.3.5 Installation below waterline ................................................................................................62
B.3.6 Raw water single circuit cooling system ............................................................................65
B.3.7 Ventilating at the first filling of the Fresh water cooling circuit - FCB only .........................66
B.4 Watercooled Exhaust System .......................................................................................67
B.4.1 Installation of the standard exhaust system .......................................................................67
B.4.2 Exhaust / water separator ..................................................................................................68
B.4.3 Installation exhaust/water separator ..................................................................................69
B.5 Fuel System Installation .................................................................................................70
B.5.1 General References ...........................................................................................................70
B.5.2 Connection of the fuel lines at the tank ..............................................................................71
B.5.3 Position of the pre-filter with water separator ....................................................................71
B.6 Generator 12V DC System-Installation .........................................................................71
B.6.1 Connection of the 12V starter battery ................................................................................72
B.6.1.1 Additional information for battery connection............................................................................ 73
B.6.2 Connection of the load .......................................................................................................74
B.6.3 Connection of the remote control panel - see remote control panel datasheet .................75
B.7 Generator AC System-Installation ................................................................................76
B.7.1 Electrical connection scheme ............................................................................................76
C Maintenance Instructions............................................................................................77
C.1 General maintenance instructions ................................................................................77
C.1.1 Checks before starting .......................................................................................................77
C.1.2 Hose elements and rubber formed component in the sound cover ...................................77
C.2 Oil circuit maintenance ..................................................................................................77
C.2.1 Engine oil change ..............................................................................................................78
C.3 Ventilating the fuel system ............................................................................................80
C.3.1 Checking the water separator in the fuel supply ................................................................80
C.3.2 Exchange of the Fuel Filter ................................................................................................80
C.4 Replace the air filter element .........................................................................................81
C.4.1 Draining the coolant ...........................................................................................................82
C.5 The raw water circuit ......................................................................................................83
C.5.1 Clean raw water filter .........................................................................................................83
C.5.2 Causes with frequent impeller waste .................................................................................83
C.5.3 Replace the impeller ..........................................................................................................84
C.6 Conservation at longer operation interruption ............................................................86
C.6.1 Measures on preparation of the winter storage .................................................................86
C.6.2 Initiation at spring ...............................................................................................................87
D Generator Failure..........................................................................................................89
D.1 Tools and measuring instruments ................................................................................89
D.2 Overloading the Generator ............................................................................................89
D.2.1 Monitoring the Generator Voltage ......................................................................................90
D.2.2 Automatic Voltage Monitoring and Auto-Shut Down ..........................................................90
D.3 Low Generator-Output Voltage .....................................................................................91
D.3.1 Discharge the capacitors ...................................................................................................91
D.3.2 Checking the capacitor ......................................................................................................92
D.3.3 Checking the generator voltage .........................................................................................93
D.3.4 Measuring the coil resistance ............................................................................................93
D.3.5 Checking the coil(s) to short-circuit ....................................................................................94
D.3.6 Measuring the inductive resistance ...................................................................................94
D.4 Starting Problems ...........................................................................................................95

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Table of contents
D.4.2 Troubleshooting Table ....................................................................................................... 96
E Tables............................................................................................................................ 97
E.1 Troubleshooting ............................................................................................................. 97
E.2 Technical Data Engine ................................................................................................. 101
E.2.1 Technical Data Generator 4000s SCB + FCB ................................................................. 102
E.3 Engine oil ...................................................................................................................... 103
E.4 Coolant .......................................................................................................................... 104
E.5 Capsule Measurements 4000s .................................................................................... 105
A Remote Control Panel P4 Control ........................................................................... 107
A.1 Remote control panel ................................................................................................... 107
A.2 Cleaning and Replacing parts at the generator ......................................................... 108
A.3 Front side ...................................................................................................................... 108
A.3.1 Back Side ........................................................................................................................ 109
A.4 Operation Manual ......................................................................................................... 109
A.4.1 Preliminary Remarks ....................................................................................................... 109
A.4.2 Override Function ............................................................................................................ 110
A.4.3 Daily routine checks before starting ................................................................................ 110
A.4.4 Starting the Generator ..................................................................................................... 111
A.4.5 Stopping Generator ......................................................................................................... 111
A.5 Installation of the Panel ............................................................................................... 112
A.5.1 Connection of the remote control panel .......................................................................... 112
A.6 Jumperconfiguration ................................................................................................... 113
A.6.1 Jumper configuration for the input ................................................................................... 113
A.6.2 Jumper J101 - J103 ......................................................................................................... 113
A.6.3 Jumper for configuraton odf the „Override“ time ............................................................. 114
A.7 Maximum ratings .......................................................................................................... 114

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5
Fischer Panda
FISCHER GENERATORS have been manufactured since 1978 and are a well-known brand for first class diesel
generators 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 generators developed 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 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 stability 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 generators 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 generators 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, Fischer Panda also supply the super compact high-tech sound-insulated battery
charging generators from the DC/AC Panda AGT series, which is a very interesting solution for the production of mobile
power.
The 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)
Fischer Panda GmbH, 33104 Paderborn, reserves all rights regarding text and graphics. Details are given to the best of our knowledge. No liability is accepted for correct-
ness. Technical modifications for improving the product without previous notice may be undertaken without notice. Before installation, it must be ensured that the pictures,
diagrams and related material are applicable to the genset supplied. Enquiries must be made in case o doubt.
Icemaster GmbH Fischer Marine
Generators Conclusion Fischer - Icemaster GmbH 100 % water cooled Panda generators Panda Vehicle Generators
since
1977
since
1978
since
1988
since
1988
since
1988

6
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 regulations
before you attempt to assemble or use unit.
This 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.
Dieses Gefahrensymbol bezieht sich auf elektrische Gefahr und weist auf spezielle Warnungen,
Anweisungen oder Verfahren hin, die - wenn sie nicht beachtet werden - einen elektrischen
Schlag ergeben können, der Personenschäden oder den Verlust des Lebens zur Folge haben
kann.
This warning symbol draws attention to special warnings, instructions or procedures which, if not
strictly observed, may result in damage or destruction of equipment
Warning sign: Danger of fire
Prohibitation: Do not smoke
Prohibitation: Fire and open flames prohibited
Prohibitation: Turn on / start operation prohibited

7
Danger warning: Automatic start. generator can be started by an external signal
Danger warning: High voltage / danger by electricity - Danger for life
Danger warning: Danger for life and/or equipment
Danger warning: Harmfull if accumulate
Danger warning: Electric shock
Danger warning: Keep hand and body away from rotating parts
Danger warning: Risk of explosion
Danger warning: Hot surface

8
Danger warning: Danger carrosive material - contermination of persons possible
Instruction: Wear personal protective equipment (PPE)
Instruction: Read the manual instructions
Instruction: Wear protective glasses
Instruction: Wear safety gloves
Instruction: Be mindful of enviroment and the ecology

9
Tools
This symbols are used throughout this manual to show which tool must be used at maintenance or installation.
Spanners
X = required size
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

10
Manufacturer declaration in accordance with the machine guideline 98/37/EG
Manufacturer declaration in accordance with the machine guideline 98/37/EG
The generator has been developed in such a way, that all assembly groups correspond to the CE guidelines. If
machine guideline 98/37/EG is applied, then it is forbidden to start the generator, until it has been ascertained that
the system into which the generator is to be integrated, also 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 respective
system. 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 and
inappropriate use in its installed state. The responsibility lies with those who undertake installation of the generator in
the final system.
Customer registration and garantie
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 disturbances result
from errors in the periphery.
Problems due to errors in the installation can be recognized in the apron.
Technical Support per Internet: [email protected]
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.

11
Safety instructions - Safety first!
Safe operation
Careful operation is your best assurance against an accident. Read and understand this manual
carefully before operating the engine. All operators, no matter how much experience they may have,
should read this and other related manuals befor operating the generator or any equipment atta-
ched to it. It is the owner´s obnligation to provide all operators with this information and instruct them
on safe operation.
Observe safety instructions
Read and understand carefully this manual and „Labels at the engine“ before attempting to start and operate the
generator. Learn how to operate and work safely. Know how your equipment and its limitations. Always keep the
generator in good condition. Do not modify the generator Unauthorized Modifikations to the generator may impair the
function and/or the safety and affect generator life.
Wear safe clothing and Personal Protective Equipment PPE
Do not wear loose, torn or bulky clothing around the maschine that may catch on working controls
and prejections or into fans, pulleys ond other moving parts causing personal injury.
Use additional safety items-PPE, e.g. safety protection, safety googles, gloves , ect.
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.
Cleanness protect
Keep the engine and surrounding clean.
Be shure to stop the generator before cleaning. Keep the generator clean and free of accumula-
ted dirt, grease and trash to avoid fire. Store flammable liquids in proper containers and cabinets
away from sparks and heat. Check for and repair leaks immidiately.

12
Safe handling of fuel and lubricants - Keep away from fire
Always stop the generator befor refueling and/or lubrivating. Do not smoke or allow flames or
sparks in your work area. Fuel is extremely flammable and explosive under certain conditions.
Refuel at a well ventilated and open place. When fuel and/or lubrication are spilled, refuel after
letting the generator cool down.
Do not mix gasoline or alkohol with diesel fuel. The mixture can couse a fire or severe generator
damage.
Do not use unapproved containers e.g. buckets, bottles, jars. Use approved fuel starrage contai-
ners and dispensers.
Exhaust gases and fire prevention
Generator exhaust fumes can be very harmful af allowed to accumulated. Be sure to run the
engine 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 them imidiatly.
The exhaust gas and the engine can be very hot during and after operation very hot. To prevent
a fire, do not expose dry gras, moved gras, or any other combustible material to exhaust gas or
the hot generator surface.
o 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.
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.

13
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. Coo-
lant system can be under pressure, Open the coolant system only, when the generator is colled
down. Wear „Personal Protective Equipment „.
Be shure that the coolant system is closed and all hose clamps are tightend before operating the
generator.
.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 component parts may deteriorate
earlier than expected, which may shorten the the service life or cause an explosion. Immediatly,
add distilled water until the fluid level is between the lower and the upper marks.
.Keep sparks and open flames away from the battery, especially during charging. Do not strike a
match near the battery.
Do not check the battery charge by placing a metal object across the terminals. Use a Voltmeter
or a hydrometer.
Do not charge a frozen battery. There is a riosk of explosion. When frozen, warm the battery up to
at least 16°C.(61°F).
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 drive belt,
ra´w water pump drive belt, pulley or Flywheel.
Do not operate the generator without safety guards. Install safety guards securly before operation.
Anti-Freeze and Disposal of Fluids
Anti-freeze contains poison. Wear rubber gloves to avoid personal injuri. In case of contact with
skin, whash it off immideately.
Do not mix different types of Anti-freeze. The mixture can produce chemical reactioncausing
harmful substances. Use approved or genuine Fischer Panda Anti-freeze.
Ne mindful of the enviroment and the ecology. Before draining any fluids, determine the correct
way to dispose of them. Observe the relevant enviromental protection regulations when disposing
of oil, fuel, coolant, breakfluid, filters and batteries.
When drainin g fluids from the generator, place a siutable container underneath the generator
body.
Do not poor waste onto the ground, down a drain, or into any water source. Disposal of waste
fluids according to the environmental regulations.

14
Conducting safety checks and maintenance
Disconnect the battery from the generator before conducting service. Put a „DO NOT OPERATE“
tag on the remote control panel to avoid accidental starting. Disconnect any automatic starter
device, e.g. battery monitor to prevent automatic starting.
To avoid sparks from an accidental short circuit always disconnect the battery´s ground cable (-) first
and connect it last. be shure that the generator is stopped and cooleed down when conducting daily
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.
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.

15
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, then make sure, that
all rotating parts (belt-pulley, belts etc) are covered and protected so that there is no dan-
ger to life and body!
If a sound insulation covering will 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.
There is full current in the AC control box when the generator is running. It must therefore
be ensured that the control box is closed and cannot be touched when the generator is
running.
Do not work in an ambient, where there are explosives. Working on an electrical system in
an ambient where there are flammable gases is dangerous.
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.
Ground Wire:
The generator, is "earthed" as series (centre and ground are connected together in the generator
terminal box by a bridge). This is an initial ground fuse, which offers protection, as long as no other
measures 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 electrical
system are commonly "earthed" to a common potential. The bridges can be removed, if this is necessary for techni-
cal reasons and another protective system has been setup.
Safety Instructions concerning working on the generator
The battery must always be disconnected, if work on the generator or electrical system is to be car-
ried out, so that the generator cannot be unintentionally started. It is not allowed to disconnect
the battery during operation! After the generator has been stopped, the battery can be discon-
nected!
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 con-
ductors 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.

16
Safety Instructions concerning the capacitors
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 disconnection from the circuit. The contacts may not be touched for safety reasons, If
the capacitors are to be exchanged or checked, and 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.
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 positive
power 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 in
the section of the cable routed in the interior of the sound capsule. Care should be taken to avoid hot surfaces such
as the exhaust manifold or engine oil drain bolt and routed clear of any possible sources of chafing.
Recommend starter battery size
Battery
Warning:
Do not use Gel-Cel batteries, because the regulation voltage is high for this type of batteries.
Do not use large batterybanks as a starting battery. The generator must have a dedicated starter battery (maximum
size group 24).
Recommend starter battery size (if model not shown - please see engine manual)
Panda 6000 -8000 12V, 28AH equivalent Panda 18 12V, 65AH equivalent
Panda 9000-14000 12V, 36AH equivalent Panda 24-30 12V, 70AH equivalent
Panda 16 12V, 52AH equivalent Panda 33-42 12V, 100 to 120AH equi-
valent
Safety Instructions concerning operating the generator

17
Attention !! Check before installation if the starter battery voltage correspond with the
generator start system.
f.e. 12V starter battery for 12V start system
f.e. 24V starter battery for 24V start system

18
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