Endress ESE 1006 SG-GT ES DUPLEX User manual

OPERATING INSTRUCTIONS
ESE 1006 SG-GT ES DUPLEX ARTICLE NO: 113160
ESE 1006 SG-GT ES DUPLEX ARTICLE NO: 113161
ESE 1306 SG-GT ES DUPLEX ARTICLE NO: 113158
ESE 1506 SG-GT ES DUPLEX ARTICLE NO: 113159
SEA13 ARTICLE NO: 151647

2ESE 1006 / 1306 / 1506 (D)SG-GT ES Duplex Status: January 2013
ENDRESS
Elektrogerätebau GmbH
Neckartenzlinger Str. 39
D-72658 Bempflingen
Telephone: + 49 (0) 71 23 / 9737 –0
Fax: + 49 (0) 71 23 / 9737-50
Email: [e-mail]
www: http://www.endress-stromerzeuger.de
E133621
January 2013
© 2013, ENDRESS Elektrogerätebau GmbH
This documentation and parts thereof are subject to copy-
right. Any use or modification beyond the restrictions of the
Copyright Act is forbidden and subject to penalty without the
consent of ENDRESS Elektrogerätebau GmbH.
This applies in particular to copies, translations, microfilming,
as well as storage and processing in electronic systems.
Manufacturer and
publisher
Document number
Publication date
Copyright

Table of Contents
Status at: January 2013 ESE 1006 / 1306 / 1506 (D)SG-GT ES Duplex 3
1General information..........................................................................................7
1.1 Documents and accessories..............................................................................8
1.2 Safety symbols ..................................................................................................9
2General Safety Regulations............................................................................11
2.1 Important safety warning..................................................................................11
2.1.1 Intended use ..................................................................................................12
2.1.2 Foreseeable incorrect use or inappropriate handling.......................................13
2.1.3 Residual risks.................................................................................................14
2.2 Operating personnel –Qualifications and obligations.......................................16
2.3 Personal protective equipment.........................................................................16
2.4 Danger zones and work areas .........................................................................17
2.5 Signs on the generator.....................................................................................18
2.6 General safety instructions...............................................................................20
3The generator ESE 1006 / 1306 / 1506 (D)SG-GT ES Duplex .......................25
3.1 Generator components ....................................................................................25
3.2 Generator and control side components ..........................................................26
3.3 Exhaust and engine side components..............................................................27
3.4 Control panel components...............................................................................28
3.5 Function and mode of operation.......................................................................29
4Operation.........................................................................................................31
4.1 Transporting the generator...............................................................................31
4.2 Setting up the generator...................................................................................32

Table of Contents
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4.3 Refuelling the generator...................................................................................32
4.4 Starting the generator......................................................................................34
4.5 Switching the generator off ..............................................................................36
4.6 Connect up to consumers................................................................................37
4.7 ECOtronic (idle down)......................................................................................38
4.8 Monitoring the operating status via the “ECD 06 control display” .....................39
4.9 Putting the generator out of service..................................................................41
4.10 Disposal...........................................................................................................41
5Special fittings / using accessories...............................................................43
5.1 FI protection switch..........................................................................................43
5.2 Insulation monitoring (with switch off)...............................................................45
5.3 Remote start device.........................................................................................47
5.4 Wireless remote control ...................................................................................49
5.5 Exhaust hose...................................................................................................51
6Maintenance ....................................................................................................52
6.1 Maintenance plan.............................................................................................52
6.2 Maintenance work............................................................................................53
6.2.1 Charge battery ...............................................................................................53
6.2.2 Replacing the starter battery...........................................................................53
6.2.3 Motor oil.........................................................................................................55
6.3 Checking the electrical safety...........................................................................59
7Troubleshooting..............................................................................................60
8Technical specifications.................................................................................63

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9Replacement parts..........................................................................................67
9.1 Protective cover / Engine / generator...............................................................67
9.2 Electrical compartment.....................................................................................69
10 Warranty / Maintenance..................................................................................71
Table of Contents
List of illustrations
Fig. 21: Signs on the generator...............................18
Fig. 31: Views of the generator ...............................25
Fig. 32: Components of the operating and generator
side.............................................................................26
Fig. 33: Exhaust and engine side components........27
Fig. 34: Control panel components..........................28
Fig. 41: Starting the motor.......................................35
Fig. 42: Connect up to consumers...........................37
Fig. 43: Idle down rocker switch..............................38
Fig. 44: Control Display ECD 06..............................39
Fig. 51: FI protection switch ....................................44
Fig. 52: Insulation monitoring..................................45
Fig. 53: Remote start device with CON ...................47
Fig. 54: Wireless remote control..............................49
Fig. 61: Replacing the battery .................................54
Fig. 62: Oil dipstick..................................................55
Fig. 63: Pour in oil...................................................56
Fig. 64: Changing the oil .........................................57
Fig. 81: Generator dimensions................................63
Fig. 91: Protective cover / engine / generator..........67
Fig. 92: Replacement parts Electrical junction box..69

Table of Contents
6ESE 1006 / 1306 / 1506 (D)SG-GT ES Duplex Stand: January 2013
List of tables
Table 2.1: Danger zones and work areas on the generator 17
Table 2.2: Signs on the generator.......................................19
Table 5.1: FI protection switch test.....................................44
Table 5.2: Insulation monitoring plus switching off..............45
Table 5.3: Insulation monitoring whilst running without
switching off ................................................................46
Table 6.1: Generator maintenance plan..............................52
Table 7.1: Problems arising during generator operation .....61
Table 8.1: Ambient conditions for the generator .................65
Table 8.2: Generator power reduction dependent on ambient
conditions....................................................................65
Table 8.3: Maximum line length of the distribution network as
a function of the cable cross-section............................65
Table 9.1: Replacement partsProtective cover / Engine /
Alternator ....................................................................69
Table 9.2: Replacement parts Electrical junction box..........70
General note: The illustrations in these operating instructions do not always
comply completely with the actual design, in particular with
regard to the colour, and are to be considered as the depic-
tion of basic principles.
We reserve the right to make modifications in terms of
ongoing technical development.
These instructions do not include technical modifications that
occurred after printing.


General information
Status at: January 2013 ESE 1006 / 1306 / 1506 (D)SG-GT ES Duplex 7
1General information
These operating instructions must be read carefully and un-
derstood before using the generator.
These operating instructions are intended to familiarise you
with the basic operation of the generator.
These operating instructions contain important information
on using the generator safely and appropriately.
Complying with 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.
A copy of these operating instructions must be available to
the operating personnel at all times.

General information

8ESE 1006 / 1306 / 1506 (D)SG-GT ES Duplex Stand: January 2013
1.1 Documents and accessories
In addition to these operating instructions, the following doc-
uments are relevant for the generator:
Operating manual and maintenance instructions for the
engine (Subaru)
Regulations for handling the battery
Circuit diagram for the generator
The operating manual and the maintenance instructions
from the engine manufacturer are integral components of
these instructions and must be observed.


General information
Status at: January 2013 ESE 1006 / 1306 / 1506 (D)SG-GT ES Duplex 9
1.2 Safety symbols
The safety warning symbol indicates that a source of danger
exists. The safety warning symbols used in the work area of
the machine/plant and the entire technical documentation
correspond to the Council Directive 92/58/EEC - Minimum
requirements for the provision of safety and/or health signs
at work.
Warning of a general hazard
This warning symbol indicates activities where several caus-
es can lead to risks.
Warning of potentially explosive materials
This warning symbol indicates activities during which there is
an explosive hazard, possibly with lethal consequences.
Warning of a dangerous electrical voltage
This warning symbol indicates activities during which there is
the danger of an electric shock, possibly with lethal conse-
quences.
Warning of toxic substances
This warning symbol indicates activities during which there is
the danger of poisoning, possibly with lethal consequences.
Warning of environmentally damaging substances
This warning sign indicates activities during which the envi-
ronment could be endangered, possibly with catastrophic
consequences.
Warning of hot surfaces
This warning symbol indicates activities during which there is
the danger of burns, possibly with lasting consequences.

General information

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Notes

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2General Safety Regulations
This section describes the basic safety regulations for oper-
ating the generator.
Whoever operates the generator or works with it must read
this chapter and comply with its regulations in practice.
2.1 Important safety warning
ENDRESS generators are designed to operate electrical
equipment with appropriate power output requirements. Oth-
er applications can lead to injury to the operating personnel
and to damage to the generator as well as other damage to
equipment.
The majority of injuries and damage to equipment can be
avoided if all instructions given in this manual and all instruc-
tions attached to the generator are followed.
The generator must not be modified in any way. This can
lead to an accident occurring and damage to the generator
as well as devices.
WARNING!


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The following actions are not permitted.
Operation in explosion-prone environments
Operation in fire-prone environments
Operation in confined areas
Operation from a vehicle platform that has not been
swung out
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
Incorrect vehicle installation
Non-compliance with maintenance intervals
Failure to measure and test for early damage identifica-
tion
Failure to replace wearing parts
Incorrectly performed maintenance or repair work
Defectively performed maintenance or repair work
Unintended use
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 is only to be used outdoors within the indicat-
ed voltage, output, and nominal rpm ranges (see name-
plate).
You are also permitted to use it on a vehicle extension or
swivelling platform in both extended and swung out states,
providing that the air circulation is uninterrupted on all sides
of the generator and that the exhaust gases are dispersed
correctly. This is especially relevant as access to the side
with the instrument panel and the side with the exhaust gas
connection must be unrestricted.
The methods that will be used to install the generator on
these vehicle platforms require written approval from the
distributor that supplied the generator.

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The generator is not to be connected up to other energy dis-
tribution systems (e.g. public power supply) or to other ener-
gy generation systems (e.g. other generators).
The generator is not to be used in explosion-prone environ-
ments.
The generator is not to be used in fire-prone environments.
The generator must be operated according to the specifica-
tions in the technical documentation.
Every inappropriate use or all activities on the generator
which are not described in these instructions are forbidden
misuse outside the legally defined limits of liability of the
manufacturer.
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 from a vehicle platform that has not been
swung out
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
Incorrect vehicle installation
Non-compliance with maintenance intervals
Failure to measure and test for early damage identifica-
tion
Failure to replace wearing parts
Incorrectly performed maintenance or repair work
Defectively performed maintenance or repair work


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Unintended use
2.1.3 Residual risks
Before commencing design and planning, the residual risks
of the generator ESE 1006 / 1306 / 1506 (D)SG-GT ES Du-
plex were analysed and evaluated by means of a hazard
analysis according to EN 1050.
Constructionally unavoidable residual risks during the entire
service life of the ESE 1006 / 1306 / 1506 (D)SG GT (ES)
Duplex generators can be:
Risk of death
Risk of injury
Environmental hazards
Material damage to the generator
Material damage to other property
Limited performance or functionality
You can avoid existing residual risks by observing and fol-
lowing these guidelines:
the special warning notices on the generator
the general safety instructions given in these operating
instructions
the specific warnings given in these operating instruc-
tions
The specific standing instructions (the relevant opera-
tional conditions) issued by fire-brigades, civil defence
and other relief organisations
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
Too large a distribution network configuration
Risk of injury to persons at the generator can be caused by:
Inappropriate handling
Risk of death
Risk of injury

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Transport
Hot components
Recoiling starter rope on the engine
Environmental hazards involving the generator may be
caused by:
Inappropriate handling
Operating fluids (fuel, lubricants, engine oil, etc.)
Exhaust gas emission
Noise emission
Fire hazard
Leaking battery acid
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 equipment in the operating area of
the generator can be caused by:
Inappropriate handling
An overvoltage or an undervoltage
Incorrect installation in a vehicle
The generator's performance or functionality can be limited
by:
Inappropriate handling
Inappropriate maintenance or repair work
Unsuitable operating fluids
An installation altitude greater than 100 metres above
sea level
An ambient temperature exceeding 25°C
Too large a distribution network configuration
Environmental hazards
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 be able to apply them.
have read the chapter "General Safety Regulations".
has understand the content of the chapter "General Safe-
ty Regulations".
be able to use and implement the content of the chapter
"General Safety Regulations" in practice.
be trained and instructed according to the rules of con-
duct in the event of a malfunction 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 alternator.
have understood the technical documentation concerning
his responsibilities, tasks and activities on the alternator
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 and work places (work areas) around the
generator are determined by the activities to be undertaken
within the individual life cycles:
Life cycle
Activity
Danger zone
Work area
Transport
in the vehicle
Radius of 1.0 m
none
by the operating person-
nel
Radius of 1.0 m
Operation
Setting up
Operating
Radius of 5.0 m
Refuelling
Radius of 2.0 m
Service and mainte-
nance
Cleaning
Radius of 1.0 m
Shutting down
Maintenance
Table 2.1: Danger zones and work areas on the generator


18 ESE 1006 / 1306 / 1506 (D)SG-GT ES Duplex Stand: January 2013
2.5 Signs on the generator
These signs must be fitted on the generator and be kept in a
clearly legible condition:
Fig. 21: Signs on the generator
1
Nameplate
5
Reference note - Petrol
2
Reference note - Hot surface
6
Reference note - no naked flames
3
Reference note - noise emission
7
Potential equalization (earthing for FI)
4
Reference note - read operating instruc-
tions

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Sign
Name
Nameplate
Hot surface
warning
Reference note - noise
emission
Reference note - read
operating instructions
Reference note - Petrol
Reference note - no na-
ked flames
Potential equalization
(earthing for FI)
Table 2.2: Signs on the generator


20 ESE 1006 / 1306 / 1506 (D)SG-GT ES Duplex Stand: January 2013
2.6 General safety instructions
The generator's construction may not be modified in any
way.
The motor's nominal rpm has been set in the factory and
may not be changed.
All protective covers must be at hand and functional.
All signs on the generator must be in place and be in a clear-
ly legible condition.
The operational reliability and functionality must be checked
before and after each use/operation.
The generator is only be used outdoors and with sufficient
ventilation.
Do not use open flames, lights, or spark-inducing devices in
the generator’s danger area.
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.
The authorised personnel are obligated to wear personal
protective equipment.
Only authorised personnel may remain in the generator's
danger zone.
Smoking is absolutely prohibited in the generator's danger
zone.