Endress ESE 608 DHG ES DI DUPLEX User manual

OPERATING INSTRUCTIONS
ESE 608 DHG ES DI DUPLEX Article No.: 113023

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Version: Jan. 2011
ENDRESS
Elektrogerätebau GmbH
Neckartenzlinger Str. 39
D-72658 Bempflingen
Tel.: + 49 (0) 71 23 / 9737-0
Fax: + 49 (0) 71 23 / 9737-50
E-mail:
[e-mail]
Web: http://www.endress-stromerzeuger.de
E133977
December 2010
© 2010, ENDRESS Elektrogerätebau GmbH
This documentation and parts thereof are subject to copy-
right. Any use or modification outside the restricted limits of
the Copyright Act without the consent of ENDRESS Elektro-
gerätebau GmbH is forbidden and subject to penalty.
In particular, this applies to copies, translations, microfilming,
as well as storage and processing in electronic systems.
Manufacturer and
publisher
Document number
Date of issue
Copyright

Version: Jan. 2011 3
Table of Contents
1 General information..........................................................................................6
1.1 Documentation / scope of delivery.....................................................................7
1.2 Safety symbols ..................................................................................................8
2 General Safety Regulations..............................................................................9
2.1 Intended use......................................................................................................9
2.1.1 Intended use.........................................................................................................9
2.1.2 Foreseeable incorrect use or inappropriate handling.........................................10
2.1.3 Residual risks .....................................................................................................11
2.2 Operating personnel – Qualifications and obligations.......................................13
2.3 Personal protective equipment.........................................................................13
2.4 Danger zones and work areas .........................................................................14
2.5 Labels on the generator...................................................................................15
2.6 General safety instructions...............................................................................17
3 Components of the ESE 608 DHG ES DI DUPLEX........................................22
3.1 Operation/engine side......................................................................................22
3.2 Rear / generator side.......................................................................................23
3.3 Control panel ...................................................................................................24
3.4 Function and mode of operation.......................................................................25
4 Operating the ESE 608 DHG ES DI DUPLEX.................................................28
4.1 Transport.........................................................................................................28
4.2 Fuelling............................................................................................................30
4.3 Commissioning................................................................................................32
4.4 Connecting appliances.....................................................................................35
4.5 Special options ................................................................................................36
4.5.1 Monitoring the operating condition using the multifunctional display.................36
4.5.2 Insulation monitoring plus switching off..............................................................38
4.6 Decommissioning.............................................................................................39

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5 Maintenance ....................................................................................................42
5.1 Maintenance plan.............................................................................................42
5.2 Maintenance work............................................................................................42
5.2.1 Drain the oil.........................................................................................................42
5.3 Check the electrical safety...............................................................................44
6 Troubleshooting..............................................................................................45
7 Technical specifications.................................................................................48
8 Replacement parts..........................................................................................51
8.1 Frame with engine and generator ....................................................................51
8.2 Electronics.......................................................................................................53
9 Replacement parts..........................................................................................56

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List of illustrations
Fig. 11: Delivery documentation / Accessories ............................................ 7
Fig. 21: Labels on the generator.................................................................15
Fig. 31: Components on the operating and engine side..............................22
Fig. 32: Electrical compartment components..............................................23
Fig. 33: Control panel components.............................................................24
Fig. 41: Ring screw for loading...................................................................29
Fig. 42: External refuelling..........................................................................31
Fig. 43: Started by hand:............................................................................33
Fig. 44: Multi-functional display...................................................................36
Fig. 51: Drain the oil. ..................................................................................43
Fig. 71: Generator dimensions ...................................................................48
Fig. 81: Replacementparts for the exhaust or generator side......................51
Fig. 82: Engine and exhaust side replacement parts ..................................52
Fig. 83: Electrical junction box spare parts .................................................53
List of charts
Table 2.1: Danger zones and work areas on the generator..........................14
Table 4.1: Insulation monitoring plus switching off........................................38
Table 4.2: Insulation monitoring whilst running without switching off ............38
Table 6.1: Problems during generator operation ..........................................45
Table 7.1: Generator technical data.............................................................49
Table 7.2: Ambient conditions of the generator............................................49
Table 7.3: Generator performance reduction in relation to the ambient
conditions....................................................................................49
Table 7.4: Maximum conduit length of the distribution network as a function of
the cable cross-section................................................................50

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Version: Jan. 2011
1 General information
These operating instructions must be read carefully and un-
derstood before using the generator.
These operating instructions are intended to make you fami-
liar with the basic operation of the generator.
These operating instructions contain important information
for using the generator safely and appropriately.
Complying with this this information helps to:
•Avoid hazards
•Reduce repair costs and downtime
•Increase the reliability and service life of the generator.
However, not only these operating instructions but also the
laws, regulations, guidelines, and standards applicable in the
country of use and at the site of operation must be observed.
These operating instructions only describe the generator
operation.
________________________________________________
The operating manual and the maintenance instructions
for the engine (see Fig. 11-(5)) are integral components of
these instructions.
________________________________________________
A copy of these operating instructions must be available to
the operating personnel at all times.

Version: Jan. 2011 7
1.1 Documentation / scope of delivery
In addition to this document, there are the following docu-
ments and standard accessories for the ESE 608 DHG ES
DI DUPLEX generator.
•Cable with test tip (see Fig. 11-(1))
•Tools (see Fig. 11(2))
•Engine circuit diagram (see Fig. 11-(3))
•Motor service centre directory (seeFig. 114))
•Engine operating instructions (seeFig. 11-(5))
•Motor replacement parts list (seeFig. 11(6))
•Motor replacement seal (seeFig. 11(7))
•Oil drain hose (seeFig. 11-(8))
•Ring screw for loading
Fig. 11: Delivery documentation / Accessories

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1.2 Safety symbols
The safety symbol represents a source of danger.
General hazard
This warning sign indicates activities where several causes
can lead to risks.
Potentially explosive materials
This warning symbol indicates activities during which there is
an explosive hazard, possibly with lethal consequences.
Dangerous electrical voltage
This warning symbol indicates activities during which there is
the danger of electric shock, possibly with lethal consequen-
ces
Poisonous substances
This warning symbol indicates activities during which there is
the danger of poisoning, possibly with lethal consequences
Environmentally damaging substances
This warning sign indicates activities during which the envi-
ronment could be endangered, possibly with catastrophic
consequences.
Hot surfaces
This warning symbol indicates activities during which there is
the danger of burns, possibly with lasting consequences.

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2 General Safety Regulations
This section describes the basic safety regulations for opera-
ting the generator.
Whoever operates the generator or works with it must read
this chapter and comply with its regulations in practice.
2.1 Intended use
The generator conforms to the state of science and techno-
logy and to the applicable safety regulations at the time it
was marketed, if used as intended.
It was not possible to avoid foreseeable misuse or residual
risks through design measures without limiting the intended
functionality.
Hazards are therefore averted by means of special warning
signs either directly on the generator and/or in the technical
documentation.
2.1.1 Intended use
The generator produces electricity in place of the power grid,
in order to supply a mobile distribution system.
The generator may only be used outdoors within the indica-
ted voltage, output, and nominal RPM ranges (see model
plate).
The generator may neither be connected to other energy
distribution systems (e.g. public power supply) nor to other
energy generation systems (e.g. other generators).
The generator may not be used in explosion-prone environ-
ments.
The generator may not be used in fire-prone environments.
The generator must be operated according to the specificati-
ons in the technical documentation.

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Any non-intended use or any activity on the generator not
described in these operating instructions are considered for-
bidden incorrect use outside the legal limits of the manufac-
turer's liability.
2.1.2 Foreseeable incorrect use or inappropriate
handling
Foreseeable incorrect use or inappropriate handling of the
generator nullifies the manufacturer's EC Declaration of Con-
formity and automatically thereby the operating licence.
Foreseeable incorrect use or inappropriate handling include:
•Operation in explosion-prone environments
•Operation in fire-prone environments
•Operation in confined areas
•Operation without the necessary safety redundancies
•Operation in existing power supply networks
•Refuelling when hot
•Refuelling during operation
•Spraying with high-pressure cleaners or fire-
extinguishing equipment
•Safety equipment removal
•Non-compliance with maintenance intervals
•Failure to measure and test for early damage identificati-
on
•Failure to replace wearing parts
•Incorrectly performed maintenance or repair work
•Defectively performed maintenance or repair work
•Unintended use

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2.1.3 Residual risks
Before design and planning were begun, the residual risks of
the ESE 608 DHG ES DI DUPLEX generator were analysed
and evaluated by means of a hazard analysis.
Structurally unavoidable residual risks during the entire
service life of the ESE 608 DHG ES DI DUPLEX generator
can be:
•Risk of death
•Risk of injury
•Environmental hazard
•Material damage to the generator
•Material damage to other property
•Limited performance or functionality
You can avoid existing residual risks by observing and follo-
wing these guidelines:
•The special warning notices on the generator
•The general safety instructions in this manual
•The special warnings in this manual
Risk of death to persons at the generator can be caused by:
•Incorrect use
•Inappropriate handling
•Missing protective equipment
•Defective or damaged electrical components
•Fuel vapours
•Engine exhaust gases
Risk of injury to persons at the generator can be caused by:
•Inappropriate handling
•Transport
•Hot components
Risk of death
Risk of injury

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Environmental hazards involving the generator may be cau-
sed by:
•Inappropriate handling
•Operating fluids (fuel, lubricants, engine oil, etc.)
•Exhaust gas emission
•Noise emission
•Fire hazard
Material damage to the generator can occur through:
•Inappropriate handling
•Overloading
•Overheating
•Too low/high oil level of the engine
•Non-compliance with the operating and maintenance
specifications
•Unsuitable operating fluids
•Unsuitable hoisting gear
Material damage to other property in the operating range of
the generator can occur through:
•Inappropriate handling
•Over and/or undervoltage
The generator's performance or functionality can be limited
by:
•Inappropriate handling
•Inappropriate maintenance or repair work
•Unsuitable operating fluids
•An installation altitude higher than 100 meters above sea
level
•An ambient temperature exceeding 27
•Too large a distribution network configuration
Environmental hazard
Material damage to the
generator
Material damage to other
property
Limits to performance or
functionality

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2.2 Operating personnel – Qualifications
and obligations
Only appropriately authorised personnel may work with or on
the generator.
The authorised operating personnel must:
•Be at least 18 years old.
•Be trained in first aid and able to provide it.
•Be familiar with the accident prevention regulations and
generator safety instructions and able to apply them.
•Have read the chapter "General Safety Regulations".
•Have understood the content of the " General Safety
Regulations".
•Be able to put the content of the "General Safety
Regulations" chapter to practical use.
•Be trained and instructed according to the rules of con-
duct in the event of malfunctions occurring.
•Have the physical and mental abilities to carry out his
responsibilities, tasks, and activities on the generator.
•Be trained and instructed in his responsibilities, tasks,
and activities on the generator.
•Have understood the technical documentation concer-
ning his responsibilities, tasks, and activities on the gene-
rator and be able to implement these in practice.
2.3 Personal protective equipment
This personal protection equipment must be worn during all
activities at the generator described in these operating in-
structions:
•Hearing protection
•Protective gloves
•Protective shoes

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2.4 Danger zones and work areas
The danger zones work areas on the generator are determi-
ned by the activities to be performed within
the individual life cycles:
Life cycle Activity Danger zone Work area
In the vehicle noneTransport By the operating person-
nel
Setting up
Within a radius of 1.0 m
Operating Within a radius of 5.0 m
Operation
Refuelling Within a radius of 2.0 m
Cleaning
Shutting down
Service and
maintenance
Maintenance
Within a radius of 1.0 m
Within a radius of 1.0 m
Table 2.1: Danger zones and work areas on the generator

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2.5 Labels on the generator
These labels must be attached to the generator and kept
in a clearly legible condition:
Fig. 21: Labels on the generator

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Version: Jan. 2011
Number Label Designation
1
Noise emission
2 Note
Line extension
3 Earth
4
Read operating instructi-
ons
5
Model plate
Generator
6
Note
Hot surfaces
7
Fuel note
8
Note
Open flame prohibited
9
Note
Hot surfaces
10
Fuel note
Table 2 . 2 : Labels on the generator

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2.6 General safety instructions
The generator's construction may not be modified in any
way.
The engine's nominal rpm has been set in the factory and
may not be changed.
All protective covers must be at hand and functional.
All labels on the generator must be in place and in clearly
legible condition.
The operational reliability and functionality must be checked
before and after each use/operation.
The generator must be used only outdoors with sufficient
ventilation.
Do not use open flames, lights, or spark-inducing devices in
the danger area of the generator.
Protect the generator against moisture and precipitation
(rain, snow) during operation.
Protect the generator against dirt and foreign matter during
operation.
The authorised personnel are responsible for the operational
reliability of the generator.
The authorised personnel are responsible for safeguarding
the generator against unauthorised operation.
The authorised personnel are obligated to observe the appli-
cable accident prevention regulations.
The authorised personnel are obligated to obey the safety
and work instructions of superiors and/or safety officers.
Authorised personnel must wear personal protective equip-
ment.
Only authorised personnel may remain in the generator's
danger zone.
Smoking is absolutely prohibited in the generator's danger
zone.

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Open flames and light are prohibited in the generator's dan-
ger zone.
Consuming alcohol, drugs, medicines, or other conscious-
ness-expanding and/or changing substances is prohibited.
The authorised personnel must be familiar with the generator
components and their function and know how to use them.
The generator may only be transported after it has cooled
down.
The generator may only be transported in a vehicle after
being fastened correctly.
The generator may only be lifted by the crane loops provi-
ded.
The generator may only be set up on sufficiently firm ground.
The generator may only be set up on even ground.
The electrical safety must be checked before each start-up.
Do not cover the equipment during use.
Do not obstruct or block the air supply.
Do not use starting aids.
Appliances must not be connected during start-up.
Only tested and authorised cables may be used for the
power network.
It is prohibited to establish a connection between existing
neutral conductors, potential equalisation conductors and/or
equipment components (safety-separated circuit).
The entire drawn output must not exceed the maximum
nominal output of the generator.
Do not operate the generator without a sound damper.
Transport
Setting up
Generating electricity

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It is prohibited to operate the generator without air filters and
with an open air filter cover.
The generator must always be operated with the hood clo-
sed.
It is prohibited to refill the fuel tank of the generator during
operation.
It is prohibited to refill the fuel tank of the generator when it is
still hot.
Use filling aids for refuelling.
To prevent overflow, do not fill the tank to the upper edge of
the filler neck.
It is prohibited to clean the generator during operation.
It is prohibited to clean the generator when it is still hot.
Refuelling
Cleaning

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Operating personnel may only carry out maintenance or re-
pair work described in these operating instructions.
All other maintenance or repair tasks may only be carried out
by specially trained and authorised specialists.
Always unclamp the starter battery before beginning
maintenance and/or repair work.
The maintenance intervals specified in these operating in-
structions must be observed.
It is prohibited to service the generator during operation.
It is prohibited to service the generator when it is still hot.
The generator should be decommissioned if it is not required
for more than 1 year (see 4.6).
Store the generator in a dry, locked room.
A copy of these operating instructions must always be to-
gether with the generator.
________________________________________________
The operating manual and the maintenance instructions
for the engine
(see Fig. 11-(5), are integral components of
these instructions.
________________________________________________
Maintenance
and repair
work
Decommissioning
Documentation