Endress ESE 1008 LG ES DIESEL DUPLEX SILENT User manual

ESE 1008 LG ES DIESEL DUPLEX SILENT Article No. 113035
ESE 1408 LG ES DIESEL DUPLEX SILENT Article No. 113032

Table of Contents
2Version: April 2016
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
E135605
April 2016
© 2016, 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: April 2016 3
Table of Contents
1.1 Documentation and accessories........................................................................6
1.2 Safety symbols ..................................................................................................7
2.1 Important safety warning....................................................................................8
2.2 Intended use......................................................................................................9
2.2.1 ....................................................Foreseeable incorrect use or inappropriate handling 10
2.2.2 ................................................................................................................ Residual risks 11
2.3 Operating personnel –Qualification and obligations ........................................13
2.4 Danger zones and work areas.........................................................................14
2.5 Signs on the generator.....................................................................................15
2.6 General safety instructions...............................................................................17
3.1 Components of the operating side ...................................................................22
3.2 Components of the rear side............................................................................23
3.3 Control panel components...............................................................................24
3.4 Function and mode of operation.......................................................................25
4.1 Transporting and setting up the generator .......................................................27
4.2 Fuelling............................................................................................................28
4.3 Start the device................................................................................................30
4.4 Stop the device................................................................................................31
4.5 Connecting up to consumers ...........................................................................31
4.6 Putting the generator out of service .................................................................32
4.7 Disposal...........................................................................................................32
5.1 Insulation monitoring........................................................................................33
5.2 FI circuit breaker..............................................................................................35
5.3 EcoTronic (speed reduction)............................................................................37
5.4 Radio impulse remote start / remote start with cable remote start / emergency
power supply....................................................................................................38
6.1 Start generator with E-MCS 5.0 .......................................................................40
6.2 Switch off generator with E-MCS 5.0................................................................40
6.2.1 ............................................................................................... Status query E-MCS 5.0 42
6.2.2 .................................................................................... Read out error codes and reset 43
6.3 Remote start with E-MCS 5.0 (cable remote operation)...................................44
6.4 Remote start with E-MCS 5.0 (radio)................................................................45

Table of Contents
4Version: April 2016
7.1 Maintenance plan.............................................................................................46
7.2 Maintenance work............................................................................................46
7.2.1 .................................................................................................................. Drain the oil. 46
7.2.2 ......................................................................................... Replacing the starter battery 48
7.3 Checking the electrical safety ..........................................................................49
10.1 Sound absorption hood / Engine / Generator...................................................55
10.2 Electronics.......................................................................................................56
List of illustrations
Figure 1-1: Delivery documentation / Accessories............... 6
Fig. 2-1: Signs on the generator.........................................15
Figure 3-1: Components of the operating and generator side
....................................................................................22
Figure 3-2: Components of the rear side............................23
Figure 3-3: Control panel components................................24
Figure 4-1: External refuelling.............................................29
Figure 5-1: Insulation monitoring ........................................33
Figure 5-2: FI circuit breaker...............................................36
Fig. 5-3: Speed reduction...................................................37
Figure 7-1: Drain the oil......................................................47
Figure 7-2: Replacing the battery .......................................48
Fig. 9-1: Generator dimensions..........................................52
Fig. 10-1: Replacementparts for the exhaust or generator
side .............................................................................55
Fig. 10-2: Spare parts for the exhaust and/or alternator side
....................................................................................56
List of tables
Table 2.1: Danger zones and work areas on the generator14
Table 5.1: Insulation monitoring plus switching off..............33
Table 5.2: Insulation monitoring whilst running without
switching off ................................................................34
Table 5.3: Checking the FI circuit breaker ..........................36
Table 8.1: Problems arising during generator operation .....50
Table 9.1: Generator technical data....................................53
Table 9.2: Ambient conditions for the generator ................53
Table 9.3: Generator power reduction dependent on ambient
conditions....................................................................53
Table 9.4: Maximum line length of the distribution network as
a function of the cable cross-section............................54
Table 10.1: Replacement parts, exhaust / alternator side...56
Table 10.2: Electronic replacement parts............................57

General information
Documentation and accessories
Status at: April 2016 5
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.
________________________________________________
The motor's operating manual (see Figure 1-1-(2)) is an in-
tegral part of these instructions.
________________________________________________
A copy of these operating instructions must be available to
the operating personnel at all times.

General information
Documentation and accessories
6Version: April 2016
1.1 Documentation and accessories
In addition to the operating manual there are also the follow-
ing documents and standard accessories for the generator.
Motor operating manual (see Figure 1-1(1))
Oil drain hose (see Figure 1-1(2))
Exhaust gas adapter (see Fig. 1-1-(3))
Figure 1-1: Delivery documentation / Accessories
1
2
3

General information
Safety symbols
Status at: April 2016 7
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.
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
a risk of an electric shock, possibly with lethal consequenc-
es.
Poisonous substances
This warning symbol indicates activities during which there is
a risk 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
a risk of burns, possibly with lasting consequences.

General Safety Regulations
Important safety warning
8Version: April 2016
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!

General Safety Regulations
Intended use
Status at: April 2016 9
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
Removal of protective equipment
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
2.2 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).
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.

General Safety Regulations
Intended use
10 Version: April 2016
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.
2.2.1 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 identifica-
tion
Failure to replace wearing parts
Incorrectly performed maintenance or repair work
Defectively performed maintenance or repair work
Unintended use

General Safety Regulations
Intended use
Status at: April 2016 11
2.2.2 Residual risks
The points analysed and evaluated before beginning the
design and planning of the generator were the residual risks
using a risk analysis tool according to EN ISO 14121.
Residual risks which cannot be avoided by implementing
design measures during the whole life cycle of the generator
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 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

General Safety Regulations
Intended use
12 Version: April 2016
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
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
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
Welding generator's
performance or
functionality limitations

General Safety Regulations
Operating personnel –Qualification and obligations
Status at: April 2016 13
2.3 Operating personnel – Qualification and
obligations
Only appropriately authorised personnel may work with or on
the generator.
The authorised operating personnel must:
be of age.
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.

General Safety Regulations
Danger zones and work areas
14 Version: April 2016
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

General Safety Regulations
Signs on the generator
Status at: April 2016 15
2.5 Signs on the generator
These signs must be fitted on the generator and be kept in a
clearly legible condition:
Fig. 2-1: Signs on the generator
1
Noise emission
5
Note on the hot surface
2
Generator model plate
6
Oil drainage note
3
Open flame prohibited note
Fuel note
7
Reference note - engine maintenance
4
Reference note - read operating instruc-
tions
1
2
3
4
7
5
6

General Safety Regulations
Signs on the generator
16 Version: April 2016
Sign
Name
Noise emission
Open flame prohibited
Fuel note
Reference note - read
operating instructions
Generator model plate
Motor maintenance note
Note on the hot surface
Table 2.2: Signs on the generator

General Safety Regulations
General safety instructions
Status at: April 2016 17
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 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.
Only authorised personnel may remain in the generator's
danger zone.
Smoking is absolutely prohibited in the generator's danger
zone.
Open flames and light are prohibited in the generator's dan-
ger zone.

General Safety Regulations
General safety instructions
18 Version: April 2016
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 is only be transported after it has cooled
down.
The generator may only be transported in a vehicle after be-
ing fastened correctly.
The generator may only be lifted by the crane loops provid-
ed.
The generator is 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.
Devices must not be connected during start-up.
Only tested and authorised cables may be used for the pow-
er 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 nom-
inal output of the generator.
Do not operate the generator without a sound damper.
It is prohibited to operate the generator without air filters and
with an opened air filter cover.
Transport
Setting up
Generating electricity

General Safety Regulations
General safety instructions
Status at: April 2016 19
The generator must always be operated with the hood
closed.
It is prohibited to refill the generator's fuel tank during opera-
tion.
It is prohibited to refill the fuel tank on 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

General Safety Regulations
General safety instructions
20 Version: April 2016
Operating personnel may only carry out the maintenance or
repair work described in these operating instructions.
All other maintenance or repair tasks may only be carried out
by specially trained and authorised specialists.
Always disconnect the starter battery before beginning
maintenance and/or repair work.
The maintenance intervals shown in the operating manual
for the engine should always 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 kept
together with the generator.
________________________________________________
The engine's operating manual (see Figure 1-1-(2), is an in-
tegral part of these instructions.
________________________________________________
Maintenance and repair
work
Decommissioning
Documentation