Panda PMS 8mini E-TEC Operation Manual (V02)
Panda PMS 8mini E-TEC Operation Manual (V02)
Panda PMS 8mini E-TEC Operation Manual (V02)
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since 1977 since 1978 since 1988 since 1988 since 1988
Icemaster GmbH Fischer Marine Conclusion Fischer - 100 % water cooled Panda Vehicle
Generators Icemaster GmbH Panda generators Generators
Fischer Panda
FISCHER GENERATORS have been manufactured since 1978 and are a well-known brand for first class diesel gene-
rators with especially effective sound-insulation.
Fischer has been one of the leading manufacturers in respect of quality and know-how during this period.
FISCHER, as the worldwide manufacturer of modern marine diesel generators, developed the Sailor-Silent series for
example and produced a GFK sound-insulated capsule as early as 1979 and the basis for new generator technology.
The companies Fischer and Icemaster amalgamated under the direction of Icemaster in 1988, in order to concentrate
on the development of new products. Production was moved to Paderborn.
The amalgamation of the two qualified companies led to the development of a complete new programme within a short
space of time. The gensets developed at that time set new technological standards worldwide.
The gensets became more efficient and powerful than other gensets in the same nominal performance range, because
of the improved cooling. Panda generator demonstrated its superiority in several tests by renowned institutes and
magazines during the past years. The patented VCS (voltage Control System) means it can meet all demands including
motor speed. The start-booster (ASB) means Panda generators meet the highest demands in respect of voltage stabi-
lity and starting values A Panda generator, with the same drive motor, produces 15% more effective output than the
majority of conventional generators. This superiority in efficiency also ensures a fuel saving to the same extent.
The 100% water-cooled Panda genset are currently manufactured in the performance range from 2 to 100 kW in
various versions. Fast running motors are preferred for performances up to approx 30 kW (Nominal speed 3000 rpm).
The heavier slow runners are preferred for the higher range. The fast running gensets have proved themselves many
times for many uses, that they meet the demands in quality of yachts and vehicles, and offer space and weight saving
of 50% compared to slow running generators.
In addition to the Panda series, Icemaster also supply the super compact high-tech sound-insulated battery charging
genset from the DC/AC Panda AGT series, which is a very interesting solution for the production of mobile power.
The new HTG-alternators ensure that a charging rate of 285 amps is achieved that was scarcely thought possible for
this compact construction. This alternator replaces a separate shipboard generators (constant 230 volts AC with up to
3500 kW from the main machine)
ICEMASTER GmbH, 33104 Paderborn, reserves all rights regarding text and graphics. Details are given to the best of our knowledge. No liability is accepted for 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.
iii
Safety first
These symbols are used throughout this manual and on labels on the maschine itself to warn of the possibility of per-
sonal 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 per-
sonal 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.
iv
Tools
This symbols are used throughout this manual to show which tool must be used at maintenance or installation.
Spanners
X = number of spanner
Screw driver, for slotted head screws and for recessed head screws
v
CALIFORNIA
Proposition 65 Warning
vi
Safety Precautions
The generator may not be taken into use with the cover removed.
The rotating parts (belt-pulley, belts, etc) must be so covered and protected do that there is no danger to life and
body!
If a sound insulation covering must be produced at the place of installation, then well-placed signs must show that
the generator can only be switched on with a closed capsule.
All servicing-, maintenance or repair work may only carried out, when the motor is not running.
Electrical voltages above 48 volts ( battery chargers greater than 36 volts) are always dangerous to life). The rules of
the respective regional authority must be adhered to. Only an electrician may carry out installation of the electrical
connections for safety reasons.
Protective Conductor:
The generator is „earthed " as standard (The centre and earth are connected by means of a bridge in the generator
terminal box). This is a basic safety function, which offers basic safety as long as no other component has been
installed. It is, above all, conceived for supply and an eventual test run.
This "earth" (PEN) is only effective, if all parts of the electrical system is earthed, and has a common “potential”. The
bridges can be removed, if this is required for technical reasons and another protection system has been installed.
The full voltage is exploited at the AC control box, when the generator is run. It must therefore be ensured
that the control box is closed and cannot be tampered with, if the generator is running.
The battery must always be disconnected, if work on the generator or electrical system is to be carried out,
so that the generator cannot be unintentionally started.
All load must be disconnected, in order to avoid damages to the devices. In addition the semi conductors in the AC
control box must be disconnected in order to avoid the boat capacitors being activated. The minus pole of the battery
ought to be removed.
Capacitors are required to run the generator. These have two varying functions:
A) The working capacitors
B) The (Booster) capacitors
Both Groups are located in a sound cover of the genset.
Capacitors are electrical stores. There could be a residual of high electrical current at the contacts for a period dis-
connection from the circuit. The contacts my not be touched for safety reasons, If the capacitors are to be exchanged
or checked, then a short circuit between the contacts should be made so that the stored energy is discharged.
If the generator is switched off in the normal manner, the working capacitors are automatically discharged by means
of the windings. The booster capacitors are discharged by means of internal discharge resistors.
All capacitors must be short-circuited before work is carried out on the AC-Control box for safety reasons.
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viii
Table of Contents
Current revison status ........................................................................................................... ii
Tools ........................................................................................................................................ v
01 25
24
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23
02
11
22
03
09
21
14
04
08 20
12
19
05
18
06
07 13 15 16 17
02 03 04 05 06 07 08
01 09
10
11
14
12
15
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16
24 23 22 21 20 19 18 17
01
02
03
04
05
06
08
07
09 10
12
13
11
14 15 16 17 18 19 20 21 22
01. Ventilation screw thermostat housing 12. Injection hose, freshwater from external expansion tank
02. Ventilation screw internal cooling water pump 13. Fuel filter
03. Thermostat housing with thermostat set 14. Control box
04. Pulley for internal cooling water pump 15. Raw water inlet
05. 12V DC-alternator 16. Fuel intake connection
06. V-belt for DC-alternator and internal cooling water pump 17. Fuel backflow connection
07. Raw water pump 18. Cable fuel pump
08. Freshwater intake pipe 19. Oil drain hose
09. Hose for raw water intake 20. Cable for fuel level sensor
10. Engine oil filter 21. Passage for cable starter battery minus (-)
11. Oil pressure switch 22. Passage for cable starter battery plus (+)
01 02
03
04
05
06
07
08
09
10
11
12 13 14 15
01. Cooling water filler neck 09. Cover for oil-cooled bearing
02. Booster capacitor (1x60µF) 10. Control box
03. Water-cooled exhaust elbow 11. Passage for cable control panel
04. Air suction housing with air filter 12. Connection external ventilation valve
05. Excitation capacitors (4x50µF) 13. Intake to external cooling water expansion tank
06. Solid state relay for booster capacitor 14. Backflow from external cooling water expansion tank
07. Generator front cover 15. Passage for cable load
08. Fuse for DC-system (30A)
01 03 04 05 06 07 08
02
09
10 11 12 13 14 15 16 17 18 19
01. Solid state relay for booster capacitor 11. Air suction housing with air filter
02. Booster capacitor (1x60µF) 12. Control box
03. Cooling water filler neck 13. Cylinder head thermo-switch
04. Ventilation hose to external expansion tank 14. Air suction hose to induction elbow
05. Water-cooled exhaust elbow 15. Actuator
06. Engine oil filler neck 16. Fuel solenoid valve
07. 12V DC-alternator 17. Stop solenoid
08. Ventilation screw thermostat housing 18. Ventilation screw internal cooling water pump
09. Excitation capacitors (4x50µF) 19. Pulley for internal cooling water pump
10. Charge control for DC-alternator
01 24
10 23
02
11
22
03
09
21
14
04
08 20
12
19
05
18
06
07 13 15 16 17
02 03 04 05 06 07 08
09
01
10
11
14
12
15
13
16
24 23 22 21 20 19 18 17
01
02
03
04
05
06
08
07
09 10
12
13
11
14 15 16 17 18 19 20 21 22
01. Ventilation screw thermostat housing 12. Injection hose, freshwater from external expansion tank
02. Ventilation screw internal cooling water pump 13. Fuel filter
03. Thermostat housing with thermostat set 14. Control box
04. Pulley for internal cooling water pump 15. Raw water inlet
05. 12V DC-alternator 16. Fuel intake connection
06. V-belt for DC-alternator and internal cooling water pump 17. Fuel backflow connection
07. Raw water pump 18. Cable fuel pump
08. Freshwater intake pipe 19. Oil drain hose
09. Hose for raw water intake 20. Cable for fuel level sensor
10. Engine oil filter 21. Passage for cable starter battery minus (-)
11. Oil pressure switch 22. Passage for cable starter battery plus (+)
01 02
03
04
05
06
07
08
09
10
11
12 13 14 15
01. Cooling water filler neck 09. Cover for oil-cooled bearing
02. Booster capacitors (2x40µF) 10. Control box
03. Water-cooled exhaust elbow 11. Passage for cable control panel
04. Air suction housing with air filter 12. Connection external ventilation valve
05. Excitation capacitors (4x50µF) 13. Intake to external cooling water expansion tank
06. Solid state relays for booster capacitors 14. Backflow from external cooling water expansion tank
07. Generator front cover 15. Passage for cable load
08. Fuse for DC-sysetm (30A)
01 03 04 05 06 07 08
02
09
10 11 12 13 14 15 16 17 18 19
01. Solid state relays for booster capacitors 11. Air suction housing with air filter
02. Booster capacitors (2x40µF) 12. Control box
03. Cooling water filler neck 13. Cylinder head thermo-switch
04. Ventilation hose to external expansion tank 14. Air suction hose to induction elbow
05. Water-cooled exhaust elbow 15. Actuator
06. Engine oil filler neck 16. Fuel solenoid valve
07. 12V DC-alternator 17. Stop solenoid
08. Ventilation screw thermostat housing 18. Ventilation screw internal cooling water pump
09. Excitation capacitors (4x50µF) 19. Pulley for internal cooling water pump
10. Charge control for DC-alternator
The remote control panel is equipped with some new monitoring functions, which increases the
operational safety of the generator. A failure message is shown over contacts which are normaly
closed. If a connection is intermitted triggers this a failure message.
01
02 03 04 05 06
Heat exchanger
Separates the raw water system from the
freshwater system.
Ventilation valve
Freshwater backflow
The cooling water is fed to the heat
exchanger from the water-cooled manifold
by means of the pipe shown in the dia-
gram.
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).
Heat exchanger
Separates the raw water system from the
freshwater system.
1 2
Fuel filter
A consequential filtering of fuel is especi-
ally important for all marine systems. A fine
filter, which is firmly attached to the inside
of the sound insulation capsule for the
marine version, is supplied on delivery, and
loose for other makes. In all cases a further
pre-filter with water separator must be
installed. See directions for fuel filter instal-
lation.
Injection nozzles
If the engine does not start after the venti-
lation, the fuel injection lines must be de-
aerated individually.
Glow plugs
The glow plugs serve the pre-chamber for
the heating with cold start. The heat-treat
fixture must be operated, if the tempera-
ture of the generator is under 16°C. This
is practically with each start the case. The
heat-treat fixture may be held down also
during start and favoured the starting pro-
cedure.
Exhaust elbow
On the back of the engine is the water-
cooled exhaust elbow. On the top side the
pipe union for the internal raw water cir-
cuit is to be seen and the filler neck for the
cooling water. This cooling water filler
neck is used only at first filling. Control of
the cooling water and if necessary refill
takes place at the external cooling water
expansion tank.
Exhaust outlet
Connect the exhaust pipe with the water
lock.
2 1
1 2
Starter motor
1. Starter motor and
2. Solenoid switch
The Diesel engine is electrically started. 2
On the back of the engine is accordingly
the electrical starter with the solenoid
switch.
DC-alternator
All Panda generators from Panda 6.000
are provided with its own charge system
for the 12V DC mains. This DC-alternator
is powered over a v-belt together with the
internal cooling water pump.
The 12V charge system may be used only
for the generator-own starter battery.
Relays
K0 power relay for ground isolate relay
K1 power relay for starter motor K1 K2 K3 K4 K5 K6
K2 power relay for glow plugs
K2.1 power relay for glow plugs
K3 power relay for fuel pump
K4 power relay for stop solenoid
Fuses
F1 fuse 20A for relay K0
F2
Thermo-switch at water-cooled
exhaust elbow
120°C/105°C at 120V/60Hz
105°C/90°C at 230V/50Hz
Thermo-sensor exhaust
Oil dipstick
At the dipstick the permissible level is indi-
cated by the markings "maximum" and
"minimum". The engine oil should be
never filled up beyond the maximum con-
ditions.
Oil filter
The oil filter should be exchanged with an
oil change.
The external compensation tank should be filled up to a maximum of in a cold state. It is very important that large
expansion area remains above the cooling water level.
For safety reasons, the seacock must be closed after the generator has been switched off. It should be re-opened
before starting the generator.
The raw water filter must be regularly checked and cleaned. The impeller fatigue increases, if residual affects the
raw water intake.
Leaks at hose connections must be immediately repaired, especially the raw water impeller pump. It is certainly
possible that the raw water impeller pump will produce leaks, depending upon the situation. (This can be caused
by sand particles in the raw water etc.) In this case, immediately exchange the pump, because the dripping water
will be sprayed by the belt pulley into the sound insulated casing and can quickly cause corrosion.
This is especially the case with the temperature switch contacts, which automatically switch off the generator in
case of faults. There is only safety if these systems are regularly checked, and these systems will protect the gen-
erator, when there is a fault.
The mounting screws must be checked regularly to ensure the generator is safe. A visual check of these screws
must be made, when the oil level is checked.
8. Switch the Land Electricity/Generator Switch to Zero before Starting or Switch Off all the load.
The generator should only be started when all the load have been switched off. The excitation of the generator will
be suppressed, if the generator is switched off with load connected, left for a while, or switched on with extra load,
thus reducing the residual magnetism necessary for excitation of the generator to a minimum. In certain circum-
stances, this can lead to the generator being re-excitated by means of a DC source. If the generator does not exci-
tate itself when starting, then excitation by means of DC must be carried out again.
Removing a cable end from the monitoring switch carries out this control test. The generator should then automat-
ically switch off. Please adhere to the inspection timetable (see Checklist in the appendix).
The load is switched off, before the generator is switched off. The generator is not to be started with load connec-
ted. If necessary, the main switch or fuse should be switched off or the load should be individually switched off.
7. Switch on load.
At higher ambient temperatures (more than 25°C) the generator should always run for at least 5 minutes without
load, before it is switched off, regardless of the load.
The remote control panel is equipped with some monitoring functions, which increases the operational safety of
the generator. A failure message is shown over contacts which are normaly closed. If a connection is intermitted
triggers this a failure message.
01
02 03 04 05 06
ATTENTION: It is not allowed to program two panels at the same time. Pragram first one panel and then the
second.
To get into the „Program mode“ press the buttons „Program Level (S2)“ and „Display shift (S3)“ at the same time.
An failure override button enables an immediate restart facility of the generator, should it cut out, even if this was
caused by over-heating. There is normally a requirement to wait until the motor has cooled down to the correct
temperature. This can last for several hours in certain circumstances, since the generator is enclosed in a sound-
insulated casing, which prevents heat loss.
This period can be reduced by pushing the „Alarm Mute“ button. By pressing the button all faults are overrided for
10 seconds. When the button is pressed again during the 10 seconds, 10 seconds will be added to the remaining
time. The generator can be started. The button bypasses any faults allowing the generator to run.
Before depressing the button, a manual check of the oil dipstick must be carried out to determine whether the
generator has sufficient oil, as it is possible that the oil pressure switch causes the generator to cut out. If it has
been ascertained that the reason for the motor cutting out is overheating and not lack of oil, the generator can be
run for several minutes without load, so that the motor is cooled by the circulating coolant.
ATTENTION:
If the temperature is the reason for the generator cutting out when it is running under load, then an immediate
check must be made to determine the cause. It could be a fault with the cooling system, one of the fans, the air-
intake or a fault with the external cooling system.
Continual use of the starter-override switch should be avoided, while the generator cuts out during operation. The
generator must always run without load for several minutes before being switched off, so that a temperature com-
pensation occurs. Heat accumulation can cause the generator to overheat, even after ist has been switched off.
Should the overheating alarm be set off, caused by heat accumulation, after the generator has been switched off,
then this can also be bypassed using the switch.
Push:
„Alarm Mute“ to acknowledge
again „Alarm Mute“ to deactivate all sensors and
„Motor Start“ to restart the engine