Endress ESE 808 DBG ES DUPLEX SILENT User manual

OPERATING INSTRUCTIONS
ESE 808 DBG ES DUPLEX SILENT Article No. 113007
ESE 1308 DBG ES DUPLEX SILENT Article No. 113008
ESE 1408 DBG ES DUPLEX SILENT Article No. 113022

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]
Web: http://www.endress-stromerzeuger.de
E131267
June 2010
© 2010, ENDRESS Elektrogerätebau GmbH
This documentation and parts thereof are subject to
copyright. Any use or modification outside the restricted
limits of the Copyright Act without the consent of ENDRESS
Elektrogerätebau GmbH is forbidden and subject to penalty.
In particular, this applies to copies, translations, microfilming,
as well as storage and processing in electronic systems.
Manufacturer and
publisher
Document number
Date of issue
Copyright

Table of Contents
Version: May 2011 ESE 808 / 1308 / 1408 DBG ES DUPLEX SILENT 3
Table of Contents
1General information.....................................................................................................8
1.1 Further documents.................................................................................................9
1.2 Safety symbols.....................................................................................................10
2General Safety Regulations.....................................................................................12
2.1 Intended use ........................................................................................................12
2.1.1 Intended use...............................................................................................12
2.1.2 Foreseeable incorrect use or inappropriate handling......................................13
2.1.3 Residual risks.............................................................................................14
2.2 Personal protective equipment............................................................................18
2.3 Danger zones and work areas.............................................................................19
2.4 General safety instructions..................................................................................22
3ESE 808 /1308 /1408 DBG ES Duplex Silent........................................................27
3.1 Components on the operating and engine side ..................................................27
3.2 Components on the exhaust and generator side................................................28
3.3 Accessory components........................................................................................30
3.3.1 Standard accessories..................................................................................30
3.3.2 Specialaccessories.....................................................................................30
3.4 Function and mode of operation..........................................................................31
4Operation......................................................................................................................33
4.1 Transporting the generator..................................................................................33
4.2 Setting up the generator ......................................................................................34
4.3 Refuelling the generator.......................................................................................34
4.4 Starting the generator..........................................................................................36
4.5 Switching the generator off..................................................................................39
4.6 Connecting appliances.........................................................................................40
4.7 Putting the generator out of service.....................................................................41

Table of Contents
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5Special fittings / using accessories......................................................................43
5.1 FI protection switch..............................................................................................43
5.2 Monitoring the operating condition using the multifunctional display..................45
5.3 Insulation monitoring with E-MCS 3.0 .................................................................48
5.3.1 Insulation monitoring without switching off....................................................48
5.3.2 Insulation monitoring plus switching off.........................................................49
5.4 Insulation monitoring without E-MCS 3.0 ............................................................51
5.4.1 Insulation monitoring without switching off....................................................51
5.4.2 Insulation monitoring plus switching off.........................................................52
5.5 Speed lowering in idle..........................................................................................54
5.6 Remote start device.............................................................................................55
5.7 External start device............................................................................................57
5.8 Battery charge conservation................................................................................58
5.9 3-way fuel tap / fueling device .............................................................................61
5.10 Exhaust hose.......................................................................................................64
6Maintenance ................................................................................................................65
6.1 Maintenance plan.................................................................................................65
6.2 Maintenance work................................................................................................66
6.2.1 Engine oil...................................................................................................66
6.2.2 Replacing the starter battery........................................................................69
6.2.3 Replacing fuses..........................................................................................70
6.3 Check the electrical safety...................................................................................71
7Troubleshooting.........................................................................................................72
8Technical specifications ..........................................................................................76
9Replacement parts.....................................................................................................80
9.1 Sound-absorbing hood.........................................................................................80
9.2 Engine ..................................................................................................................82
9.3 Control panel and electronics..............................................................................83
9.4 Fuses....................................................................................................................85
9.5 Accessories amd markings..................................................................................86

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10 Declaration of conformity..........................................................................................1
List of illustrations
Fig. 2-1: Labels on the generator.........................................20
Fig. 3-1: Components of the operating and generator side.27
Fig. 3-2: Exhaust and engine side components ..................28
Fig. 3-3: Electrical compartment components .....................29
Fig. 3-4: Components of the standard accessories.............30
Fig. 3-5: Components of the special accessories................30
Fig. 4-1: Starting the engine.................................................37
Fig. 4-2: Emergency start.....................................................38
Fig. 4-3: Connecting appliances ..........................................40
Fig. 5-1: FI protection switch................................................43
Fig. 5-2: Multi-functional display ..........................................45
Fig. 5-3: Insulation monitoring with E-MCS 3.0 ...................48
Fig. 5-4: Insulation monitoring without E-MCS 3.0..............51
Fig. 5-5: Idling speed reduction rocker switch.....................54
Fig. 5-6: Remote start device with Harting plug...................55
Fig. 5-7: Remote start device with CAN plug.......................56
Fig. 5-8: Connecting up an external start device.................57
Fig. 5-9: Connecting up the battery charge conservation
device............................................................................58
Fig. 5-10: Connecting up the battery charge conservation
device............................................................................59
Fig. 5-11: Connecting up the battery charge conservation
device............................................................................60
Fig. 5-12: 3-way fuel tap.......................................................61
Fig. 5-13: Connect up fueling device...................................62
Fig. 5-14 Connecting up the exhaust hose..........................64
Fig. 6-1: Dipstick...................................................................66
Fig. 6-2: Change the oil........................................................67
Fig. 6-3: Replacing the battery.............................................69
Fig. 64: Replacing a fuse .....................................................70
Fig. 8-1: Generator dimensions ...........................................76
Fig. 10-1: Sound-absorbing hood ........................................80
Fig. 10-2: Alternator and exhaust side replacement parts ..81
Fig. 10-3: Replacement parts for the engine .......................82
Fig. 10-4: Replacement parts Generator and electronics....83
Fig. 10-5: Replacement parts for fuses................................85
Fig. 10-6: Replacement parts for accessories.....................86
Fig. 10-7: Replacement parts forspecial accessories..........87

Table of Contents
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List of charts
Table 2.1: Danger zones and work areas on the generator 19
Table 2.2: Labels on the generator......................................21
Table 5.1: FI protection switch test......................................44
Table 5.2: Insulation monitoring without switching off.........48
Table 5.3: Insulation monitoring whilst running without
switching off ..................................................................49
Table 5.4: Insulation monitoring plus switching off..............49
Table 5.5: Insulation monitoring whilst running without
switching off ..................................................................50
Table 5.6: Insulation monitoring without switching off.........51
Table 5.7: Insulation monitoring whilst running without
switching off ..................................................................52
Table 5.8: Insulation monitoring plus switching off..............52
Table 5.9: Insulation monitoring whilst running without
switching off ..................................................................53
Table 5.10: Switchingpositions of the 3-way fuel tap ..........61
Table 6.1: Generator maintenance plans ............................65
Table 6.2: Location of the fuses..........................................70
Table 7.1: Problems during generator operation.................74
Table 8.1: Ambient conditions of the generator...................78
Table 8.2: Generator performance reduction in relation to the
ambient conditions ........................................................78
Table 8.3: Maximum conduit length of the distribution
network as a function of the cable cross-section.........78
Table 10.1: Replacement parts for the frame with covers...82
Table 10.2: Replacement parts for the engine ....................82
Table 10.3: Replacement parts for an engine with an exhaust
and fuel system.............................................................84
Table 10.4: Replacement parts for fuses.............................85
Table 10.5: Replacement parts for accessories / special
accessories...................................................................86
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 as the
depiction of basic principles.
We reserve the right to modifications in terms of ongoing
technical development.
Technical modifications after printing these operating
instructions are not considered.

Table of Contents
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General information
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1 General information
These operating instructions must be read carefully and
understood before using the generator.
These operating instructions are intended to make you
familiar with the basic operation of the generator.
These operating instructions contain important information
for using the generator safely and appropriately.
Complying with this 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
Further documents
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1.1 Furtherdocuments
In addition to these operating instructions, the following
documents 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)
•Wiring diagram of the generator
•Handling procedure battery

General information
Safety symbols
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1.2 Safety symbols
The safety symbol represents 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
safety 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 electric shock, possibly with lethal
consequences.
Poisonous substances
This warning symbol indicates activities during which there is
the danger of poisoning, possibly with lethal consequences.
Warning of environmentally damaging substances
This warning sign indicates activities during which the
environment 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
Safety symbols
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Notes

General Safety Regulations
Intended use
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2 General Safety Regulations
This section describes the basic safety regulations for
operating the generator.
Whoever operates the generator or works with it must read
this chapter and comply with its regulations in practice.
2.1 Intended use
The generator complies with the state of scientific and
technical knowledge as well as the applicable safety
regulations at the time of placing on the market in the context
of its intended use.
It was not possible to avoid foreseeable misuse or residual
risks through design measures without limiting the intended
functionality.
Hazards are therefore averted by means of special warning
signs either directly on the generator and/or in the technical
documentation.
2.1.1 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
indicated 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 generator 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.

General Safety Regulations
Intended use
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The method that will be used to install the generator on
these parts of a vehicle requires written approval from the
distributor that supplied the generator.
The generator may neither be connected to other energy
distribution systems (e.g. public power supply) nor to other
energy generation systems (e.g. other generators).
The generator may not be used in explosion-prone
environments.
The generator may not be used in fire-prone environments.
The generator must be operated according to the
specifications in the technical documentation.
Any non-intended use or any activity on the generator not
described in these operating instructions are considered
forbidden incorrect use outside the legal limits of the
manufacturer's liability.
2.1.2 Foreseeable incorrect use or inappropriate handling
Foreseeable incorrect use or inappropriate handling of the
generator nullifies the manufacturer's EU Declaration of
Conformity and automatically revokes 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 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
•Incorrectvehicle installation

General Safety Regulations
Intended use
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•Non-compliance with maintenance intervals
•Failure to measure and test for early damage
identification
•Failure to replace wearing parts
•Incorrectly performed maintenance or repair work
•Defectively performed maintenance or repair work
•Unintended use
2.1.3 Residual risks
Before commencing design and planning, the residual risks
of theESE 808 / 1308 DBG ES DUPLEX SILENT generator
were analysed and evaluated by means of a hazard analysis
in accordance with EN 1050.
Structurally unavoidable residual risks during the entire
service life of theESE 808 / 1308 DBG ES DUPLEX SILENT
generator can be:
•Risk of death
•Risk of injury
•Environmental hazard
•Material damage to the generator
•Material damage to other property
•Limited performance or functionality
You can avoid existing residual risks by observing and
following 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
instructions
•The specific standing instructions (the relevant
operational 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
Risk of death

General Safety Regulations
Intended use
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•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
•Over and/or undervoltage
•Incorrect installation in a vehicle
The generator's performance or functionality can be limited
by:
•Inappropriate handling
Risk of injury
Environmental hazard
Material damage to
the
generator
Material damage to other
property
Limits to perfo
rmance or
functionality

General Safety Regulations
Intended use
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General Safety Regulations
Intended use
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•Inappropriate maintenance or repair work
•Unsuitable operating fluids
•An installation altitude higher than 100 meters above sea
level
•An ambient temperature exceeding 25°C
•Too large a distribution network configuration

General Safety Regulations
Personal protective equipment
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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 able to apply them.
•Have read the chapter "General Safety Regulations".
•Have understood the content of the " General Safety
Regulations ".
•Be able to put the content of the " General Safety
Regulations " chapter to practical use.
•Be trained and instructed according to the rules of
conduct 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 generator.
•Have understood the technical documentation
concerning his responsibilities, tasks, and activities on
the generator and be able to implement these in practice.
2.2 Personal protective equipment
This personal protection equipment must be worn during all
activities at the generator described in these operating
instructions:
•Hearing protection
•Protective gloves
•Hard hat
•Protective shoes
•Fireproof protective clothing (in areas where the danger
of fire is high)

General Safety Regulations
Danger zones and work areas
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2.3 Danger zones and work areas
The danger zones work areas on the generator are
determined by the activities to be performed within the
individual life cycles:
Life cycle Activity Danger zone Work area
In the vehicle noneTransport By the operating
personnel
Setting up
Within a radius of 1.0 m
Operating Within a radius of 5. m
Operation
Refuelling Within a radius of 2.0 m
Cleaning
Shutting down
Service and
maintenance
Maintenance
Within a radius of 1.0 m
Within a radius of
1.0 m
Table 2.1: Danger zones and work areas on the generator

General Safety Regulations
Danger zones and work areas
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These labels must be attached to the generator and kept
in a clearly legible condition:
Fig. 2-1: Labels on the generator
1 Read operating instructions 7 Noise emission
2 Earthing 8 Short operating instructions
(on the upper side of the hood)
3 Distribution network 9 Third party fuelling
4 Tank fill level 10 Hot surface
5 Model plate 11 Choke
6 Engine maintenance 12 Fuel