Endress ESE 1306 HS-GT ES User manual

OPERATING INSTRUCTIONS
ESE 1306 HS-GT ES Article No. 230028A
ESE 1306 DHS-GT ES Article No. 230029A
ESE 1506 DHS-GT ES Article No. 230031A

2ESE 1306 - 1506 Version: September 2013
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]
www: http://www.endress-stromerzeuger.de
E134971
September 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: September 2013 ESE 1306 - 1506 3
Table of Contents
1General information..........................................................................................7
1.1 Further documents.............................................................................................8
1.2 Safety symbols ..................................................................................................9
2General Safety Regulations............................................................................11
2.1 Important safety warning..................................................................................11
2.2 Intended use....................................................................................................12
2.2.1 Residual risks .....................................................................................................13
2.3 Operating personnel –qualifications and obligations .......................................16
2.4 Personal protective equipment.........................................................................16
2.5 Danger zones and work areas .........................................................................17
2.6 Labels on the generator...................................................................................18
2.7 General safety instructions...............................................................................19
2.8 Function and mode of operation.......................................................................23
3Operation.........................................................................................................25
3.1 Transporting the generator...............................................................................25
3.2 Setting up the generator...................................................................................26
3.3 Refuelling the alternator...................................................................................26
3.4 Starting the generator......................................................................................28
3.5 Switching the generator off ..............................................................................30
3.6 Connecting up consumers/appliances..............................................................31
3.7 Putting the alternator out of service..................................................................32
3.8 Disposal...........................................................................................................32
4Special fittings / using accessories...............................................................34
4.1 Remote start device.........................................................................................34
5Maintenance ....................................................................................................36
5.1 Maintenance plan.............................................................................................36

Table of Contents
4ESE 1306 - 1506 Version: September 2013
5.2 Maintenance work............................................................................................37
5.2.1 Charge battery....................................................................................................37
5.2.2 Replacing the starter battery ..............................................................................37
5.2.3 Motor oil..............................................................................................................39
5.3 Checking the electrical safety ..........................................................................41
6Troubleshooting..............................................................................................42
7Technical specifications.................................................................................45
8Replacement parts..........................................................................................49
8.1 Frame / alternator / motor ................................................................................49

Table of Contents
Status: September 2013 ESE 1306 - 1506 5
List of illustrations
Fig. 3-1: Starting the motor.................................................29
Fig. 3-2: Connecting up consumers/appliances..................31
Fig. 4-1: Remote start device with CAN plug......................34
Fig. 5-1: Replacing the battery............................................37
Fig. 5-2: Oil dipstick............................................................39
Fig. 7-1: Generator dimensions..........................................45
Fig. 8-1: Frame / alternator / motor.....................................49
List of charts
Table 2.1: Danger zones and work areas on the generator 17
Table 5.1: Generator maintenance plan .............................36
Table 6.1: Problems arising during generator operation .....43
Table 7.1: Ambient conditions for the generator .................47
Table 7.2: Generator performance reduction dependent on
the ambient conditions.................................................47
Table 7.3: Maximum line length of the distribution network as
a function of the cable cross-section............................47
Table 8.1: Replacement parts for the frame with covers.....50
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 a representa-
tion of basic principles.

Table of Contents
6ESE 1306 - 1506 Version: September 2013
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: September 2013 ESE 1306 - 1506 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 1306 - 1506 Version: September 2013
1.1 Further documents
In addition to these operating instructions, the following doc-
uments are relevant for the generator:
Operating manual and maintenance instructions for the
engine
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: September 2013 ESE 1306 - 1506 9
1.2 Safety symbols
The safety symbol illustrates a source of danger. The safety
symbols 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 safe-
ty and/or health signs at work.
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 an electric shock, possibly with lethal conse-
quences.
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.

General information
10 ESE 1306 - 1506 Version: September 2013
Notes

Status: September 2013 ESE 1306 - 1506 11
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!

12 ESE 1306 - 1506 Version: September 2013
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
2.2 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 indicat-
ed voltage, output, and nominal rpm ranges (see model
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 alternator 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 method that will be used to install the generator on
these surfaces of a vehicle requires written approval from the
distributor that supplied the generator.

Status: September 2013 ESE 1306 - 1506 13
The generator may not be connected to other energy distri-
bution systems (e.g. public power supply) or 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 specifica-
tions in the technical documentation.
Any non-intended use or any activity on the generator not
described in these operating instructions is considered for-
bidden incorrect use outside the legal limits of the manufac-
turer's liability.
2.2.1 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 1050.
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 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:
Risk of death

14 ESE 1306 - 1506 Version: September 2013
Incorrect use
Inappropriate handling
Missing protective equipment
Defective or damaged electrical components
Fuel vapours
Engine exhaust
Too large a distribution network configuration
Risk of injury to persons at the generator can be caused by:
Inappropriate handling
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 property in the operating range of
the generator can occur through:
Inappropriate handling
An over and/or an undervoltage
Incorrect installation in a vehicle
Risk of injury
Environmental hazards
Material damage to the
generator
Material damage to other
property

Status: September 2013 ESE 1306 - 1506 15
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
Limits to performance or
functionality

16 ESE 1306 - 1506 Version: September 2013
2.3 Operating personnel –qualifications and obligations
Only appropriately authorised personnel may work with or on
the alternator.
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 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 alternator.
have understood the technical documentation concerning
his responsibilities, tasks and activities on the alternator
and be able to implement these in practice.
2.4 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
hard hat
protective shoes
fireproof protective clothing (in areas where the danger of
fire is high)

Status: September 2013 ESE 1306 - 1506 17
2.5 Danger zones and work areas
The danger zones work places (work areas) on the genera-
tor are determined by the activities to be performed 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 per-
sonnel
Radius of 1.0 m
Operation
Setting up
Operating
Radius of 5.0 m
Refuelling
Radius of 2.0 m
Service and
maintenance
Cleaning
Radius of 1.0 m
Shutting down
Maintenance
Table 2.1: Danger zones and work areas on the generator

18 ESE 1306 - 1506 Version: September 2013
2.6 Labels on the generator
These labels must be attached to the generator and be kept
in a clearly legible condition:
Label
Designation
Reference note - read
operating instructions
Potential equalization
(earthing for FI)
Model plate
Maintenance interval
for the engine
Note on the hot sur-
face
Fuel note

Status: September 2013 ESE 1306 - 1506 19
2.7 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 labels on the generator must be in place and in a clearly
legible condition.
The operational reliability and functionality must be checked
before and after each use/operation.
The generator must only be used outdoors 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 alternator against dirt and foreign matter during
operation.
The authorised personnel are responsible for the operational
reliability of the alternator.
The authorised personnel are responsible for safeguarding
the alternator 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.

20 ESE 1306 - 1506 Version: September 2013
Open flames and light are prohibited in the generator's dan-
ger zone.
Consumption of alcohol, drugs, medications, or other mind-
altering substances is prohibited.
The authorised personnel must be familiar with the alternator
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 be-
ing fastened in place correctly (on the transport device).
The generator may only be lifted by the carrying handles
provided.
The generator must be carried by at least as many persons
as there are handles provided.
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.
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.
Transport
Setting up
Generating electricity