Endress ESE 67 IW Operational manual

ESE power generator
TRANSLATION OF THE ORIGINAL OPER-
ATING MANUAL
ESE 67 IW/RS Item No. 333363 / 333373
ESE 90 IW/RS Item No. 333364 / 333374
ESE 110 IW/RS Item No. 333365 / 333376

2
Manufacturer ENDRESS Elektrogerätebau GmbH
Neckartenzlinger Str. 39
D-72658 Bempflingen, Germany
Tel: + 49 (0) 71 23 / 9737 - 0
Fax: + 49 (0) 71 23 / 9737 – 50
Email: [e-mail]
www: http://www.endress-stromerzeuger.de
Document number /
version
E136457 / i03
Publication date June 2021
Copyright 2021 ENDRESS Elektrogerätebau GmbH
This documentation and parts thereof are subject to copyright. Any use or modi-
fication 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.
Notes on printing All descriptions, technical details and illustrations refer to the version of the gen-
erator for printing.
We reserve the right to make modifications in terms of ongoing technical devel-
opment. This operating manual does not include technical modifications that oc-
curred after printing.
The colours in this operating manual do not always comply completely with the
actual designs due to technical printing reasons.

3
Table of Contents
1Directories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.1 Constituent parts of the documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.2 Using this operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.1 Welcome to ENDRESS! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.2 Your product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.2.1 A device description and intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.2.2 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.3 Scope of delivery of your generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.4 Labels on the generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4 For your safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
4.1 Safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
4.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
4.3 Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
4.4 Authorised operating personnel – qualifications and obligations. . . . . . . . . . . . . . . . . . . . .23
4.5 Danger zones and work areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
5 Checking the electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6 Description of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6.1 Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6.2 Exhaust gas and battery side components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
6.3 Components on the maintenance side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
6.4 Components for operating panel and switch box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
7.1 Transporting and preparing your generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
7.2 Refuelling your generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
7.3 Starting the generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..36
7.4 Low load diesel engine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
7.5 Turning off your power generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
7.6 Turn off your generator in the event of an EMERGENCY . . . . . . . . . . . . . . . . . . . . . . . . . .38
7.7 Connection of power consuming equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
7.8 Residual current circuit breaker (RCD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
8 The device in-use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
8.1 Operating the E-MCS 7.0 control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
8.1.1 Operating panel for control module E-MCS 7.0 . . . . . . . . . . . . . . . . . . . . . . . . . . .47
8.1.2 Display window on the control module’s screen . . . . . . . . . . . . . . . . . . . . . . . . . . .49
8.2 Select operating mode (II / TN-S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
8.2.1 Direct supply mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
8.2.2 Building supply operating mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
8.3 Insulation monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..54
8.4 2-way fuel valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
8.5 HARTING remote starting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

4
9 Optional fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
9.1 Powerlock-Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
9.2 Dummy load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
9.3 External battery charging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
10.1 Maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
10.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..64
10.3 Starter battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
10.3.1 Replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
10.4 Engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
10.4.1 Changing the engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
10.5 Checking the coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..68
11 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
12 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
13 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
14 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
15 Replacement parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Keyword index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

5
Directories
1 Directories
1.1 List of illustrations
1.2 List of tables
Fig. 3-1 Example of a type plate .9
Fig. 3-2 Included with delivery .12
Fig. 3-3 Labels on the device .13
Fig. 6-1 Views of the generator .27
Fig. 6-2 Components on the connecting side .28
Fig. 6-3 Components on the maintenance side .29
Fig. 6-4 Components for operating panel and external switch box .30
Fig. 7-1 Setting up personal protection measures (source: DGUV) .33
Fig. 7-2 Manually starting and stopping the power generator .36
Fig. 7-3 Connecting consumers .41
Fig. 7-4 Built-in types of residual current circuit breaker (RCD) .44
Fig. 7-5 Differential current release .45
Fig. 8-1 Control module’s display .46
Fig. 8-2 Control module’s control panel .47
Fig. 8-3 Operating display on the control module .48
Fig. 8-4 Sample from control module’s display screen .50
Fig. 8-5 TN system / TT system version example .53
Fig. 8-6 Insulation monitoring .55
Fig. 8-7 Refuelling device connection .57
Fig. 8-8 Remote starting device with HARTING® socket .59
Fig. 9-1 POWERLOCK BOX .60
Fig. 9-2 Display with dummy load operating .61
Fig. 9-3 230 V feed plug for battery charger .62
Fig. 10-1 Starter battery (illustration similar) .65
Fig. 10-2 Manual oil scavenger pump .67
Fig. 10-3 Checking the coolant .68
Fig. 15-1 Spare parts over endressparts.com .75
Tab. 3-1 Labels on the device .15
Tab. 4-1 Danger zone on Generators .24
Tab. 5-1 Recommended test intervals .26
Tab. 8-1 Control buttons on the control module .48
Tab. 8-2 Operating display on the control module .49
Tab. 13-1 Troubleshooting .72
Tab. 14-1 Power generator technical data .73

6
About this manual
2 About this manual
We would like to explain to you the safe and correct use of your generator in the
best possible way through this operating manual. To do this we have oriented
ourselves to the new European standard DIN EN 82079-1 for preparing the user
manuals.
It is absolutely essential for safe and appropriate use that you read through this
manual very carefully and understand it before using the device for the first time.
Your observance of it creates the foundation for,
• avoiding dangers for yourself and others,
• reducing repair costs and downtimes as well as
• increasing the reliability and service life of the generator.
Not only this manual but also the laws, regulations, guidelines, and standards ap-
plicable in the country of use must be observed.
This document only describes the safe operation of the generator when used as
a complete unit. The following also includes detailed technical operating instruc-
tions that are binding with regard to using the device's specific components.
This documentation and also the product described in it are subject to a contin-
uous improvement process. In doing this we ensure that the full product is com-
pliant with the current safety requirements and the current state-of-the-art. The
respective most up to date language version of the operating manual and the
original operating manual can be found on our website
www.endressparts.com
2.1 Constituent parts of the documentation
Apart from this operating manual, the following documents are part of your de-
vice’s complete documentation:
• Operating and maintenance manual for the engine (FPT-Iveco)
• Documentation of the electrical generator (MECC ALTE company, on CD-
ROM)
• Generator circuit diagram
• Starter battery handling instructions (electric start)
• EU Declaration of Conformity
• Generator test report
• POWERLOCK BOX operating and maintenance manual (optional)
NOTICE!
The complete documentation is an integral part of the device and you must
adhere to it.
► All of the integral parts of the documentation must always be accessible to
the operating personnel and they should be kept with the device.
2.2 Using this operating manual
In order to increase the legibility, comprehensibility and transparency of
the document, certain information is highlighted or identified according a
uniform system. The following particularly belong in this category:

7
About this manual
signs warning about dangers to life and limb
Safety and warning notices are necessary at all locations where there is potential
danger from the device which cannot be eliminated by design or operational
measures. We restricted ourselves to the permitted minimum in order to place
the required distinctive warning notices at the correct point in time without impair-
ing the legibility and comprehensibility of the operating manual. This is according
to the regulations contained in the international standard DIN ISO 3864 de-
scribes a fixed rule for all safety and warning notices, as shown in the following
example.
Examples:
DANGER!
Electrical voltage
Risk of suffering potentially deadly electrocution by touching live parts
► Only use undamaged connecting lines
► Avoid all damp / wetness when connecting consumers
► Never operate the power generator with an opened control panel
The standard mentioned classifies the safety risks according to different risk po-
tentials. To understand and avoid dangers to one’s health and even life, please
be sure to read the explanations given in Chapter 4.1 .
Safety symbols
These warning notices are usually used in a safety symbol which also emphasis-
es the type of danger; see next example. A list of the safety symbols used in this
operating manual can be found in Chapter Fig. 3-1 . The safety symbols never
stand alone.
Notices on avoidance of damage to the device
According to DIN ISO 3864, notices which warn against false operation and pos-
sible damage to the device or to the equipment used should be clearly distin-
guishable from previously named warning notices in as far there is no danger to
health. An example of such a notice can be seen here:
NOTICE!
Use of wrong or outdated fuel damages or destroys the engine.
► Only use released diesel fuel.
► Observe the shelf life of the fuel according to the supplier.
► Observe the Operating manual from the engine manufacturer
Symbols and formattings in the text
In order to increase the legibility, comprehensibility and transparency of the doc-
ument, various information and activities are awarded uniformly repeating bullets
or formattings. The following example shows presentation of a sequence of ac-
tions with established work steps:
Example: Prerequisites which must be fulfilled before starting any sequence of actions
1. Action steps according to a fixed sequence.
2. The action steps must be fully completed.
3. The sequence must be observed.

8
About this manual
Results of the action which should be achieved after performing the sequence of
action.
Additional notices for operation or for function of a unit are marked with the
adjacent symbol.
NOTICE!
The adjacent symbol is situated anywhere where the supplier documenta-
tion must be read and observed and refers to,
► appropriate information,
►tasks or
► action steps.
References to details and components in figures are made with blue bordered
position numbers in the text such as the example of CE signs on the type plate
demonstrates, see Fig. 3-1 .

9
Product identification
3 Product identification
3.1 Welcome to ENDRESS!
We are pleased that you have made the decision to purchase a ENDRESS
power generator. You have purchased a high-performance product into
which we have embodied decades of our experience and have integrated
many functions oriented on daily use. Through careful selection of high
quality components and materials in combination with the proverbial Swa-
bian engineering performance you have in your possession a device which
will operate reliably for many years, also under the hardest of operating
conditions.
3.2 Your product
Customer service In order to precisely identify your device there is a type plate attached to the Gen-
erators (see Fig. 3-1 ), which includes details about the device designation and
"S/N" serial number. If you have any questions about device details, functions or
notices concerning operation, please contact our
Customer service: Tel. [phone]
Email: [e-mail]
You will find competent contact persons there, also concerning original spare
parts and wear parts. (see also Chapter 15 )
Type plate The type plate shown below is a representation of the adhesive label placed on
the device. Please be prepared, when contacting our service team, to assist us
in exactly identifying your device. Refer to your generator's operating instructions
for further information about finding the type plate.
Fig. 3-1 Example of a type plate
3.2.1 A device description and intended use
As part of network backup, the power generator creates electricity that can be
used in alternating operation as an “on-site operation” OR as a “building supply”
(IT-TN version).
Your power generator creates electricity for the “on-site operation” mode as part
of a network backup operation, through which you can supply a mobile distribu-
tion system with electricity. This enables mobile use of commercially available
electrical devices with single-phase 230 V AC / 50 Hz or three-phase 400V AC /
50 Hz (depending on the equipment being used).

10
Product identification
Your power generator has been designed for manual or automatic operation (re-
mote start) with one or more electrical consumers. To protect against electric
shock (i.e. current flowing through your body), automatic switch-off according to
DIN VDE 0100-551: 2017-02 is used as the protective separation measure. The
protective conductor system from the attached consumers will take over the
earthing function. The terminal strip (Fig. 6-4 ) is used for connecting a suitable
earth (e.g. an earthing stake). Proper is needed and it must be done by a quali-
fied electrician.
In “building supply” mode (see Chapter 8.2 , the power generator serves as an
emergency power supply for a stationary system through a flexible cable connec-
tion. For this, there is a separate CEE 400 V / 50 Hz socket with white colour
marking.
Your generator consists of an AC generator driven by a combustion engine that
is bolted onto it. This unit is mounted elastically inside a closed, sound-insulated
housing, and vibration dampers are used to ensure low vibration.
The unit generates AC (three-phase) current with a nominal voltage of 400 V at
50 Hz. More detailed technical data can be found in Chapter 14 . An integrated
voltage regulator ensures that the stability of the generated voltage is within the
nominal rotational speed range. Power is taken through a spray-water-protected
Schuko socket with nominal voltage of 230 V / 50 Hz 1~ or CEE sockets for 230
V / 50 Hz / 1~ or 400 V / 50 Hz / 3~ (see Fig. 6-4 ).
The generator is only to be used outdoors within the indicated voltage, output,
and nominal RPM ranges (see type plate).
The power generator must never be used for direct feed into other power distri-
bution systems (e.g. public power supply) or be used with other power generation
systems (e.g. other power generators).
The generator is not to be used in explosion-prone environments.
The generator is not to be used in environments where there is a risk of fire.
The generator must be operated according to the specifications in the technical
documentation.
Every inappropriate use or all activities on the generator that are not described
in this manual is prohibited misuse beyond the manufacturer’s legally defined
limits of liability.
3.2.2 Foreseeable misuse
Apart from the description of appropriate use, the lawmaker also requires
concrete references to the results of “reasonably foreseeable misuse“. In
a case of incorrect use or inappropriate handling of the generator the man-
ufacturer's EU Declaration of Conformity, and automatically thereby also
the operating licence, are nullified. For products with a manufacturer’s war-
ranty the manufacturer will reject any claims made under warranty for dam-
ages which were caused by misuse and its direct as well as indirect
consequences.
In particular unauthorised misapplications include:
• operation of the generator takes place without valid checks for
– electrical safety
– checking that the stipulated servicing and maintenance work has been
done
• operation of the generator taking place without the protective equipment in-
stalled by the manufacturer
• constructional or electrical modifications were made to the generator

11
Product identification
• software was modified or changes were made to the generator's factory set-
tings
• use of the generator by inadequately instructed operating personnel
Furthermore at all costs avoid the following Misuses:
• Never refuel the generator’s own tank when the engine is running. The vibra-
tions and strong exhaust streams during operation can lead to fuel spillage.
This leads to an increased risk of explosion and fire and therefore danger to
operating personnel, the environment and the device.
• Never refuel the generator’s own tank when it is hot. Overflowing fuel and ex-
haust fuel vapours can ignite on hot parts of the device.
• Never open the generator’s tank cover whilst it is running or if it is hot. Over-
flowing hot fuel and escaping fuel vapours can ignite on the device’s hot
parts.
• The generator is never to be connected up to another energy distribution sys-
tem (e.g. public power supply) or to other power generating systems (e.g.
other generators, solar plants, etc.). To start with this is usually not permitted
by . In both cases this will inevitably lead to severe damage and possibly also
severe injury.
• Never place the generator in explosion-prone environments. The individual
components of the generator are not designed to be EX-protected.
• Never operate the generator in rooms, narrow pits or vehicles. The combus-
tion exhaust gases contain poisonous substances including the odourless
but deadly gas carbon monoxide (CO) which, when breathed in, can accu-
mulate in cases of poor air circulation to reach deadly concentrations. Also a
lack of fresh air circulation leads to overheating and possible damage to the
generator right through to destruction.
• For the same reasons of risk, never divert exhaust gases for the purposes of
heating rooms or vehicles.
• Never clean the generator with the aid of a high pressure cleaner or a strong
jet of water.
• Never allow water to find its way inside the generator. Never pour water over
the generator and never clean it using a water hose or a high pressure clean-
er.
• Never operate the generator in any area where it could be flooded by high
water or any other events. The device's protection class (see Chapter 14 )
allows operation with spray water, however not in the case of floods.

12
Product identification
3.3 Scope of delivery of your generator
Apart from the technical documentation mentioned in Chapter 2.1 the following
items are Scope of delivery of your generator:
Fig. 3-2 Included with delivery
Item Name
Earth stake with connection cable
Key for POWERLOCK BOX (optional)
Universal key for access hatch
Filling aid with hopper
Technical documentation, see Chapter 2.1

13
Product identification
3.4 Labels on the generator
An important part of the operating manual is the labelling and notices on your
generator. These labels must not be removed and must always be maintained in
legible condition. If there is damage to a Labels can be ordered from our custom-
er service team. The following figures and tables show the stipulated attachment
point and a brief explanation of the labels.
Fig. 3-3 Labels on the device

14
Product identification
Item label Meaning
Mandatory sign
Read the operating manual
before starting up
Note
Operate the power genera-
tor only with the mainte-
nance hatches closed.
Note
Crane loading lug
Example of maximum de-
vice weight
Note
Noise emissions
Warning
Burn hazard
Hot surfaces
Type plate
Example:
Note
2-way fuel valve
External tank
Internal tank
Note
Fuel quality
and tank contents
Prohibition signs
No smoking!
Open flame prohibited!

15
Product identification
Tab. 3-1 Labels on the device
POWERLOCK sticker
Open, connect and discon-
nect only when de-ener-
gized.
The connection terminal is
for potential equalization
(left) with IT networks and
for earthing (right) with TN
networks.
DGUV instruction on
Generators
of Version C
Death hazard
Live parts when opening the
cover
The EMERGENCY STOP
switch turns off the power
generator immediately if
there is an emergency.
Warning symbols
Dangerous voltage
For electricians only
Brief operating manual
Warning notices
Do not use starting aids!
Explosion hazard
Item label Meaning

16
For your safety
4 For your safety
The following chapter describes basic Safety instructions for safe operation of
your generator. Your device is a very high-performance electrical machine which
is potentially dangerous when operated if it has not been installed, commis-
sioned, used, serviced and repaired according to the operating manual. If neces-
sary, the operating manual will also include different supplements that depend on
the country of use, in addition to the present one.
Operation, use, servicing as well as any work with or on the generator is therefore
only permitted by such persons who have read this chapter and have put its pro-
visions into practice!
Concrete warning notices can also be found regarding basic safety instructions
further on in this operating manual. These are always placed in an explanatory
text immediately before the description of work steps which can be dangerous if
the warning notice is not observed. Read the following sections for correct and
rapid understanding of these safety and warning notices. They describe their
systematic structure as well as the meaning of markings and symbols.
4.1 Safety symbols
The safety symbol indicates graphically that a source of danger exists. We
use the internationally valid safety symbols from ISO 7010 for rapid and
unique classification of the respective dangerous situation. In the follow-
ing there is a description of the warning symbols used in this operating
manual with an explanation about the respective dangerous situations.
Warning of a general hazard
This warning symbol indicates activities where several causes can lead to risks.
The concrete danger must be respectively more clearly specified by further no-
tices.
Warning of a dangerous electrical voltage
This warning symbol is indicates activities where the danger of electric shock ex-
ists, possibly with lethal consequences.
Warning of potentially explosive materials
This warning symbol indicates activities where the danger of an explosion exists,
possibly with lethal consequences.
Warning of toxic substances
This warning symbol indicates activities where a risk of poisoning exists, possibly
with lethal consequences.

17
For your safety
Warning of corrosive substances
This warning symbol indicates activities where a risk of chemical burns to the en-
vironment as well as people exists, possibly with lethal consequences.
Warning of environmentally damaging substances
This warning symbol indicates activities where a risk of contaminating the envi-
ronment exists, 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.
Warning of a suspended load
This warning symbol indicates activities where the danger of falling loads exists,
possibly with lethal consequences.
Warning of automatically starting machines
This warning symbol indicates activities where a danger of being injured by self-
starting machines exists, possibly with lethal consequences.

18
For your safety
4.2 General safety instructions
ENDRESS Generators are designed to operate electrical equipment with
appropriate power output requirements. Other uses can lead to severe in-
jury to operating personnel and people nearby. There is also increased risk
of damage to the generator and further property damage.
DANGER!
Mortal danger due to an electric shock if live parts are touched.
► Never operate the device if it is in a damaged condition.
► Never operate the electrical consumers and connecting cable (power con-
suming equipment) in a damaged condition.
► Never feed directly into existing networks that are already connected to a
power source (e.g. power supplier, solar plant, etc.).
► Never operate the device with wet hands.
Most injuries and equipment damage can be avoided if all instructions given in
this manual and all instructions attached to the device are followed.
The Generators must not be modified in any way, not even temporarily. This pose
a death hazard to operating and deployed personnel and damage to the gener-
ator and the consumers being used.
Operating company and Operating personnel are to use the Generators only ac-
cording to regulations contained in the entire technical documentation (hereinaf-
ter referred to as appropriate use).
Every instance of inappropriate use and all activities on the Generators that are
not described in this manual are prohibited misuse beyond the legally defined
limits of the manufacturer’s liability. In return all claims for damages and warranty
claims against ENDRESS-Elektrogerätebau GmbH that are associated with mis-
use are null and void.
4.3 Residual risks
As a manufacturer of EU-compliant machines, ENDRESS make great ef-
forts to create designs which already eliminate possible risk potentials at
the design stage. If this is not possible without significantly impairing the
functions of a device, we implement suitable protective measures protect
the user from injury.
If there are still some residual risks associated with working with the de-
vice, we clearly advise the user about these sources of danger, possible
consequences as well as measures to avoid such dangers.
The residual dangers were analyzed and Residual dangers identified during the
development and design of your Generators by means of a danger analysis ac-
cording to DIN EN 60204, DIN EN ISO 12100 and DIN EN ISO 8528-13.
References to general sources of danger can be found in chapters 4 and 5 .
From Chapter 6 one can find concrete warning notices placed before every ac-
tion step which represents a residual risk.
The exact structure and contents of warning notices are defined in the
ISO 3864 series of standards and follow an established identification mark-
ing required to immediately be able to estimate the degree of the respective
danger. Exactly impress upon yourself the identification marking of the

19
For your safety
four different danger levels in order to be able to reliably assess the dan-
gers associated with the individual operating states and action steps when
reading the operating manual.
DANGER!
DANGER describes a danger which represents a high level of risk,which
can lead to death or severe injuries,when not avoided.
► The individual points provide instructions and
► notices as aids to avoid the danger
► or to reduce the risk to an acceptable level.
WARNING!
WARNING describes a danger which represents a medium level of
risk,which can lead to death or severe injuries,when not avoided.
► The individual points provide instructions and
► notices as aids to avoid the danger
► or to reduce the risk to an acceptable level.
CAUTION!
CAUTION describes a danger which represents a low level of risk,which
can lead to minor or medium level injurieswhen not avoided.
► The individual points provide instructions and
► notices as aids to avoid the danger
► or to reduce the risk to an acceptable level.
NOTICE!
ATTENTION! describes a situation or action that might result in damage to
equipment and/or malfunctions if it is not prevented.
► The individual points provide instructions and notices
► as an aid to avoid or prevent damage to equipment.
DANGER!
Mortal danger due to an electric shock if live parts are touched.
► Never operate the device if it is in a damaged condition.
► Never operate the electrical consumers and connecting cable (power con-
suming equipment) in a damaged condition.
► Never feed directly into existing networks that are already connected to a
power source (e.g. power supplier, solar plant, etc.).
► Never operate the device with wet hands.

20
For your safety
DANGER!
Engine exhaust gases contain poisonous and partially invisible gases such
as carbon monoxide (CO) and carbon dioxide (CO2).
Risk of death due to poisoning or asphyxiation.
► Ensure that there is good ventilation during the whole period of operation.
► Only operate the generator in the open.
► Never direct the exhaust gases into rooms or pits.
DANGER!
Danger of severe or mortal injuries being incurred from falling loads.
► Never stand under or close to a suspended load, also not to provide assis-
tance.
► Ensure that there is no person in the area of swivel of the lifting device.
► Use all suitable measures to prevent the suspended load from swaying.
DANGER!
Leaking engine oil and fuel can burn or explode.
A risk of suffering severe even deadly burns.
► Prevent engine oil or fuel from leaking out.
► Never open the tank cover during operation or when it is hot.
► Remove leaked operating fluids immediately and appropriately.
► Never use an additional starting aid.
► Smoking, naked flames and sparks are forbidden.
DANGER!
Hot parts can ignite flammable and explosive materials.
A risk of suffering severe even deadly burns.
► Never operate the generator in the vicinity of combustible or flammable ma-
terials.
► Never operate the generator in an environment prone to an explosion.
WARNING!
There is a risk of explosion and fire in the case of inappropriate handling
and spark development when working with the battery.
Danger from spraying sulphuric acid. Danger of suffering severe even deadly
burns and chemical burns. Danger of being blinded.
► Never lay electrically conductive parts on the starter battery.
► Flames, sparks, an open light and smoking are prohibited.
► Avoid sparks when handling cables and electrical devices, as well as electro-
static discharge.
► Avoid short-circuits.
► Wear acid-resistant protective clothing.