Fischer Panda Panda 6000i PMS User manual

Panda_6000i_System_eng_s01835.book.R01 16.1.09
Panda 6000i PMS
Super silent technology
230V 50Hz 6kW
Fischer Panda GmbH

2
Revision
Document
Akcuell: Panda_6000i_System_eng_s01835.book.R01_16.1.09
Replace
Revision Page
Copyright
Duplication and change of the manual is permitted only in consultation with the manufacturer!
Fischer Panda GmbH, 33104 Paderborn, reserves all rights regarding text and graphics. Details are given to
the best of our knowledge. No liability is accepted for correctness. Technical modifications for improving
the product without previous notice may be undertaken without notice. Before installation, it must be ensu-
red that the pictures, diagrams and related material are applicable to the genset supplied. Enquiries must be
made in case o doubt.

16.1.09 Panda_6000i_System_eng_s01835.book.R01 - Table of contents Page 3
Table of contents
Panda 6000i PMS.................................................................................................................... 1
Revision................................................................................................................................... 2
A Panda 6000i system....................................................................................................... 7
A.1 Components ..................................................................................................................... 7
A.2 Range of operation ........................................................................................................... 8
A.2.1 Main features of the Panda 6000i ....................................................................................... 8
Panda 6000i............................................................................................................................. 9
Part 1: Generator Manual....................................................................................................... 9
Current revision status........................................................................................................ 10
Safety first............................................................................................................................. 12
Tools...................................................................................................................................... 13
Safety Precautions............................................................................................................... 15
B Panda 6000i PMS generator....................................................................................... 19
B.1 Type plate at the generator ........................................................................................... 19
B.2.1 Right side view .................................................................................................................. 20
B.2.2 Left side view ..................................................................................................................... 21
B.2.3 Front view .......................................................................................................................... 22
B.2.4 Back view .......................................................................................................................... 23
B.2.5 View from above ................................................................................................................ 24
B.3 Details of function units ................................................................................................ 25
B.3.1 Remote control panel - See Panda iControl manual ......................................................... 25
B.3.2 Components of the cooling system (raw- and freshwater) ................................................ 25
B.3.3 Components of the fuel, air intake and exhaust system .................................................... 26
B.3.4 Components of the electrical system ................................................................................ 27
B.3.5 Components of the lubrication system .............................................................................. 28
B.3.6 Sensors and switches for operating surveillance .............................................................. 29
B.4 Operation instructions - See Panda iControl panel manual ....................................... 30
B.4.1 Daily routine checks before starting - See Panda iControl manual ................................... 30
B.4.2 Starting generator - See Panda iControl manual .............................................................. 30
B.4.3 Stopping the generator - See Panda iControl manual ....................................................... 30
C Installation Instructions .............................................................................................. 31
C.1 Placement ....................................................................................................................... 31
C.1.1 Advice for optimal sound insulation ................................................................................... 31
C.2 Generator connections .................................................................................................. 32
C.3 Cooling system installation - Raw water ...................................................................... 33
C.3.1 General information ........................................................................................................... 33
C.3.2 Installation of the thru hull fitting in yachts ......................................................................... 33
C.3.3 Quality of the raw water sucking in line ............................................................................. 33
C.3.4 Generator installation above waterline .............................................................................. 34
C.3.5 Generator installation below waterline .............................................................................. 35
C.3.6 Indirect cooling of the genset housing (by the heat exchanger) ........................................ 36

Page 4 Panda_6000i_System_eng_s01835.book.R01 - Table of contents 16.1.09
Table of contents
C.4 The freshwater coolant circuit .......................................................................................37
C.4.1 Position of the external cooling water expansion tank .......................................................37
C.4.2 Pressure test for controlling the cooling water circuit ........................................................ 37
C.4.3 Scheme for freshwater circuit at two circuit cooling system ..............................................38
C.5 Water-cooled exhaust system .......................................................................................39
C.5.1 Installation of the standard exhaust system .......................................................................39
C.5.2 Exhaust / water separator ..................................................................................................40
C.5.3 Installation exhaust-water-separator ..................................................................................41
C.6 Installation of the fuel system .......................................................................................43
C.6.1 General references ............................................................................................................43
C.6.2 The electrical fuel pump .....................................................................................................44
C.6.3 Connection of the fuel lines at the tank ..............................................................................44
C.6.4 Position of the pre-filter with water separator ....................................................................45
C.7 Generator 12VDC system installation ...........................................................................46
C.7.1 Connection of the 12V starter battery ................................................................................46
C.7.2 Connection of the remote control panel - See Panda iControl panel manual ....................46
C.8.1 Installation PMGi inverter - See separat PMGi 6000 inverter manual ...............................48
D Generator Failure..........................................................................................................49
D.1 Tools and measuring instruments ................................................................................49
D.2 Overloading the generator .............................................................................................49
D.2.1 Low generator-output voltage ............................................................................................50
D.3 Starting problems ...........................................................................................................50
D.3.1 Fuel solenoid valve ............................................................................................................50
D.3.2 Dirty fuel filter .....................................................................................................................51
D.4 Troubleshooting table ....................................................................................................51
E Maintenance Instructions............................................................................................53
E.1 General maintenance instructions ................................................................................53
E.1.1 Checks before starting .......................................................................................................53
E.1.2 Check of hoses and rubber parts in the sound insulated capsule .....................................53
E.2 Oil change intervals ........................................................................................................53
E.2.1 Execution of an oil change .................................................................................................54
E.3 Ventilating the fuel system ............................................................................................57
E.3.1 Replace of the fuel filter .....................................................................................................58
E.3.2 Checking the water separator in the fuel supply ................................................................59
E.4 Replace the air filter mat ................................................................................................60
E.5 Ventilation of the Coolant Circuit / Freshwater ............................................................61
E.6 Replace of the v-belt for the internal cooling water pump .........................................63
E.7 The Raw water circuit .....................................................................................................65
E.7.1 Clean raw water filter .........................................................................................................65
E.7.2 Reason for frequent impeller wear .....................................................................................65
E.7.3 Replace the impeller ..........................................................................................................66
E.8 Conservation of the generator (long operation interruption) .....................................68
E.8.1 Measures for preparation of winter storage .......................................................................68
E.8.2 Initiation during spring ........................................................................................................69
F Tables............................................................................................................................71
F.1 Troubleshooting .............................................................................................................71

16.1.09 Panda_6000i_System_eng_s01835.book.R01 - Table of contents Page 5
Table of contents
F.2 Technical data ................................................................................................................ 74
F.2.1 Technical data generator ................................................................................................... 74
F.2.2 Technical data engine ....................................................................................................... 75
F.3 Engine oil specification ................................................................................................. 77
F.4 Coolant specifications ................................................................................................... 78
Panda i-series....................................................................................................................... 79
Part 2: Panel Panda iControl Manual.................................................................................. 79
Current revision status........................................................................................................ 80
A Panda iControl ............................................................................................................. 81
A.1 Safety instructions ......................................................................................................... 82
A.2 Connection of the iControl ............................................................................................ 82
A.3 Buttons and display of the iControl ............................................................................. 83
A.4 Engine control ................................................................................................................ 84
A.5 Operation manual ........................................................................................................... 84
A.5.1 Daily routine checks before starting .................................................................................. 84
A.5.2 General .............................................................................................................................. 85
A.5.3 Long time run of the generator .......................................................................................... 86
A.5.4 Start of the generator ........................................................................................................ 86
A.5.5 Stop of the generator ......................................................................................................... 87
A.5.6 Automatic start .................................................................................................................. 87
A.5.7 Additional information ........................................................................................................ 87
A.6 Error warnings ................................................................................................................ 88
A.7 Errors ............................................................................................................................... 88
A.8 Electronic board ............................................................................................................. 89
A.8.1 Location at the Panda i-series generator .......................................................................... 89
A.9 Technical data ................................................................................................................ 90
A.9.1 Intended use ...................................................................................................................... 90
A.9.2 Dimensions ........................................................................................................................ 91
Panda i-series....................................................................................................................... 93
Part 3: PMGi 6000 inverter Manual...................................................................................... 93
Current revision status........................................................................................................ 94
A Panda PMGi 6000........................................................................................................ 95
A.1 Safety instruction ........................................................................................................... 96
A.2 Type plate ........................................................................................................................ 96
A.3 Front side/connection side ............................................................................................ 97
A.3.1 Socket pins of the PMGi 6000 ........................................................................................... 97
A.4 Back side - Top side ....................................................................................................... 98
A.5 Operation manual ........................................................................................................... 99
A.5.1 Primary remarks / Winter operation ................................................................................... 99

Page 6 Panda_6000i_System_eng_s01835.book.R01 - Table of contents 16.1.09
Table of contents
A.5.2 Load at the PMGi ...............................................................................................................99
A.5.3 Automatic start ...................................................................................................................99
A.6 Status LED´s ...................................................................................................................99
A.7 Cooling of the PMGi .....................................................................................................100
A.8 Installation of the PMGi ................................................................................................100
A.8.1 Electrical connection. .......................................................................................................100
A.8.2 Installation of the ferrites ..................................................................................................101
A.9 Technical Data ..............................................................................................................102
A.9.1 General Data ...................................................................................................................102
A.9.2 Generator Spezifikation ...................................................................................................102
A.9.3 PMGi out ..........................................................................................................................103
A.10 PMGi protections ..........................................................................................................104
A.10.1 Overload - switch point ....................................................................................................104
A.10.2 Short circiut ......................................................................................................................104
A.10.3 Under voltage and signal .................................................................................................104
A.10.4 Overheat ..........................................................................................................................105

Panda 6000i system
16.1.09 Panda_6000i_System_eng_s01835.book.R01 - Chapter A: Panda 6000i system Page 7
A. Panda 6000i system
A.1 Components
1. Panda 6000i PMS Generator
Permanent-Magnet-Generator
Art. no. C10060BX1SV01
Manual see “Part 1: Generator Manual” on
page 9.
Fig. A.1-1: Panda 6000i generator
2. Panel Panda iControl with
electronic board at the generator
Art no. 21.02.02.011H (Panel)
Art no. 21.02.01.005H (electronic board)
Manual see “Part 2: Panel Panda iControl
Manual” on page 79.
Fig. A.1-2: iControl panel
3. Panda PMGi 6000 Inverter AC/AC
6kW 230V / 50Hz
Art. no. 21.07.03.008P
Manual see “Part 3: PMGi 6000 inverter
Manual” on page 93.
Fig. A.1-3: PMGi 6000 inverter

Panda 6000i system
Page 8 Panda_6000i_System_eng_s01835.book.R01 - Chapter A: Panda 6000i system 16.1.09
A.2 Range of operation
Reliable power supply on sailing boats.
A.2.1 Main features of the Panda 6000i
• Extremely high starting capacity, perfect for a Bauer junior II compressor or air conditioner!
• 230V / 50Hz system for all your domestic appliances!
• Compact and light, takes up less space!
• Super silent sound insulation capsule!
• Graphical Display, easy to operate!
• Option for reduce speed at lower loads, saves fuel!
• Pure sinus wave, higher frequency and voltage stability!
• Optimized engine rpm (2800 rpm) for a long generator life!

Panda 6000i PMS
230V/50Hz 6kW
Fischer Panda GmbH
Panda 6000i
Part 1: Generator Manual

10
Current revision status
Document
Actual: Panda 6000i generator_s01835_eng.R01_16.1.09
Replace:
Revision Page

11
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 GPR 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 generator sets 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 3.000 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 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)
Fischer Panda GmbH, 33104 Paderborn, reserves all rights regarding text and graphics. Details are given to the best of our knowledge. No liability is accepted for
correctness. Technical modifications for improving the product without previous notice may be undertaken without notice. Before installation, it must be ensured that the
pictures, diagrams and related material are applicable to the aggregate supplied. Enquiries must be made in case of doubt.
Icemaster GmbH Fischer Marine
Generators Conclusion Fischer - Icemaster GmbH 100 % water cooled Pan- da generators Panda Vehicle Genera- tors
since
1977
since
1978
since
1988
since
1988
since
1988

12
Safety first
These symbols are used throughout this manual and on labels on the maschine itself to warn of the possibility of
personal injutry. 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.
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 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

13
Tools
This symbols are used throughout this manual to show which tool must be used at maintenance or installation.
Spanners
X = number of spanner
Hook wrench for oil filter
Screw driver, for slotted head screws and for recessed head screws
Multimeter, multimeter with capacitor measuring
Infrared temperature mesuring pistol
Current clamp (DC for synchron generators; AC for asynchron generators)
X

14
Socket wrench set
Hexagon wrench keys

15
Safety Precautions
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.
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.
Use the advantages of the customer registration:
• Thus you receive extended product information, which are sometimes safety-relevant
• You receive free upgrades, if necessary
Further advantages:
With your full information, the Fischer Panda technicians can give you fast assistance, since 90 % of the distur-
bances result from errors in the periphery.
Problems according to errors in the installation can be recognized in advance.
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.

16
The electrical Installations may only be carried out by trained and
examined personnel!
The generator may not be taken into use with the cover removed.
The rotating parts (belt-pulley, belts, etc) must be covered and protected so that there is no danger to life and body!
If a sound insulation cover 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 be carried out, when the motor is not running.
Electrical power: DANGER TO LIFE!
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.
General safety references for the enterprise of a generator.
With all energized systems, with which the current is more than 50 Ampère, special safety precautions must be
made, in order to protect the environment of the components against fire.
It is to be ensured absolutely that at the battery a main switch in well accessible place is accommodated, so that with
danger of the main switches can be separated immediately. The main switch must be however also directly at the
battery installed. If this place is not well accessible, a power relay must be used instead of the main switch which can
be served manually, which can be served then if necessary from different places. The switches for the power relay
are to mark accordingly as main switches DC battery "with danger switch off!".
ATTENTION!
Do not connect the minus pole of the starter battery to the ground of the boat because of galvanic reason.
CAUTION!
Contact of the electrical contacts may be DANGER TO LIFE!
The PMGi cable must be secured at the generator and at the PMGi with appropriate safety devices.
The generator is also included into the CO
2
- fire-extinguishing system.
Fire protection measures
All construction units in the environment of energized parts, which carry more than 50 Amp., must be fire protection-
moderately secured.
All junction points at the energized parts must be examined on heating up regularly (infrared thermometers).

17
Safety Instrictions for handling batteries
These instructions must be noticed additionally to the instructions of the battery manufacturer:
• If the batteries are working, someone should be in your near area to help you in a case of emergency.
• Water and soap must be hold ready if battery acid corrode your skin.
• Wear eye protection and protective clothing. During working with the batteries don´t touch the eyes.
• If you got an acid splash on your skin or clothing, wash it out with much water and soap.
• If you got acid in your eyes, rinse them immediately with clear water until no cauterization is noticeable. Visit a doc-
tor immediately.
• Don´t smoke in the area of the batteries. Avoid open fires. In the area of batteries there is a danger of explosions.
• Pay attention that no tools will fall on the battery poles, if necessary cover them up.
• During the installation, don´t wear a wrist watch or arm jewels, under these circumstances you can create a battery
short-circuit. Skin burnings could be the result.
• Protect every battery contact against unintentional touch.
• Use only cyclical profoundly dischargeable batteries. Starter batteries are not appropriate. Lead-gel batteries are
commended. They are maintenance-free, profoundly dischargeable and produce no gas.
• Do not charge a frozen battery.
• Avoid a battery short-curcuit.
• Take care that the battery is good ventilated in order to drain off developing gas.
• The battery connection terminals must be checked for tightness before operating.
• The battery connection cable must be mounted carefully. Check for incorrect heating at operation with load. The
vibrating devices must be checked regulary for scour points and flaw in the isolation.
Technical Support by Internet: [email protected]

18
Intentionally Blank

Panda 6000i PMS generator
16.1.09 Panda 6000i generator_s01835_eng.R01 - Chapter: B: Panda 6000i PMS generator Page 19
B. Panda 6000i PMS generator
B.1 Type plate at the generator
Fig. B.1-1: Type plate
Fig. B.1-2: Discription type plate

Panda 6000i PMS generator
Page 20 Panda 6000i generator_s01835_eng.R01 - Chapter: B: Panda 6000i PMS generator 16.1.09
B.2 Description of the generator
B.2.1 Right side view
Fig. B.2.1-1: Right side view
01
03
04
06
12
02
05
07 08 09 1110
13
14
15
01) Thermostat housing
02) DC-alternator 12V
03) Oil pressure switch
04) Oil filter
05) Cooling water pipe, heat exchanger - water pump
06) Sound cover base part
07) Heat exchanger
08) Starter motor
09) Solenoid switch for starter motor
10) Exhaust outlet
11) Thermosensor
12) Exhaust hose
13) Raw water injection pipe
14) Ventilation pipe to external expansion tank
15) Watercooled exhaust elbow