Endress ESE 406 HG-GT ES DUPLEX Operating Instructions Manual
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Endress ESE 406 HG-GT ES DUPLEX Operating Instructions Manual

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ORIGINAL OPERATING INSTRUCTIONS
ESE 406 HG-GT DUPLEX
ESE 406 HG-GT ES DUPLEX
ESE 506 HG-GT DUPLEX
ESE 506 HG-GT ES DUPLEX
ESE 606 DHG-GT DUPLEX
ESE 606 DHG-GT ES DUPLEX
Article No.: 113552
Article No.: 113553
Article No.: 113554
Article No.: 113555
Article No.: 113556
Article No.: 113557

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Summary of Contents for Endress ESE 406 HG-GT ES DUPLEX

  • Page 1 ORIGINAL OPERATING INSTRUCTIONS ESE 406 HG-GT DUPLEX Article No.: 113552 ESE 406 HG-GT ES DUPLEX Article No.: 113553 ESE 506 HG-GT DUPLEX Article No.: 113554 ESE 506 HG-GT ES DUPLEX Article No.: 113555 ESE 606 DHG-GT DUPLEX Article No.: 113556 ESE 606 DHG-GT ES DUPLEX Article No.: 113557...
  • Page 2 Publication date / Version August 2017 / i04 Copyright © 2017, 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.

  • Page 3: Protective Measures And Rules Of Behaviour

    Table of Contents Caution! Important notes on commissioning and op- eration of the construction and assembly lo- cations. For this operation special protective measures and rules of behaviour for commissioning must be observed ac- cording to the DGUV Information 203-032 Mai 2016 Edi- tion.
  • Page 4 Table of Contents residual current protection devices (RCDs) with a rated differential current not greater than 30 mA (0.03 A) for the second and every additional con- sumer. a separating transformer for the second and every additional consumer for increased danger through having a conductive environment with limited free- dom of movement.

  • Page 5: Table Of Contents

    Table of Contents Table of Contents Protective measures and rules of behaviour ..............3 General information ..................9 Further documents and documentation ............10 Safety symbols ....................10 General Safety Regulations................13 Important safety warning .................. 13 2.1.1 Intended use ...................... 14 2.1.2 Foreseeable incorrect use or inappropriate handling ........
  • Page 6 Table of Contents 4.7.1 Incident scenes operation .................. 46 4.7.2 Supplying power to a building................47 ECOtronic (idle down) ..................50 Monitoring the operating status via the “ECD 02 control display” ..... 51 Putting the generator out of service ..............52 Disposal ......................
  • Page 7 Table of Contents Figure 2-1: Signs on the generator ........20 Figure 3-1: Views of the generator........29 Figure 3-2: Components on the operating and exhaust side ..................30 Figure 3-3: Engine and maintenance side components ..31 Figure 3-4: Control panel components * ......32 Figure 4-1: Attachment of the carrying straps .....36 Figure 4-2: Hand start operating controls......40 Figure 4-3: Hand choke position .........40...

  • Page 8: Status: August

    Table of Contents General note: The illustrations in these operating instructions do not always comply completely with the actual design, in particular with re- gard to the colour, and are to be considered a representation of basic principles. We reserve the right to make modifications in terms of ongoing technical development.

  • Page 9: General Information

    Table of Contents 1. General 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.

  • Page 10: Further Documents And Documentation

    “Import note for generators with a connection for potential equalization“.  supplementary sheet “Installation of ENDRESS genera- tors in vehicles, containers or other closed rooms“ All documents named are a constituent part of the operating instructions. They describe appropriate use of the generator and provide the prerequisites in order to ...
  • Page 11 Table of Contents 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.
  • Page 12 General information Safety symbols Notes ESE 406 - 606 (D)HG-GT (ES) Duplex Status: August 2017...

  • Page 13: General Safety Regulations

    Whoever operates the generator or works with it must read this chapter and comply with its regulations in practice. Important safety warning ENDRESS generators are designed to operate electrical equipment with appropriate power output requirements. Other applications can lead to injury to the operating personnel and to damage to the generator as well as other damage to equip- ment.

  • Page 14: Intended Use

    General Safety Regulations Important safety warning The following actions are not permitted.  Operation in explosion-prone environments  Operation in fire-prone environments  Operation in confined areas  Operation in vehicles  Operation without the necessary safety redundancies  Operation in existing power supply networks ...

  • Page 15: Foreseeable Incorrect Use Or Inappropriate Handling

    General Safety Regulations Important safety warning The generator is not to be connected up to other energy dis- tribution systems (e.g. public power supply) or to other energy generation systems (e.g. other generators). The generator is not to be used in explosion-prone environ- ments.

  • Page 16: Residual Risks

    General Safety Regulations Important safety warning Residual risks 2.1.3 The points were analysed and evaluated using a risk analysis tool before beginning the design and planning of the generator for residual risks according to DIN EN 60204, DIN EN ISO 12100 or 12601.

  • Page 17: Operating Personnel - Qualifications And Obligations

    General Safety Regulations Operating personnel – qualifications and obligations  Inappropriate handling  Operating fluids (fuel, lubricants, engine oil, etc.)  Exhaust gas emission  Noise emission  Fire hazard  Leaking battery acid Material damage to the Material damage to the generator can occur through: generator ...

  • Page 18: Personal Protective Equipment

    General Safety Regulations Personal protective equipment  is at least 18 years old,  is trained in first aid and able to provide it,  is familiar with the accident prevention regulations and generator safety instructions and is able to apply them, ...

  • Page 19: Danger Zones And Work Areas

    General Safety Regulations Danger zones and work areas 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 in the vehicle...

  • Page 20: Signs On The Generator

    General Safety Regulations Signs on the generator Signs on the generator These signs must be fitted on the generator and be kept in a clearly legible condition: Figure 2-1: Signs on the generator Note concerning fuel quality Open flame prohibited Reference note - noise emission Potential equalization terminal Generator model plate...

  • Page 21: Table 2.2: Signs On The Generator

    General Safety Regulations Signs on the generator Sign Name Note Fuel quality Note No naked flames Note Noise emission Potential equal- ization (earthing for FI) Nameplate Warning surface Note DGUV infor- mation Warning Dangers in- curred during engine opera- tion Note Compartment for operating in-...

  • Page 22: General Safety Instructions

    General Safety Regulations General safety instructions 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 clearly legible condition.
  • Page 23 General Safety Regulations General safety instructions Open flames and light are prohibited in the generator's danger 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. Transport The generator is only be transported after it has cooled down.
  • Page 24 General Safety Regulations General safety instructions It is prohibited to operate the generator without air filters and with an opened air filter cover. Refuelling 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.
  • Page 25 General Safety Regulations General safety instructions Environmental protection The packaging material must be recycled according to the en- vironmental protection regulations applicable at the place of use. The workplace must be protected against contamination by leaking operating fluids. Used or leftover fuels and lubricants must be recycled accord- ing to the environmental regulations applicable at the place of use.

  • Page 26: Checking The Electrical Safety

    General Safety Regulations Checking the electrical safety Checking the electrical safety Checking of electrical safety requires different measures to be taken which may only be undertaken by respectively author- ised personnel. In doing so the respective, pertinent VDE pro- visions, EN and DIN standards, in their respectively valid ver- sions, must be observed.
  • Page 27 General Safety Regulations Checking the electrical safety We recommend the following checks and deadlines as gen- eral guideline values: When How/what  First start-up at the Operating per- See Chapter 4; also observe operating location sonnel the operating manual of the en- gine manufacturer ...
  • Page 28 General Safety Regulations Checking the electrical safety Notes ESE 406 - 606 (D)HG-GT (ES) Duplex Status: August 2017...

  • Page 29: The Generator Ese 406 - 606 (D)Hg-Gt (Es) Duplex

    The generator ESE 406 - 606 (D)HG-GT (ES) Duplex Views of the generator 3. The generator ESE 406 - 606 (D)HG-GT (ES) Duplex The components and functionality of the generator are de- scribed in this section. Views of the generator The generator components are distributed on all four sides.

  • Page 30: Components On The Operating And Exhaust Side

    The generator ESE 406 - 606 (D)HG-GT (ES) Duplex Components on the operating and exhaust side Components on the operating and exhaust side 1 1 7 Figure 3-2: Components on the operating and exhaust side Tank filling opening Tank fill level indicator Retainer bracket for loading by crane Terminal for potential equalization (earthing for operation with RCD)

  • Page 31: Engine And Maintenance Side Components

    The generator ESE 406 - 606 (D)HG-GT (ES) Duplex Engine and maintenance side components Engine and maintenance side components Figure 3-3: Engine and maintenance side components Fuel valve Oil filling and checking screw Oil drain screw Engine Recoil starter grab handle Engine air filter Manual choke * Engine switch *...

  • Page 32: Control Panel Components

    The generator ESE 406 - 606 (D)HG-GT (ES) Duplex Control panel components Control panel components Figure 3-4: Control panel components * Line circuit breaker (and FI protection Switch for EcoTronic (speed reduction) switch *) (under hinged window) * Engine start switch ** Choke switch ** Multi-functional display Schuko (shockproof) power sockets 230...
  • Page 33 The generator ESE 406 - 606 (D)HG-GT (ES) Duplex Control panel components Function und operating principle The synchronous generator is firmly coupled to the drive en- gine. The aggregate is installed in a stable frame with a cover hood and equipped with flexible and low vibration suspension elements.
  • Page 34 The generator ESE 406 - 606 (D)HG-GT (ES) Duplex Control panel components Notes ESE 406 - 606 (D)HG-GT (ES) Duplex Status: August 2017...

  • Page 35: Operation

    Operation Transporting the generator 4. Operation The operation of the generator is described in this section. Transporting the generator Proceed as follows to transport the generator. Requirements The following requirements must be met:  The generator must be turned off ...

  • Page 36: Figure 4-1: Attachment Of The Carrying Straps

    Operation Transporting the generator WARNING! Danger of severe or mortal injuries being incurred from falling loads.  Never stand under or close to a suspended load, also not to provide assistance.  Ensure that there is no person in the area of swivel of the lifting device.

  • Page 37: Setting Up The Generator

    Operation Setting up the generator Setting up the generator Proceed as follows to set up the generator. Requirements The following requirements must be met:  An even and firm substratum outdoors  There are no inflammable materials at the operating site ...

  • Page 38: Refuelling The Generator

    Operation Refuelling the generator Refuelling the generator Proceed as follows to refuel the generator. Requirements The following requirements must be met:  the device must be shut off.  the device must be cooled down.  there must be an adequate air supply and air removal ...

  • Page 39: Starting The Generator

    Operation Starting the generator  The device is refuelled. Starting the generator At this location starting of the generator is described for man- ual assignment, that is with consumers which are connected to the power sockets of the generator. To operate as a re- placement network plant (operating mode “supplying power to a building“), see Chapter 4.7.2 Requirements...

  • Page 40: Figure 4-2: Hand Start Operating Controls

    Operation Starting the generator WARNING! Heat or moisture destroys the device.  Avoid overheating (sufficient ventilation).  Avoid moisture. Starting the motor Proceed as follows to start the generator in the hand start ver- sion. Figure 4-2: Hand start operating controls Figure 4-3: Hand choke position Started by hand: 1.

  • Page 41: Figure 4-4: Electrical Start

    Operation Starting the generator 4. Start the engine by briskly pulling the recoil starter (Figure 4-2-(4))  The motor starts. 5. Bring the choke slowly to the right into the (Figure 4-3-(1)) position (Figure 4-3-(3))  The engine has started. NOTE The electrical devices can be connected and/or hooked up af- ter a warming-up phase of about one minute.
  • Page 42 Operation Starting the generator 4. Release the engine start switch ; the switch (Figure 4-4-(2)) springs into the “RUN” position. 5. Release choke button (Figure 4-4-(1))  The engine has started. NOTE The electrical devices can be connected and/or hooked up af- ter a warming-up phase of about one minute.

  • Page 43: Switching The Generator Off

    Operation Switching the generator off Switching the generator off Proceed as follows to shut down the generator. WARNING! Hot parts can ignite flammable and explosive materials.  Avoid flammable materials at the operating site.  Avoid explosive materials at the operating site. ...

  • Page 44: Connect Up To Consumers

    Operation Connect up to consumers  Close the fuel cock (petrol feed) as soon as possible after ending operation of the generator.  Close the fuel cock after use before transport. Connect up to consumers Selection of the correct connection decisively depends on the intended operating mode.

  • Page 45: Figure 4-5: Connect Up To Consumers

    Operation Connect up to consumers Figure 4-5: Connect up to consumers ONLY supplying power to a building CEE socket 400V / 16 A / 3~ / 7h-position ONLY on-site operation CEE socket 400V / 16 A / 3~ / 6h-position Schuko attachment sockets 230 V / 16 A / 1~ Connect up to consumers This is how you connect the consumer to the 12 V power...

  • Page 46: Changeover Of Operating Mode (Ii / Tn-S)

    Operation Changeover of operating mode (II / TN-S) Changeover of operating mode (II / TN- The following section explains the exact procedure for opera- tion of the generator and the connection of consumers under various operating conditions. The switchover function offers you the possibility to operate the generator optionally for on- site operation with a mobile distributor system or for supplying power to a building in a fixed plant.

  • Page 47: Supplying Power To A Building

    Operation Changeover of operating mode (II / TN-S) Supplying power to a building 4.7.2 The operating mode “Supplying power to a building“ serves to feed stationary plant such as that found in residential buildings or facilities according to VDE 0100 Part 551:2017-02 Annex ZC.
  • Page 48 Operation Changeover of operating mode (II / TN-S)  generator is ready for operation  the changeover switch of the building side feed distributor is in the position “Network“ or “0“ (analogously). Create the power feed Proceed as follows in order to create a power feed connection connection between the generator and the on-site installed feed distribu- tor:...

  • Page 49: Figure 4-7: Equipment Specification Example Main Distribution Tn System / Tt System

    Operation Changeover of operating mode (II / TN-S) Figure 4-7: Equipment specification example Main distribution TN system / TT system ESE 406 - 606 (D)HG-GT (ES) Duplex Status at: August 2017...

  • Page 50: Ecotronic (Idle Down)

    Operation ECOtronic (idle down) ECOtronic (idle down) Proceed as follows to operate the generator with idling speed reduction. Requirements The following requirements must be met:  generator is ready for operation  generator has been started (see 4.4) Switching the idle down Figure 4-8: Idle down rocker switch Switching the idle down Switch on idle speed reduction as follows:...

  • Page 51: Monitoring The Operating Status Via The "Ecd 02 Control Display

    Operation Monitoring the operating status via the “ECD 02 control display” Monitoring the operating status via the “ECD 02 control display” The display is always active when the genera- (see Figure 4-9) tor is running. Figure 4-9: Multi-functional display 1. The current voltage (V) is displayed after the generator starts , shown by means of the illuminated (see Figure 4-9-(1))

  • Page 52: Putting The Generator Out Of Service

    Observe all local laws and regulations concerning correct disposal of such parts and substances. Your author- ised ENDRESS generator dealer is happy to advise you. Please observe the pertinent environmental protection regu- lations when disposing of the old oil. We recommend bring- ing the oil in a closed container to an old oil collection centre for disposal.
  • Page 53 Operation Disposal Notes ESE 406 - 606 (D)HG-GT (ES) Duplex Status at: August 2017...

  • Page 54: Using Special Fittings / Accessories

    Using special fittings / accessories 5. Using special fittings / accessories RCD fault current safety equipment / FI protection switch The FI protection switch option can only be supplied by the factory. The FI protection switch (RCD) serves as a protective meas- ure against dangerous body currents according to DIN VDE 0100 Part 551.

  • Page 55: Table 5.1: Fi Protection Switch Test

    Using special fittings / accessories RCD fault current safety equipment / FI protection switch Figure 5-1: FI protection switch Checking the FI protection 1. The generator must have been started (see 4.4). switch: 2. Put the protection switch into Position 1. (seeFigure 5-1-(1)) 3.

  • Page 56: Insulation Monitoring With Switch Off

    Using special fittings / accessories Insulation monitoring with switch off The insulation monitoring serves to provide electrical safety of the generator as well as all connected consumers and ca- ble connections during continuous operation. The operating personnel must check the function of the Important note shutoff for every start-up by pressing the test button on the insulation monitoring (see also Chapter 2.7 Electrical safety...

  • Page 57: Table 5.3: Insulation Monitoring Whilst Running Without Switching Off

    Using special fittings / accessories Insulation monitoring with switch off  The insulation monitoring test has been run. 1. After checking, the Reset button must (see Figure 5-2-(1)) be pressed and the circuit breaker must be turned back to Pos. 1 so that the unit can be used again. Insulation monitoring 1.

  • Page 58: Remote Start Device

    Using special fittings / accessories Remote start device Proceed as follows to operate the generator using the re- mote start device. Requirements The following requirements must be met, before you connect the remote start device:  Generator is ready for operation ...

  • Page 59: Figure 5-4: Cable Remote Control

    Using special fittings / accessories Remote start device Disconnecting the remote Proceed as follows to disconnect a cable remote control. start device 1. Switch the generator (engine start switch (Figure 5-3-(3)) into the “OFF” position! 2. Turn the locking ring on the connector counterclockwise until the lock is released.

  • Page 60: Emergency-Stop Switch

    Using special fittings / accessories Switch off the engine 1. Switch off or disconnect consumers. using remote start 2. Continue to run the engine for about two minutes. to the “Off“ position. 3. Turn the switch (Figure 5-4-(1))  The generator is switched off. ...

  • Page 61: Maintenance

    Overhaul engine whenever nec- every 1000h essary Table 6.1: Generator maintenance plan 1) After the first 20 operating hours 2) To be undertaken by a specialist or an Endress service station. ESE 406 - 606 (D)HG-GT (ES) Duplex Status at: August 2017...

  • Page 62: Maintenance Work

    Maintenance Maintenance work Only authorised personnel are allowed to carry out mainte- nance tasks. Carry out all maintenance tasks specified in the maintenance plan according to the specifications in the enclosed operating and maintenance instructions for the engine. These operating and maintenance instructions of the engine manufacturer are an integral component of these operating instructions.
  • Page 63 Maintenance Maintenance work Checking the oil Check the oil level as follows: 1. Unscrew the grey oil level gauge (Figure 6-1-(1)) 2. Use a clean cloth to wipe the oil level gauge (Figure 6-1-(1)) 3. Reinsert the dipstick and take it out again. (Figure 6-1-(1)) The oil level read on the dipstick must be within the range which is specified in the maintenance and opera-...

  • Page 64: Charging The Battery

    Maintenance Using the wrong motor oil will destroy the motor.  Only use engine oil according to instructions given in the maintenance and operator's manual from the engine manufacturer!  In doing so also observe the actual ambient and operating conditions.

  • Page 65: Replacing The Starter Battery

    9. Screw the cattery cable onto the negative-terminal last. 10. Put on the terminal protection cap.  The battery has been replaced. WARNING! The Endress battery is maintenance-free throughout its entire service life.  Never open the battery — this may destroy it.

  • Page 66: Troubleshooting

    Troubleshooting 7. Troubleshooting This section describes problems during operation that au- thorized personnel can remove. Each occurring problem is described with its possible cause and the respective corrective measure. The authorised personnel must immediately shut down the generator and inform the responsible and authorised service personnel if a problem cannot be solved with the aid of the following table.

  • Page 67: Table 7.1: Troubleshooting During Generator Operation

    Troubleshooting Maintenance work Malfunction Possible cause Correction Foam element of the air filter Clean foam element and if is dirty or dry. necessary moisten. The engine starts briefly and Too little fuel in the tank. Refuel then shuts down. Ventilation holes on tank Clean ventilation holes.
  • Page 68 Troubleshooting Notes ESE 406 - 606 (D)HG-GT (ES) Duplex Status: August 2017...

  • Page 69: Technical Specifications

    Technical specifications Maintenance work 8. Technical specifications The technical specifications concerning use of the generator are described in this section. Name Value ESE 406 HG-GT ESE 506 HG-GT ESE 606 (D)HG- (ES) Duplex (ES) Duplex GT (ES) Duplex Nominal output 6.0 ~3 4.8 ~1 [kVA]...

  • Page 70: Table 8.1: Ambient Conditions For The Generator

    Technical specifications Ambient conditions Name Value Unit Setting up height above sea < 100 level Temperature < 25 [°C] Relative air humidity < 30 Table 8.1: Ambient conditions for the generator Reduced power Power reduction for each addi- Unit tional [°C] Table 8.2: Generator power reduction dependent on ambient conditions Distribution network...
  • Page 71 Technical specifications Maintenance work Notes ESE 406 - 606 (D)HG-GT (ES) Duplex Status at: August 2017...

  • Page 72: Replacement Parts

    Tel. +49-(0)-7123-9737-44 service@endress-stromerzeuger.de Note the article number and serial number of your device be- forehand to exactly identify the correct replacement part num- ber. You will find these details on the type plate (see Table 2.2).

  • Page 73: Table 9.1: Replacement Parts For The Frame / Engine / Generator

    Replacement parts Item Article name Engine Silencer Hinged window No. 40978 Gen syn. G gram BG2 G tank V02 M-side panel R M-side panel L Carrying handle, black Inset handle made of soft PVC KAPSTO sealing cap Vibration damper Form B 12V/20Ah battery Operating instructions for the 406-606 Table 9.1: Replacement parts for the frame / engine / generator...

  • Page 74: Electrical Junction Box

    Replacement parts Electrical junction box Figure 9-2: Replacement parts Electrical junction box Item Article name M - E housing in plastic 2HC40XD capacitor AVR controller Control panel Line circuit breaker 230 V / 16 A Schuko power socket 400V / 16 A 5P CEE socket EMERGENCY-STOP switch Idle controller for BG 112 Rocker switch green, 1-pin...

  • Page 75: Written Guarantee

    Written guarantee 10. Written guarantee ESE 406 - 606 (D)HG-GT (ES) Duplex Status at: August 2017...
  • Page 76 Written guarantee ESE 406 - 606 (D)HG-GT (ES) Duplex Status: August 2017...
  • Page 77 Written guarantee Notes ESE 406 - 606 (D)HG-GT (ES) Duplex Status at: August 2017...

  • Page 78: Proof Of Maintenance

    Proof of maintenance 11. Proof of maintenance ESE 406 - 606 (D)HG-GT (ES) Duplex Status: August 2017...
  • Page 79 Elektrogerätebau GmbH Neckartenzlinger Str. 39 D-72658 Bempflingen Telephone: + 49 (0) 71 23 / 9737 – 0 Telefax: + 49 (0) 71 23 / 9737 – 50 Email: info@endress-stromerzeuger.de www: www.endress-stromerzeuger.de © 2017, ENDRESS Elektrogerätebau GmbH...

This manual is also suitable for:

Ese 606 dhg-gt es duplexEse 506 hg-gt duplexEse 506 hg-gt es duplexEse 606 dhg-gt duplex

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