Endress ESE 807 DBG DIN User manual

OPERATING INSTRUCTIONS
ESE 807 DBG DIN Article No. 151203 / 156203
ESE 807 DBG ES DIN Article No. 151213 / 156213
ESE 1107 DBG DIN Article No. 151215 / 156215
ESE 1307 DBG DIN Article No. 151216 / 156216
ESE 1407 DBG DIN Article No. 151219 / 156219

2ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN Status at: February 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
E134022
February 2013
© 2013, ENDRESS Elektrogerätebau GmbH
This documentation and parts thereof are subject to copy-
right. Any use or modification beyond the restrictions of the
Copyright Act is forbidden and subject to penalty without the
consent of ENDRESS Elektrogerätebau GmbH.
This applies in particular to copies, translations, microfilming,
as well as storage and processing in electronic systems.
Manufacturer and
publisher
Document number
Publication date
Copyright

Table of Contents
Status at: February 2013 ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN 3
Table of Contents
1General information..........................................................................................7
Documentation and accessories........................................................................81.1
Safety symbols ..................................................................................................91.2
2General Safety Regulations............................................................................11
Important safety warning..................................................................................112.1
Intended use....................................................................................................122.2
2.2.1 Residual risks .....................................................................................................13
Operating personnel –qualifications and obligations .......................................162.3
Personal protective equipment.........................................................................162.4
Danger zones and work areas.........................................................................172.5
Signs on the generator.....................................................................................182.6
General safety instructions...............................................................................212.7
3Description of the generator ESE 807 - 1407 DBG (ES) DIN........................26
Views of the generator.....................................................................................263.1
3.1.1 Components on the operating and engine side..................................................27
3.1.2 Components on the exhaust and generator side ...............................................28
3.1.3 Control panel components..................................................................................29
3.1.4 Accessory components ......................................................................................30
Function and mode of operation.......................................................................313.2
4Operating ESE 807 - 1407 DBG (ES) DIN.......................................................33
Transporting the generator...............................................................................334.1
Setting up the generator...................................................................................334.2
Refuelling the generator...................................................................................344.3
Starting the generator......................................................................................354.4
Switching the generator off ..............................................................................404.5
Connecting up to consumers ...........................................................................414.6
Check the protective conductor........................................................................424.7
Monitoring the operating status using the multifunction display........................434.8
Putting the generator out of service .................................................................464.9

Table of Contents
4ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN Status at: February 2013
Disposal...........................................................................................................464.10
5Special fittings / using accessories...............................................................48
FI protection switch..........................................................................................485.1
Insulation monitoring using E-MCS 4.0 (without switching off).........................505.2
Speed lowering in idle......................................................................................525.3
Remote start device.........................................................................................535.4
External start device ........................................................................................555.5
Battery charge retention...................................................................................565.6
3-way fuel valve / Refuelling device .................................................................585.7
Exhaust hose...................................................................................................615.8
6Maintain generator ESE 807 - 1407 DBG (ES) DIN........................................62
Maintenance plan.............................................................................................626.1
Maintenance work............................................................................................626.2
6.2.1 Motor oil..............................................................................................................63
6.2.2 Replacing the starter battery ..............................................................................66
6.2.3 Replacing fuses..................................................................................................67
Checking the electrical safety ..........................................................................686.3
7Troubleshooting..............................................................................................69
8Technical specifications.................................................................................73
List of illustrations
Fig. 2-1: Signs on the generator.........................................18
Fig. 3-1: Views of the generator..........................................26
Fig. 3-2: Components on the operating and engine side.....27
Fig. 3-3: Components on the exhaust and generator side ..28
Fig. 3-4: Control panel components....................................29
Fig. 3-5: Components of the standard accessories.............30
Fig. 3-6: Components of the special accessories................30
Fig. 4-1: Actuate manual choke..........................................37
Fig. 4-2: Standard design of operating panel......................37
Fig. 4-3: Connecting up to consumers................................41
Fig. 4-4: Check the protective conductor ............................42
Fig. 4-5: Multi-functional display.........................................43
Fig. 5-1: FI protection switch...............................................49

Table of Contents
Status at: February 2013 ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN 5
Fig. 5-2: Insulation monitoring using E-MCS 4.0.................50
Fig. 5-3: Switching the idle down on pressure switch..........52
Fig. 5-4: Remote start device with Harting plug ..................53
Fig. 5-5: Remote start device with CAN plug ......................54
Fig. 5-6: Connecting up an external start device.................55
Fig. 5-7: Connecting up the battery charge retention device
....................................................................................56
Fig. 5-8: Connecting up the battery charge retention device
....................................................................................57
Fig. 5-9: Connecting up the battery charge retention device
....................................................................................57
Fig. 5-10: 3-way fuel valve..................................................58
Fig. 5-11 Connecting the exhaust hose..............................61
Fig. 6-1: Oil dipstick............................................................63
Fig. 6-2: Change the oil......................................................64
Fig. 6-3: Replacing the battery............................................66
Fig. 6-4: Replacing a fuse...................................................67
Fig. 8-1: Generator dimensions..........................................73
List of tables
Table 2.1: Danger zones and work areas on the generator17
Table 2.2: Signs on the generator.......................................20
Table 4.1: Protective conductor test lamp...........................42
Table 5.1: FI protection switch test.....................................49
Table 5.2: Insulation monitoring without switching off.........50
Table 5.3: Insulation monitoring whilst running without
switching off ................................................................51
Table 5.4: Switchingpositions of the 3-way fuel tap ............58
Table 6.1: Generator maintenance plan .............................62
Table 6.2: Location of the fuses.........................................67
Table 7.1: Problems arising during generator operation .....71
Table 8.1: Ambient conditions for the generator .................76
Table 8.2: Generator power reduction dependent on ambient
conditions....................................................................76
Table 8.3: Maximum line length of the distribution network as
a function of the cable cross-section............................76
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.
We reserve the right to make modifications in terms of
ongoing technical development.

Table of Contents
6ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN Status at: February 2013
These instructions do not include technical modifications that
occurred after printing.

General information
Status at: February 2013 ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN 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.
________________________________________________
The operating manual for the engine is an integral com-
ponent of these instructions.
________________________________________________
A copy of these operating instructions must be available to
the operating personnel at all times.

General information
8ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN Status at: February 2013
Documentation and accessories1.1
In addition to these operating instructions, the following doc-
uments are relevant for the generator:
Operating instructions and maintenance instructions for
the engine (Briggs & Stratton Corporation)
Important safety information and instructions for: engine
selection, engine installation, engine operation (Briggs &
Stratton Corporation)
Briggs & Stratton Service Germany (Briggs & Stratton
Corporation)
Test protocol for the power generator
Maintenance instructions for the battery
Circuit diagram for the generator

General information
Status at: February 2013 ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN 9
Safety symbols1.2
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.
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
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 807 / 1107 / 1307 / 1407 DBG (ES) DIN Status at: February 2013
Notes

Status at: February 2013 ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN 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.
Important safety warning2.1
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 807 / 1107 / 1307 / 1407 DBG (ES) DIN Status at: February 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
Intended use2.2
The generator produces electricity in place of the power grid,
in order to supply a mobile distribution system.
The generator is only to be used outdoors within the indicat-
ed voltage, output, and nominal rpm ranges (see name-
plate).
You are also permitted to use it on a vehicle extension or
swivelling platform in both extended and swung out states,
providing that the air circulation is uninterrupted on all sides
of the 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.

Status at: February 2013 ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN 13
The methods that will be used to install the generator on
these vehicle platforms require written approval from the
distributor that supplied the generator.
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.
Any non-intended use or any activity with the generator not
described in these operating instructions is considered for-
bidden incorrect use and is outside the legal limits of the
manufacturer's liability.
2.2.1 Residual risks
The points analysed and evaluated before beginning the
design and planning of the ESE 807 - 1407 DBG (ES) DIN
generator were the residual risks identified using a risk anal-
ysis tool.
Structurally unavoidable residual risks during the entire ser-
vice life of the ESE 807 / 1407 DBG (ES) DIN 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

14 ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN Status at: February 2013
The specific standing instructions (the relevant opera-
tional conditions) issued by fire-brigades, civil defence
and other relief organisations
Risk of death to persons at the generator can be caused by:
Incorrect use
Inappropriate handling
Missing protective equipment
Defective or damaged electrical components
Fuel vapours
Engine exhaust
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
Risk of death
Risk of injury
Environmental hazards
Material damage to the
generator

Status at: February 2013 ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN 15
Material damage to other equipment in the operating area of
the generator can be caused by:
Inappropriate handling
An overvoltage or an undervoltage
Incorrect installation in a vehicle
The generator's performance or functionality can be limited
by:
Inappropriate handling
Inappropriate maintenance or repair work
Unsuitable operating fluids
An installation altitude greater than 100 metres above
sea level
An ambient temperature exceeding 25°C
Too large a distribution network configuration
Material damage to other
property
Limits to performance or
functionality

16 ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN Status at: February 2013
Operating personnel – qualifications and obligations2.3
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.
Personal protective equipment2.4
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 at: February 2013 ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN 17
Danger zones and work areas2.5
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 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 807 / 1107 / 1307 / 1407 DBG (ES) DIN Status at: February 2013
Signs on the generator2.6
These signs must be fitted on the generator and be kept in a
clearly legible condition:
Fig. 2-1: Signs on the generator
1
Reference note - noise emission
6
Cable extension
2
Reference note - maintenance inter-
vals (inner side)
7
Reference note - read operating in-
structions
3
Reference note - three-way valve
8
Reference note - no naked flames
4
Reference note - Hot surface
9
Short operating instructions
5
Potential equalisation screw (earthing
for an optional FI)
10
Nameplate

Status at: February 2013 ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN 19
Sign
Name
Reference note - noise
emission
Reference note -
maintenance intervals
External refuelling
Potential equalization
(earthing for FI)
Note
Line extension
Reference note - read
operating instructions
Reference note - no
naked flames

20 ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN Status at: February 2013
Sign
Name
Short operating in-
structions
Note EMERGENCY-
STOP
Nameplate
Table 2.2: Signs on the generator