Fischer Panda 8000 NE User manual

Marine_Panda_8000NE_Operation Manual 9.1.08
Fischer Panda GmbH
Marine Generator
Panda 8000 NE
Super silent technology
230V - 50 Hz / 6,5 kW
Operation Manual
Description of the generator and operation manual

2
Current revison status
Dokument
Actual: Marine_Panda_8000NE_Operation Manual_9.1.08
Replace:
Revision Page

Marine_Panda 8000NE_PMS_Betriebsanleitung - Inhaltsverzeichnis - Seite1
Contents
Current revison status........................................................................................................... 2
Safety first............................................................................................................................... 4
Tools........................................................................................................................................ 5
Safety Precautions................................................................................................................. 7
A The Panda Generator..................................................................................................... 9
A.1 Description of the Generator............................................................................................ 9
A.1.1 Right Side View.................................................................................................................... 9
A.2 Details of functional units .............................................................................................. 14
A.2.2 Components of the Cooling System (Fresh Water)............................................................ 16
A.2.3 Components of Fuel System.............................................................................................. 20
A.2.4 Components of Combustion Air ......................................................................................... 22
A.2.5 Components of the Electrical System ................................................................................ 25
A.2.6 The Operation Surveillance System................................................................................... 29
A.2.7 Components of the Oil Circuit ............................................................................................ 32
A.2.8 Other Components............................................................................................................. 33
B Impellerfilter ................................................................................................................. 35

Leere Seite

3
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

4
Safety first
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 perso-
nal injury or loss of life.
This danger symbol refers to electric danger and draws attention to special
warnings, instructions or procedures which, if not strictly observed, may result in
electrical shock which will result in severe personal injury or loss of life.
This warning symbol draws attention to special warnings, instructions or procedures
which, if not strictly observed, may result in damage or destruction of equipment,
severe personal injury or loss of life.
This warning symbol draws attention to special warnings, instructions or procedures
which, if not strictly observed, may result in damage or destruction of equipment

5
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

6
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.
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.
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.
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: [e-mail]

7
Safety Precautions
The electrical installations may only be carried out by trained and
qualified personnel!
Safety Instructions concerning operating the generator
• 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 danger 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 con-
trol 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 elec-
trical 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 com-
monly "earthed" to a common potential. The bridges can be removed, if this is necessary for technical 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 carried 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 disconnected!
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.

8
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 dis-
connection 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.

The Panda Generator
9.1.08 Panda 8000 PMS Operation Manual.V02 - Kapitel A: The Panda Generator Seite 9
A. The Panda Generator
A.1 Description of the Generator
A.1.1 Right Side View
Fig. A.1.1-1: Right Side View
06
03
05
08
13
16
09
11 12
14
17 18 19
20
15
10
07
02 04
01
21
01. Cooling water filler neck
02. Water-cooled exhaust manifold
03. 12 V DC-alternator
04. Exhaust manifold thermo-switch
05. V-belt for DC-alternator and cooling water pump
06. Magnetic switch for starter motor
07. Generator housing with winding
08. Oil pressure switch
09. Exhaust connection
10. Injector for cooling water
11. Engine oil filter
13. Cooling water backflow pipe
14. Generator power terminal box
15. Connection for external cooling water expansion tank
16. Sound cover - base part
17. Engine connecting flange
18. Exhaust thermo-switch
19. Exhaust hose connection
20. Connection for external ventilation valve
21) Eyelet

The Panda Generator
Seite 10 Panda 8000 PMS Operation Manual.V02 - Kapitel A: The Panda Generator 9.1.08
A.1.2 Left Side View
Fig. A.1.2-1: Left Side View
01 02
04
05
17 18 19 20 21 22 23
06
07
08
09
10
11
12
13
03
14
15
16
01) Charge control for DC-alternator
02) Air suction housing with air filter
03) Actuator for speed control
04) Generator housing with winding
05) Cooling water connection block
06) Ventilation screw thermostat housing
07) Ventilation screw internal cooling water pump
08) Pulley for internal cooling water pump
09) Fuel solenoid valve
10) Ventilation screw fuel solenoid valve
11) Adjusting screw
12) Stop screw for setting maximum speed
13) Seawater pump
14) Oil dipstick
15) Fuel fine filter
16) Seawater inlet
17) Engine connecting flange
18) Flat fuse 15Amps (blue)
19) Flat fuse 25Amps (white)
20) Starter relay Ks
21) Pre-glow relay (glow plugs) K2
22) Fuel pump start relay K3
23) Failure override switch

The Panda Generator
9.1.08 Panda 8000 PMS Operation Manual.V02 - Kapitel A: The Panda Generator Seite 11
A.1.3 Font View
Fig. A.1.3-1: Front View
01 07
10
12
13 22 2314 15 16 17 18 21 19 20
02 03
05
08
09
11
06
04
01) Ventilation screw internal cooling water pump
02) Fuel solenoid valve
03) Pulley for internal cooling water pump
04) Freshwater intake pipe
05) Seawater pump
06) Fuel fine filter
07) Ventilation screw thermostat housing
08) Thermostat housing with thermostat set
09) Alternator 12 V
10) V-belt for DC-alternator and internal cooling water pump
11) Engine oil filter
12) Earth switch relay
13) Seawater inlet
14) Fuel intake connection
15) Fuel backflow connection
16) Fuel pump cable (2x1,5mm²)
17) Oil drain hose
18) Remote control panel cable (12x1mm²)
19) Electronic Voltage Control cable VCS (5x1mm²)
20) AC-Control box cable
21) Load
22) Batterie minus (-)
23) Batterie mlus (+)

The Panda Generator
Seite 12 Panda 8000 PMS Operation Manual.V02 - Kapitel A: The Panda Generator 9.1.08
A.1.4 Back View
Fig. A.1.4-1: Back View
01
02
05
07
03 04
08
10 11 09
06
01. Cooling water filler neck
02. Exhaust manifolf thermo-switch
03) Air suction housing with air filter
04) Charge control for DC-alternator
05) Generator front plate
06) Oil flow glas
07) Thermo switch at oil cooled bearing
08) Cooling water connection block
09) Intake external cooling water expansion tank
10) Backflow external cooling water expansion tank
11) External ventilation valve connection

The Panda Generator
9.1.08 Panda 8000 PMS Operation Manual.V02 - Kapitel A: The Panda Generator Seite 13
A.1.5 View from above
Fig. A.1.5-1: View from above
02
01
03
05
07
08
10
09
04
11
12 13 14
06
15
01) Intake external cooling water expansion tank
02) Cooling water filler neck
03) Exhaust manifold thermo-switch
04) Engine oil filler neck
05) Air suction housing with air filter
06) Cylinder head thermo-switch
07) Charge control for DC-alternator
08) 12 V DC-alternator
09) Thermostat housing with thermostat set
10) Ventilation screw thermostat housing
11) Ventilation screw internal cooling water pump
12) Injection nozzle
13) Fuel solenoid valve
14) Ventilation screw fuel solenoid valve
15) Eyelet

The Panda Generator
Seite 14 Panda 8000 PMS Operation Manual.V02 - Kapitel A: The Panda Generator - Details of functional units 9.1.08
A.2 Details of functional units
A.2.1 Components of the Cooling System (Raw Water)
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-section of the
intake pipe should be nominally larger
than the generator connection.
Fig. A.2.1-1: Raw water intake
Raw water impeller pump
The raw water pump is fitted with a rubber
impeller. This pump is self-inductive. 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. A.2.1-2: Raw water impeller pump

The Panda Generator
9.1.08 Panda 8000 PMS Operation Manual.V02 - Kapitel A: The Panda Generator - Details of functional units Seite 15
Heat exchanger
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 connection piece at the heat
exchanger outlet.
Fig. A.2.1-3: Heat Exchanger
Ventilation 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 connecting pieces are bridged
by a formed piece of hose.
Fig. A.2.1-4: Connection ventilation valve
Raw Water Injection
The injection point for the marine genera-
tor water-cooled exhaust system is situa-
ted at the exhaust connection pieces The
exhaust connections must be regularly
checked for signs of corrosion.
Fig. A.2.1-5: Raw Water Injection

The Panda Generator
Seite 16 Panda 8000 PMS Operation Manual.V02 - Kapitel A: The Panda Generator - Details of functional units 9.1.08
A.2.2 Components of the Cooling System (Fresh Water)
Cooling water filler neck
The cooling water filler necks situated at
the water-cooled manifold are only used,
when the generator is initially started.
Since the generator is normally already fil-
led with cooling water, these components
are only by the user, if repairs are to be
carried out. Topping up with cooling water
may only carried out at the external coo-
ling water compensation tank. Note that
the water level in the cooling water com-
pensation tank is only 20 % of the volume
in a cold state.
Fig. A.2.2-1: Cooling water filler neck
Freshwater backflow
If the generator is fitted with a dual cooling
system, the fresh water circulation 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.
Fig. A.2.2-2: Freshwater backflow

The Panda Generator
9.1.08 Panda 8000 PMS Operation Manual.V02 - Kapitel A: The Panda Generator - Details of functional units Seite 17
Ventilation pipe
The ventilation pipe at the water-cooled
exhaust manifold leads to the external
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. A.2.2-3: Ventilation pipe
Hose 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 ven-
tilation is only necessary when the gene-
rator is initially filled, or if the cooling water
is not circulating.
Fig. A.2.2-4: External Expansion Tank
Heat exchanger
The internal freshwater circulation system
is separated from the Raw water circula-
tion system by the heat exchanger. This
means the Raw water circulation system
does not come into contact with the gene-
rator components. The Raw water is fed
directly to the exhaust connection at the
heat exchanger outlet.
Fig. A.2.2-5: Heat Exchanger

The Panda Generator
Seite 18 Panda 8000 PMS Operation Manual.V02 - Kapitel A: The Panda Generator - Details of functional units 9.1.08
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 termi-
nal block assumes the function of a sacri-
ficial anode.
Fig. A.2.2-6: Cooling Water Connection Block
IInternal 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. A.2.2-7: Internal Cooling Water Pump
Cooling 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".
Fig. A.2.2-8: Cooling water intake
A
B