Endress Ecopower Series User manual

OPERATING
INSTRUCTIONS
ECOPOWER L
I
NE
Power Generators
GB
www.endress-generators.de
ESE 3
000 BS
240 209
ESE 6000 BS
240 210
ESE 6000 DBS
240 211

Operating Instructions
2
ENDRESS Elektrogerätebau GmbH
Neckartenzlinger Straße 39
D-72658 Bempflingen
Email: [e-mail]
WWW: http://www.endress-generators.de
E133811
January 2011
© 2010, ENDRESS Elektrogerätebau GmbH
This documentation, including all parts thereof, is protected
by copyright. Every use and adaptation outside of what is
strictly authorised under the copyright law is, without the
permission of the ENDRESS Elektrogerätebau GmbH Com-
pany, illegal and punishable by law.
This applies in particular to reproductions, translations, copy-
ing by microfilming and storage and processing in electronic
systems.
Published by
Document number
Date of issue
Copyright

About these instructions
Signs and Symbols used
3
List of Contents
1 About these instructions..................................................................................5
1.1 Signs and Symbols used....................................................................................6
1.1.1 General Signs / Symbols.........................................................................................6
1.1.2 Safety symbols………. ............................................................................................7
2 General Safety Guidelines................................................................................8
2.1 Intended Use .....................................................................................................8
2.1.1 Intended use…………. ............................................................................................8
2.1.2 Foreseeable misuse and incorrect operation..........................................................9
2.1.3 Residual Risks………............................................................................................10
2.2 Qualifications and Duties .................................................................................12
2.3 Personal Safety Equipment..............................................................................12
2.4 Hazard Areas and Work Places .......................................................................12
2.5 Labelling on the Power Generator....................................................................13
2.6 General Safety Instructions..............................................................................15
3 Description ......................................................................................................19
3.1 Function and Mode of Operation......................................................................20
4 Putting the Power Generator into Operation ................................................21
4.1 Dismantle the transport safety device ..............................................................21
4.1 Transporting the Power Generator...................................................................22
4.2 Setting-up the Power Generator.......................................................................23
4.3 Fuelling the Power Generator ..........................................................................24
4.4 Filling the Power Generator with Motor Oil.......................................................25
4.5 Starting the Power Generator...........................................................................27

About these instructions
Signs and Symbols used
4
4.6 Switching off the Power Generator...................................................................33
4.7 Shutting down Power Generator (longer term shut down)................................34
5 Servicing the Power Generator......................................................................38
5.1 Service Plan.....................................................................................................38
5.2 Servicing work .................................................................................................39
5.3 Checking Electrical Safety ...............................................................................39
6 Trouble Shooting ............................................................................................40
7 Technical Data.................................................................................................42
8 Terms of Warranty ..........................................................................................45

About these instructions
Signs and Symbols used
5
1 About these instructions
Before you use this power generator, carefully read and
make sure you understand these instructions.
These instructions are intended to enable you to understand
the basic operating principles of the power generator.
These instructions contain important information on how to
use this power generator in a correct and safe manner.
Following the instructions will help:
•to avoid dangers
•to minimise costs of repair and down-time
•to increase the dependability and operational life of the
power generator.
Irrespective of these instructions, the laws, regulations and
guidelines of the country and location where the generator is
operated must be observed.
Irrespective of these instructions, the locally applicable laws
for health and safety and the regulations for the protection of
the environment pertaining to the country and location where
the generator is operated must be observed.
These instructions only provide information regarding the
use of the power generator.
A copy of these instructions must be made available at all
times to the operating personnel.

About these instructions
Signs and Symbols used
6
1.1 Signs and Symbols used
The signs and symbols in these instructions are designed to
assist in the understanding of the instructions and to enable
the operator to commence use of the generator quickly and
safely.
1.1.1 General Signs / Symbols
Advanced Organizer
The Advanced Organizer provides brief information on the
content of the following section.
Notes provide hints and information to assist you to make
the most effective and practical use of the generator and
these instructions.
The prescribed order of the work steps will make it easier for
you to operate the generator correctly and safely.
Result
Here you will find the description of the result achieved by
the completion of the work steps.
NOTE



1.
Work steps
2. ….
3. ….

About these instructions
Signs and Symbols used
7
1.1.2 Safety symbols
Safety symbols highlight a source of danger.
Warning about a general danger
These warning symbols indicate activities that could lead to
several sources of danger.
Warning about explosive materials
These warnings symbols indicate activities that could lead to
the risk of explosion with possibly fatal consequences.
Warning about danger from electrical voltage
These warning symbols indicate activities that could lead to
the risk of an electric shock with possibly fatal consequenc-
es.
Warning on environmentally damaging substances
This warning sign indicates activities, during which the envi-
ronment could be endangered, possibly with catastrophic
consequences.
Warning on hot surfaces
This warning sign indicates activities, during which there is
the danger of burns, possibly with lasting consequences.

General Safety Guidelines
Intended Use
8
2 General Safety Guidelines
In this section you will find the basic safety guidelines for
operation of the power generator.
Every person who operates the power generator, or works
with someone who operates the power generator is obliged
to read this chapter and observe the guidelines when operat-
ing the power generator.
2.1 Intended Use
The power generator conforms to the most up-to-date stand-
ards of science and technology, as well as to the safety
regulations currently applicable at the time the product is put
into circulation.
Incorrect use and residual risks cannot be constructively
prevented without reducing the function of the intended use.
Information about risks of danger is conveyed either directly
by the generator itself and/or by the technical documenta-
tion.
2.1.1 Intended use
The power generator is a mains replacement that generates
electrical power for supply to a mobile distribution system.
The power generator must be operated outdoors within the
prescribed voltage, output and rated speed limits (see type
plate).
The power generator must not be connected to other electri-
cal supply systems (e.g. public electrical supply) or electric
generation systems (e.g. other power generators).
The power generator may not be used in environments
where there is a risk of explosion.
The power generator may not be used in environments
where there is a risk of fire.

General Safety Guidelines
Intended Use
9
The power generator must be operated in accordance with
the conditions set out in the technical documentation.
All improper use of the power generator including all uses
not described in these instructions will constitute unauthor-
ised incorrect usage for which the manufacturer is not legally
liable.
2.1.2 Foreseeable misuse and incorrect operation
Instances of foreseeable misuse and/or incorrect operation
of the power generator invalidate the manufacturer’s EU dec-
laration of conformity, together with the operating license.
Foreseeable misuse and/or incorrect operation includes:
•Operation in environments where there is a risk of explo-
sion
•Operation in environments where there is a risk of fire
•Operation in enclosed areas
•Operation under direct exposure to rain or snowfall
•Operation without the requisite safety precautions
•Operation connected to existing supply network systems
•Refuelling when hot
•Refuelling when in operation
•Spraying with high-pressure cleaners or fire extinguishing
equipment
•Operation when safety devices are removed
•Non-compliance with regular servicing requirements
•Failure to carry out measurements and checks for early
detection of defects.
•Failure to replace wear and tear parts
•Improper servicing and repairs
•Inadequate servicing and repairs
•Incorrect operation

General Safety Guidelines
Intended Use
10
2.1.3 Residual Risks
Analysed and evaluated by means of a risk assessment un-
dertaken prior to the planning and construction of the power
generator.
Residual risks that are constructively unavoidable and which
may arise during the operating life of the power generator
are:
•Danger to life
•Risk of injury
•Environmental hazards
•Material damage to the power generator
•Material damage to other material property
•Reduction in performance and functionality
You can avoid existing residual risks by implementing and
observing the following guidelines:
•the special warning notices on the power generator
•the general safety notices in these instructions
•the special warning notices in these instructions
Danger to the life of persons from the power generator can
arise through:
•Misuse
•Incorrect operation
•Improper safety equipment
•Defective or damaged electrical components
•Touching with wet hands
•Fuel vapours
•Engine exhaust fumes
Risk of injury to persons from the power generator can arise
through:
•Incorrect operation
•Transportation
•Hot parts
•Recoil of the Engine starter cable
Danger to Life
Risk
of Injury

General Safety Guidelines
Intended Use
11
Environmental hazards from the generator can arise from:
•Incorrect operation
•Operating materials (fuel, lubricants, Engine oils etc.)
•Exhaust emissions
•Sound emissions
•Risk of fire
Material damage to the electrical generator can arise from:
•Incorrect operation
•Overloading
•Over heating
•Too low / too levels of high Engine oil
•Failure to observe operating and servicing guidelines
•Use of improper operating materials
Material damage to other property in the vicinity of the power
generator can arise from:
•Incorrect operation
•Excess or undervoltage
Reduction in the performance or function of the power gen-
erator can arise from:
•Incorrect operation
•Incorrect servicing or repair
•Unsuitable operating materials
•An operational location more than 100 meters above sea
level
•An ambient temperature above 25°C
•Excessive size of the distribution network
Environmental Hazards
Material damage to the
Electrical Generator
Material Damage to
other Property
Reduction in the
Performance and
Functionality

General Safety Guidelines
Qualifications and Duties
12
2.2 Qualifications and Duties
All activities in relation to the electrical generator may only
be carried out by personnel qualified for this purpose.
They must
•know and apply the Prevention of Injury regulations and
the safety instructions for the power generator.
•have read the "General Safety Guidelines" section.
•have understood the contents of the "General Safety
Guidelines" section.
•be able to practically implement the contents of the
"General Safety Guidelines" section.
•understand and be able to practically implement the
technical documentation.
2.3 Personal Safety Equipment
You must wear the following personal safety equipment dur-
ing all activity with the power generator as described in these
instructions:
•Hearing protection
•Protective gloves
2.4 Hazard Areas and Work Places
The hazard areas and work places (work areas) for the pow-
er generator are defined for the activity undertaken within the
individual work phase:
Work Phase
Activity
Hazard Area
Work Area
Transportation In vehicle Radius of 1.0 m none
By operating personnel Radius of 1.0 m
Operation Set up
Operating Radius of 5.0 m
Re-fuelling Radius of 2.0 m
Maintenance and
Servicing
Cleaning Radius of 1.0 m
Shut down
Servicing
Tab. 2.1: Hazard Areas and Work Places of the Power Generator

General Safety Guidelines
Labelling on the Electrical Generator
13
2.5 Labelling on the Electrical Generator
These labels must be attached to the electrical generator
and be easy to read:
•These
Fig. 2.1: Labels on the generator
1 General warnings 5 Hot surface warning
2 Earth 6 Fuel cock warning
3 Sound power level warning 7 Choke (cold start) warning
4 Fire hazard warning 8 Model plate

General Safety Guidelines
Labelling on the Electrical Generator
14
Label Designation No.
General warnings 1
Earth 2
Sound power level
warning 3
Fire hazard warning 4
Hot surface warning 5
Fuel tap warning 6
Choke 7
Model plate
See page 40 for explanation 8
Tab. 2.2: Labels on the generator

General Safety Guidelines
General Safety Instructions
15
2.6 General Safety Instructions
The operator must know the functions of, and be able to use,
the components of the power generator.
The operator is responsible for the safe operation of the
power generator.
The operator is responsible for preventing unauthorized use
of the power generator.
The operator must wear the appropriate personal safety
equipment.
The labelling on the electrical generator must be complete
and maintained in a readable condition.
Constructive changes may not be carried out on the electri-
cal generator.
The rated speed of the motor has been set during manufac-
ture and may not be changed.
The operating safety and correct functioning must be
checked before and after each use.
The power generator may only be used outside.
No naked flames, lights or spark-emitting appliances may be
used within the hazard area of the power generator.
Smoking within the hazard area of the power generator is
strictly forbidden.
During operation, the power generator must be protected
against dampness and precipitation (rain, snow).
During operation, the power generator must be protected
from dirt and foreign matter.

General Safety Guidelines
General Safety Instructions
16
The power generator may only be transported when cold.
The power generator may only be transported by vehicle
where there is adequate protection against tipping.
The power generator may only be lifted using the carry han-
dles intended for this purpose.
The power generator may only be set up on adequately sta-
ble surfaces.
The power generator may only be set up on even surfaces.
The power generator may not be set up on wet surfaces.
The electrical safety must be checked before each opera-
tional use.
The appliance may not be covered.
The air intake may not be blocked or obstructed.
Starting aids may not be used.
When starting, the load may not be connected.
Only certified and approved cables may be used for the
wired network.
The power output may not exceed the maximum rated
power.
The power generator may not be operated without the
sound absorber.
The power generator may not be operated without the air
filter or with the air filter cover open.
Transporting
Set up
Power generation

General Safety Guidelines
General Safety Instructions
17
The generator’s tank may not be refilled during operating.
The tank may not be refilled when the power generator is
hot.
Use a filling device (funnel) when re-filling.
The power generator may not be cleaned when in operation.
The power generator may not be cleaned when hot.
The power generator may not be serviced when in operation.
The power generator may not be serviced when hot.
The operator may only carry out servicing and repair work
that conforms to these instructions.
All other servicing and repair work may only be carried out
by personnel who are qualified and licensed for this purpose.
Always remove spark plug connector prior to commencing
servicing and repair work.
The service intervals set out in these instructions must be
observed.
The power generator must be shut down when not required
for periods longer than 30 days.
The power generator must be stored in a dry enclosed room.
A fuel additive should be used to prevent resinous residues.
Fuelling
Cleaning
Maintenance
and
Servicing
Shut down

General Safety Guidelines
General Safety Instructions
18
The packaging material should be recycled in accordance
with the locally applicable regulations for the protection of the
environment.
To prevent contamination the operational location must be
protected against the leakage of operating materials.
Used or residual operating materials should be recycled in
accordance with the locally applicable regulations for the
protection of the environment.
Electrical and electronic devices, batteries and rechargeable
batteries may not be disposed of in domestic waste.
The user is legally obliged to return electrical and electronic
devices, batteries and rechargeable batteries, at the end of
their useful life, to the designated public collection facilities or
to the point of sale. This is indicated either by the symbol on
the product, the instructions for use or the packaging.
Batteries and rechargeable batteries must be removed from
devices and disposed of separately.
You are making an important contribution to the protection of
our environment by carrying out recycling, material recycling
or other forms of recycling of used appliances and devices.
Notice on Protection
of the Environment

Description
19
3 Description
This section describes the power generator’s components
and functions.
Fig. 3.1: Components of the generator
1 Fuel cap 9 Oil drain plug
2 Fuel tank 10 Rocker switch for Engine (On/Off)
3 Fuel valve 11 Low oil light
4 Air filter 12 Volt./Freq./Hrs meters
5 Rope starter for motor 13 Ground connection screw
6 Carrying handle 14 Circuit breaker
7 Choke 15 Electric safety socket
8 Muffler 16 CEE socket

Description
Function and Mode of Operation
20
3.1 Function and Mode of Operation
The synchronous generator is rigidly coupled to the drive
Engine. The aggregate is mounted on a stable base plate
and is housed elastically in a low vibration state.
Power consumption is via a splash-proof shock-proof 230 V /
50 Hz socket.
The generator’s voltage regulation is provided within rated
speed limits by an automatic voltage regulator (AVR)
AVR = Automatic Voltage Regulator
The AVR evens out voltage peaks making it especially suita-
ble for electronic loads, e.g. electronically regulated power
tools such as drills as well as domestic appliances such as
cookers, heaters, television etc.
The power generator is designed for mobile operation with
one or several loads. Stationary operation required.
The power generator’s potential equalization (protective
separation) is implemented by means of a separate cable
that must be connected to a device that is suitable for earth-
ing. (not supplied)