Summary of Contents for Endress ESE 1304 DBG ES DIN
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ESE 904 DBG ES FS DIN Article No. 151023 ESE 1104 DBG ES DIN Article No. 151015 ESE 1104 DBG ES FS DIN Article No. 151025 ESE 1304 DBG ES DIN Article No. 151016 ESE 1304 DBG ES FS DIN Article No. 151026...
Table of Contents Table of Contents General information ..................7 Documentation and accessories ................ 8 Safety symbols ....................9 General Safety Regulations................11 Important safety warning .................. 11 Intended use ....................12 2.2.1 Residual risks .....................13 Operating personnel – qualifications and obligations ........16 Personal protective equipment .................
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Table of Contents 4.10 Disposal ......................46 Special fittings / using accessories ............... 48 FI protection switch ..................48 Insulation monitoring with E-MCS 4.0 .............. 50 5.2.1 Insulation monitoring without switching off ............50 5.2.2 Insulation monitoring with switch off ..............51 Speed lowering in idle ..................
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Table of Contents List of illustrations Fig. 2-1: Labels on the generator ........18 Fig. 3-1: Views of the generator ..........25 Fig. 3-2: Components of the operating and alternator side .26 Fig. 3-3: Exhaust and engine side components ....27 Fig. 3-4: Control panel components ........28 Fig.
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Table of Contents List of charts Table 2.1: Danger zones and work areas on the generator 17 Table 2.2: Labels on the generator ........20 Table 4.1: Protective conductor test lamp ......41 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: Insulation monitoring plus switching off ....52...
General information 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.
General information 1.1 Documentation and accessories 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) • Briggs & Stratton Service Germany (Briggs & Stratton Corporation) •...
General information 1.2 Safety symbols The safety symbol illustrates 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 safe- ty and/or health signs at work.
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General information Notes ESE 904 - 1304 DBG DIN Status: at January 2013...
Whoever operates the generator or works with it must read this chapter and comply with its regulations in practice. 2.1 Important safety warning ENDRESS generators are designed to operate electrical equipment with appropriate power output requirements. Oth- er applications can lead to injury to the operating personnel and to damage to the generator as well as other damage to equipment.
The 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 •...
The generator may not be connected to other energy distri- bution systems (e.g. public power supply) or to other energy generation systems (e.g. other generators). The generator may not be used in explosion-prone environ- ments. The generator may not be used in fire-prone environments. The generator must be operated according to the specifica- tions in the technical documentation.
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Risk of death 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 Risk of injury to persons at the generator can be caused by: •...
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• Incorrect installation in a vehicle Limits to performance or The generator's performance or functionality can be limited functionality • Inappropriate handling • Inappropriate maintenance or repair work • Unsuitable operating fluids • An installation altitude greater than 100 metres above sea level •...
2.3 Operating personnel – qualifications and obligations Only appropriately authorised personnel may work with or on the alternator. The authorised operating personnel must: • be at least 18 years old. • be trained in first aid and able to provide it. •...
2.5 Danger zones and work areas The danger zones work places (work areas) on the genera- tor are determined by the activities to be performed 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-...
2.6 Labels on the generator These labels must be attached to the generator and be kept in a clearly legible condition: Fig. 2-1: Labels on the generator Potential equalization (earthing for FI) 6 Reference note - "read operating in- structions" Motor model plate Short operating instructions (interior)/ Reference note regarding short oper-...
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Label Designation Potential equalization (earthing for FI) Reference note - "hot surface" Reference note - "ca- ble extension" Reference note - "fuel note" Reference note - "read operating instructions" Short operating in- structions (inner side flap) Generator model plate Reference note - "en- gine maintenance"...
Label Designation Reference note - "no naked flames" Note Noise emission Table 2.2: Labels on the generator 2.7 General safety instructions The generator's construction may not be modified in any way. The engine's nominal rpm has been set in the factory and may not be changed.
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The authorised personnel are responsible for safeguarding the alternator against unauthorised operation. The authorised personnel are obligated to observe the appli- cable accident prevention regulations. The authorised personnel are obligated to obey the safety and work instructions of superiors and/or safety officers. The authorised personnel are obligated to wear personal protective equipment.
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Generating electricity The electrical safety must be checked before each start-up. Do not cover the equipment during use. Do not obstruct or block the air supply. Do not use starting aids. Devices must not be connected during start-up. Only tested and authorised cables may be used for the pow- er network.
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Maintenance and repair Operating personnel may only carry out the maintenance or work repair work described in these operating instructions. All other maintenance or repair tasks may only be carried out by specially trained and authorised specialists. Always remove the spark plug socket before beginning maintenance and/or repair work.
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Notes ESE 904 - 1304 DBG DIN Status: at January 2013...
3 Operating generator ESE 904 - 1304 DBG DIN The components and functionality of the generator are de- scribed in this section. 3.1 Components of generator ESE 904 - 1304 DBG DIN The generator components are distributed on all four sides. Fig.
3.1.1 Components of the operating and alternator side Fig. 3-2: Components of the operating and alternator side Generator lid Tank Generator Electrical compartment Potential equalisation screw (for an Tank cover optional FI earthing connection) Carrying handle ESE 904 - 1304 DBG DIN Status: at January 2013...
3.1.3 Control panel components Fig. 3-4: Control panel components Hinged window START-STOP switch Line circuit breaker Emergency OFF button Multi-function control display Signal tone speaker Shockproof attachment sockets ~230 Contact-socket for protective earthing V AC conductor test CEE attachment socket 3~400 V AC ESE 904 - 1304 DBG DIN Status: at January 2013...
3.1.4 Accessory components 3.1.4.1 Standard accessories Fig. 3-5: Components of the standard accessories Spark plug wrench Test probes User information (operating instruc- Spark plugs (2x) tions for the engine, as well as these operating instructions) Testing cable Oil channel 3.1.4.2 Special accessories Fig.
3.2 Function and mode of operation The synchronous generator is firmly coupled to the drive motor. The assembly is installed in a stable frame and equipped with a flexible, low-vibration suspension. Splash-proof, shockproof and CEE sockets with a nominal voltage of 230V and/or 400V / 50 Hz supply the power. An integrated voltage regulator controls the voltage of the alternator in the nominal speed range of the alternator.
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Notes Status at: January 2013 ESE 904 - 1304 DBG DIN...
4 Operating generator ESE 904 - 1304 DBG DIN The operation of the alternator is described in this section. 4.1 Transporting the generator Proceed as follows to transport the generator. Requirements These requirements must be met: • The generator must be turned off. •...
Requirements These requirements must be met: • An even and firm substratum outdoors • There are no inflammable materials at the operating site • There are no explosive materials at the operating site WARNING! Leaking engine oil and petrol can contaminate the soil and groundwater.
• Prevent leaking of engine oil and petrol. • Generator is switched off. • Generator has cooled down. • Avoid open flames and sparks. WARNING! Leaking engine oil can contaminate the soil and groundwater. • Do not fill the tank completely. •...
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• Fuel tank has been filled (see 4.3) • A possibly connected fuelling device (special accessory) • sufficient oil level (fill with engine oil before initial use, see the engine operating and maintenance instructions) • ventilation must be adequate. • Fit push-on exhaust gas pipe (special accessory) if needed •...
Fig. 4-1: Actuate manual choke Fig. 4-2: Standard design of operating panel Fig. 4-3: Emergency starting the pump ESE 904 - 1304 DBG DIN Status: at January 2013...
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ELECTRICAL START 1. Pull on the manual choke in the direction of (Fig. 4-1-(1)) the arrow (all the way to the stop if the engine is cold, correspondingly less if it is hot). 2. Turn the START-STOP switch to "START" position (Fig.
4.5 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. • Allow the generator to cool down. The device is switched off as follows: Switching the device off 1.
Requirements These requirements must be met: • generator started • protective earthing conductor tested • device switched off WARNING! Electric shocks cause injury or death. • Do not earth the generator. • Do not connect protective conductor to an existing po- tential equalisation line.
4.7 Check the protective conductor Proceed as follows to check the protective conductor con- nection between the generator and the device. Requirements The following requirements must be met: • generator has been started (see 4.4) • device is connected (see 4.6) •...
Test lamp Meaning lights up protective conductor is OK green stays off Protective conductor defective / not present Table 4.1: Protective conductor test lamp The protective conductor / potential equalization for this device has been checked. Status at: January 2013 ESE 904 - 1304 DBG DIN...
4.8 Monitoring the operating condition using the multifunctional display Started by hand: The display will only be active once the engine has started. Electrical start All LEDs light up for about 2 seconds to allow checking as soon as the START-STOP switch is set to the position "Op- erate“.
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Oil pressure: If the display lights up red whilst the genera- (see Fig. 4-6-(15)) tor is running then the oil pressure is too low and the genera- tor switches automatically or the buzzer sounds, this can be acknowledged using the acknowledgement button. (Buzzer only active for the ordered special equipment “Insulation monitor- ing“, “Firecan“) Engine temperature:...
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Fuel tank filling level: The display gives a rough indication of the (see Fig. 4-6-(6)) contents of tank. Symbol Display Significance green Fill level 100% green Fill level 100% green Fill level 90% green Fill level 70% green Fill level 60% green Fill level 40% green, red...
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For a 1 and 3 phase load the total load on the generator is displayed in steps of 10%. 10 - 80% green, 80 - 100% yellow and 100 - 110% red. EMERGENCY-STOP If the “OFF” symbol glows red (see and the buzzer Fig.
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.
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Notes Status at: January 2013 ESE 904 - 1304 DBG DIN...
5 Special fittings / using accessories 5.1 FI protection switch The FI protection switch option can only be supplied by the factory. The FI protection switch (RCD) is a protective measure against dangerous body currents according to DIN VDE 0100-551. Earthing requirements: 1.
Fig. 5-1: FI protection switch Checking the FI protection 1. The generator must be started. switch: 2. Put the protection switch into position 1. (seeFig. 5-1 -(20)) 3. Activate the test switch (seeFig. 5-1 (10)) The switch position displays the result (seeFig.
5.2 Insulation monitoring with E-MCS 4.0 The insulation monitoring option can only be supplied by the factory. Fig. 5-2: Insulation monitoring with E-MCS 4.0 5.2.1 Insulation monitoring without switching off (Standard for a DIN generator) Requirements The following requirements must be met: •...
Insulation monitoring 1. Plug in the consumer and switch on. whilst running: The displayed symbol indicates the result: (see Fig. 4-6-(8)) Symbol Meaning lights up red Insulation fault (≤ 23 kΩ) The buzzer sounds stays off Connected unit is OK Table 5.3: Insulation monitoring whilst running without switching off If an insulation fault exists and the unit was previously OK when tested without a device connected (see insula-...
Symbol Result Significance Circuit breaker jumps to Pos. 0 and lights up red Insulation monitoring is OK the generator cuts out Circuit breaker stays in Pos. 1 and stays off Insulation monitoring is defective the generator continues to run Table 5.4: Insulation monitoring plus switching off The insulation monitoring test has been run.
5.3 Speed lowering in idle Proceed as follows to operate the alternator 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 Fig.
5.4 Remote start device Proceed as follows to operate the generator using the re- mote start device. Requirements The following requirements must be met: • generator is ready for operation WARNING! Devices with a remote start device are fitted with an auto- matic choke.
Disconnecting the remote Disconnect the remote start device as follows: start device 1. Release the clip and then pull the remote start operating status / generator connecting cable plug out. 2. Fold down any protective caps onto the remote start socket and lock in place with the clip.
5.5 External start device Proceed as follows to operate the generator using the exter- nal start device. Requirements The following requirements must be met: • generator has been started (see 4.4) Connecting up an external start device Fig. 5-6: Connecting up an external start device Connect up the external start device as follows: 1.
5.6 Battery charge conservation Proceed as follows to charge the starter battery for the gen- erator over the battery charge conservation device. Requirements The following requirements must be met: • generator is ready for operation Connecting up the battery Connect up the battery charge conservation device charge conservation (charge current socket A DIN 14690) as follows: device...
The charge conservation device is disconnected Connecting up the battery Connect up the battery charge conservation device charge conservation (charge current socket BEOS) as follows: device Fig. 5-8: Connecting up the battery charge conservation device 1. Unscrew cover for socket for the (Fig.
Connecting up the battery Connect up the battery charge conservation device charge conservation (MagCode socket) as follows: device Fig. 5-9: Connecting up the battery charge conservation device 1. Put plug for the external energy source (e.g. a battery charging device) / charge conservation device socket connecting cable in place.
5.7 3-way fuel tap / fuelling device Proceed as follows to use the fuelling device with the gener- ator. Requirements These requirements must be fulfilled: • generator is ready for operation • 3-way fuel tap In the course of supplying fuel you can select between the devices own tank and the fuelling device.
WARNING! The wrong fuel destroys the motor. • Only refuel with lead-free regular grade petrol RON 91. Connect up fuelling device Fig. 5-11: Connect up fuelling device Note The canister may stand at a maximum of 0.5 m below the level of fuel pump.
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Pull off quick-action coupling with hose from the con- nector. 3. Insert the cover plugs again on the quick-action coupling. The fuelling device is disconnected from the generator. Connect up canister Connect the canister to the fuelling device as follows: 1.
5.8 Exhaust hose Proceed as follows to use the exhaust hose with the genera- tor. Requirements The following requirements must be met: • Generator is ready for operation WARNING! Exhaust gases can cause fatal asphyxiation. • Provide for sufficient ventilation. •...
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Disconnecting the exhaust Disconnect the exhaust hose from the generator by: hose 1. Turn the exhaust hose grip to the left. 2. Pull the exhaust hose off the muffler’s exhaust hose con- nection. Exhaust hose is now disconnected. ESE 904 - 1304 DBG DIN Status: at January 2013...
6 Maintenance Maintenance of the alternator is described in this section. Only personnel from the manufacturer may carry out mainte- nance or repair work not described in this section. 6.1 Maintenance plan The maintenance work specified in this summary must be carried out after the indicated time intervals.
6.2 Maintenance work Only authorised personnel may carry out maintenance tasks. Perform all work in the maintenance plan according to the information in the engine's operating and maintenance man- . These operating and maintenance instruc- (Fig. 3-5-(2)) tions of the engine manufacturer are an integral component of these operating instructions.
Avoid sparks when handling cables and electrical devic- es, as well as electrostatic discharge. • Avoid short-circuits. WARNING! The Endress battery is maintenance-free throughout its entire service life. • Never open the battery — this may destroy it. 6.2.3 Motor oil...
• The engine should ideally be slightly warm (allow a cold engine to run for 5 min., then stop it and allow it to cool for 2 min.). Fig. 6-2: Oil dipstick Checking the oil Check the oil level as follows: 1.
Fig. 6-3: Change the oil Change the oil 1. Remove the oil filling screw (Fig. 6-2-(1)) 2. Prepare the oil collecting tray. 3. Mount the oil drainage trough (Fig. 6-3-(2)) 4. Set the generator at an angle of 30°. 5. Unscrew the oil drainage screw and allow the (Fig.
6.2.4 Replacing fuses Replacing fuses (only for the special accessory external start socket, socket, charging retention and/or remote start de- vice) 1. Open the fuse holder. 2. Replace a fuse 3. Close the fuse holder The fuse has been replaced. Fig.
6.3 Checking the electrical safety Only appropriately authorised personnel may check the elec- trical reliability. The electrical reliability must be checked in accordance with the applicable VDE regulations, EN and DIN standards and especially the current version of the BGV A3 accident pre- vention regulations.
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.
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Malfunction Possible cause Correction The battery connecting cables Clamp or screw on the battery are unclamped. connecting cables. Starter battery has no output. Battery is discharged. Charge battery. Battery is defective. Exchange battery. Battery terminals are oxi- Clean battery terminals and if dized.
Malfunction Possible cause Correction The test tip is not touching a Hold the test tip on a metallic metallic blank location on the blank location device. Test lamp is defective Call service staff. The protective conductor is Disconnect the device from defective.
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Notes Status at: January 2013 ESE 904 - 1304 DBG DIN...
8 Technical specifications The technical specifications concerning use of the generator are described in this section. Fig. 8-1: Generator dimensions ESE 904 - 1304 DBG DIN Status: at January 2013...
Technical specifications Designation Value Unit ESE 904 DBG ESE 1104 DBG ESE 1304 ES DIN ES DIN DBG ES DIN Nominal output 12.0 [kVA] Nominal output factor 3~ [cosφ] Nominal output factor 1~ [cosφ] Nominal frequency [Hz] Nominal speed 3000 3000 3000 [rpm]...
Ambient conditions Designation Value Unit Setting up height above sea < 100 level Temperature < 25 [°C] Relative air humidity < 30 Table 8.2: Ambient conditions for the generator Reduced output Output reduction for each addi- Unit tional [°C] Table 8.3: Generator performance reduction dependent on the ambient conditions Distribution network Line...
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Notes Status at: January 2013 ESE 904 - 1304 DBG DIN...
9 Replacement parts The replacement parts needed to run the generator are de- scribed in this section. The alternator is divided into these component groups: • Frame with covers, tank and engine • Generator and electronics • Standard accessories • Special accessories •...
Fig. 9-2: Engine and exhaust side replacement parts Position Part number Quantity Item designation E502145/10 Frame complete, yellow E130510 Bayonet tank cap, size 40 E502064/90 Carrying handle, black E130579 Inset handle made of soft PVC E133316 Plastic end cap for pipe, 25×2 151003 Generator tank, yellow 151003...
Position Part number Quantity Item designation E502125/90 Battery clip, black E132948 Protective cap for battery terminal 163040 Battery 12V - 18A (for electrical starting only) 151003 Generator E502114/90 Air baffle plate E502085/10 Manual compartment E502111/10 Air baffle plate 01 BG yellow (yellow only) E502136/10 Air baffle plate 04, yellow Table 9.1: Replacement parts for the frame with covers...
9.3 Generator and electronics Fig. 9-4: Replacement parts Generator and electronics Position Part number Quantity Item designation E131432 Generator fan hood, yellow E131428 Generator fan blade E131433 Generator regulator for 8.5kVA 13kVA E134151 2-conductor through clamp ** E134152 4-conductor through clamp ** E130975 Mini-changer relay** E131799...
Position Part number Quantity Item designation E132976 EMERGENCY-STOP button, 25 x 25 mm E130674 EMERGENCY-STOP sign E130442 Telephone socket 16A, 4-mm ESE 804 / 1104 DBG (ES) DIN E130177 Line circuit breaker E100541 Line circuit breaker ESE 1304 DBG (ES) DIN E134046 Line circuit breaker E134047...
9.4 Fuses Only for the devices remote start, battery charge retention or external start. Fig. 9-5: Replacement parts for fuses Position Part number Quantity Item designation E132672 Flat fuse holder E132680 Flat fuse insert 20 A, DIN 72581 Part 3 E132735 Flat fuse insert 15 A, DIN 72581 Part 3 E133255...
9.5 Accessories and markings Fig. 9-6: Replacement parts for accessories Position Part number Quantity Item designation E130472 Champion 12YC spark plugs (no other type may be used) E130545 Test probes E130446 100 cm measuring line Engine operating manual B&S E130534 Spark plug wrench 1000 E100592...
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