Endress ESE 608 DHG ES DI DUPLEX User manual

OPERATING INSTRUCTIONS
ESE 608 DHG ES DI DIN SILENT Article No.: 151312 / 156312

Operating Manual
2Version: 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
E133863
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

Contents
Status at: January 2013 3
Table of Contents
List of illustrations
List of tables

4Version: January 2013
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 operating manual and the maintenance instructions
for the engine (see Figure 1-1-(5)) are integral components
of these instructions.
________________________________________________
A copy of these operating instructions must be available to
the operating personnel at all times.

Status at: January 2013 5
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 DIN SILENT generator.
Cable with test tip (see Figure 1-1-(1))
Tools (see Figure 1-1-(2))
Engine circuit diagram (see Figure 1-1-(3))
Motor service centre directory (see Figure 1-1-(4))
Engine operating instructions (see Figure 1-1-(5))
Motor replacement parts list(see Figure 1-1-(6))
Motor replacement seal (see Figure 1-1-(7))
Oil drain hose (see Figure 1-1-(8))
Test report
Ring screw for loading
Wiring diagram
Figure 1-1: Delivery documentation / Accessories

6Version: January 2013
1.2 Safety symbols
The safety warning symbol indicates that a source of danger
exists.
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.

Status at: January 2013 7
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!

8Version: January 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
2.1.1Intended 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.
The generator must be operated according to the specifica-
tions in the technical documentation.

Status at: January 2013 9
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 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

10 Version: January 2013
2.1.3 Residual risks
Before design and planning were begun, the residual risks of
the ESE 608 DHG ES DI DIN SILENT generator were ana-
lysed and evaluated by means of a hazard analysis.
Structurally unavoidable residual risks during the entire ser-
vice life of the ESE 608 DHG ES DI DIN SILENT 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

Status at: January 2013 11
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 27°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

12 Version: January 2013
2.2 Operating personnel – Qualification 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

Status at: January 2013 13
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

14 Version: 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. 2-1: Signs on the generator

Status at: January 2013 15
Number
Sign
Name
1
Noise emission
2
Note
Line extension
3
Potential equalization
(earthing for FI)
4
Reference note - read
operating instructions
5
Nameplate
Generator
6
Note
Hot surfaces
7
Fuel note
8
Note
Open flame prohibited
9
Fuel note
Table 2.2: Signs on the generator

16 Version: 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 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.

Status at: January 2013 17
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 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.
Transport
Setting up
Generating electricity

18 Version: January 2013
It is prohibited to operate the generator without air filters and
with an opened air filter cover.
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

Status at: January 2013 19
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 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 4.10).
Store the generator in a dry, locked room.
A copy of these operating instructions must always be kept
together with the generator.
________________________________________________
The operating manual for the engine (see Figure 1-1-(5), are
integral components of these instructions.
________________________________________________
Maintenance and repair
work
Decommissioning
Documentation

20 Version: January 2013
Notes