Endress ESE 608 DHG ES DI DUPLEX Operating Instructions Manual
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Endress ESE 608 DHG ES DI DUPLEX Operating Instructions Manual

Endress ESE 608 DHG ES DI DUPLEX Operating Instructions Manual

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OPERATING INSTRUCTIONS
ESE 608 DHG ES DI DUPLEX
Article No.: 113023

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Summary of Contents for Endress ESE 608 DHG ES DI DUPLEX

  • Page 1 OPERATING INSTRUCTIONS ESE 608 DHG ES DI DUPLEX Article No.: 113023...
  • Page 2 This documentation and parts thereof are subject to copy- right. Any use or modification outside the restricted limits of the Copyright Act without the consent of ENDRESS Elektro- gerätebau GmbH is forbidden and subject to penalty. In particular, this applies to copies, translations, microfilming, as well as storage and processing in electronic systems.

  • Page 3: Table Of Contents

    Personal protective equipment.................13 Danger zones and work areas .................14 Labels on the generator ...................15 General safety instructions................17 Components of the ESE 608 DHG ES DI DUPLEX........22 Operation/engine side..................22 Rear / generator side ..................23 Control panel ....................24 Function and mode of operation...............25 Operating the ESE 608 DHG ES DI DUPLEX ..........28...
  • Page 4 Maintenance ....................42 Maintenance plan.....................42 Maintenance work....................42 5.2.1 Drain the oil......................42 Check the electrical safety ................44 Troubleshooting....................45 Technical specifications.................48 Replacement parts ..................51 Frame with engine and generator ..............51 Electronics .......................53 Replacement parts ..................56 Version: Jan. 2011...
  • Page 5 List of illustrations Fig. 11: Delivery documentation / Accessories ..........7 Fig. 21: Labels on the generator ..............15 Fig. 31: Components on the operating and engine side......22 Fig. 32: Electrical compartment components ..........23 Fig. 33: Control panel components .............24 Fig. 41: Ring screw for loading ..............29 Fig.

  • Page 6: 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 make you fami- liar with the basic operation of the generator. These operating instructions contain important information for using the generator safely and appropriately.

  • Page 7: Documentation / Scope Of Delivery

    1.1 Documentation / scope of delivery In addition to this document, there are the following docu- ments and standard accessories for the ESE 608 DHG ES DI DUPLEX generator. • Cable with test tip (see Fig. 11-(1)) • Tools (see Fig. 11(2)) •...

  • Page 8: Safety Symbols

    1.2 Safety symbols The safety symbol represents a source of danger. 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 consequen-...

  • Page 9: General Safety Regulations

    2 General Safety Regulations This section describes the basic safety regulations for opera- ting 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 conforms to the state of science and techno- logy and to the applicable safety regulations at the time it was marketed, if used as intended.

  • Page 10: Foreseeable Incorrect Use Or Inappropriate Handling

    Any non-intended use or any activity on the generator not described in these operating instructions are considered for- bidden incorrect use outside the legal limits of the manufac- turer's liability. 2.1.2 Foreseeable incorrect use or inappropriate handling Foreseeable incorrect use or inappropriate handling of the generator nullifies the manufacturer's EC Declaration of Con- formity and automatically thereby the operating licence.

  • Page 11: Residual Risks

    2.1.3 Residual risks Before design and planning were begun, the residual risks of the ESE 608 DHG ES DI DUPLEX generator were analysed and evaluated by means of a hazard analysis. Structurally unavoidable residual risks during the entire service life of the...
  • Page 12 Environmental hazards involving the generator may be cau- Environmental hazard sed by: • Inappropriate handling • Operating fluids (fuel, lubricants, engine oil, etc.) • Exhaust gas emission • Noise emission • Fire hazard Material damage to the generator can occur through: Material damage to the generator •...

  • Page 13: Operating Personnel - Qualifications And Obligations

    2.2 Operating personnel – Qualifications and obligations 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. •...

  • Page 14: Danger Zones And Work Areas

    2.4 Danger zones and work areas The danger zones work areas on the generator are determi- ned by the activities to be performed within the individual life cycles: Life cycle Activity Danger zone Work area Transport In the vehicle Within a radius of 1.0 m none By the operating person- Within a radius of 1.0 m...

  • Page 15: Labels On The Generator

    2.5 Labels on the generator These labels must be attached to the generator and kept in a clearly legible condition: Fig. 21: Labels on the generator Version: Jan. 2011...
  • Page 16 Number Label Designation Noise emission Note Line extension Earth Read operating instructi- Model plate Generator Note Hot surfaces Fuel note Note Open flame prohibited Note Hot surfaces Fuel note Table : Labels on the generator Version: Jan. 2011...

  • Page 17: General Safety Instructions

    2.6 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. All protective covers must be at hand and functional. All labels on the generator must be in place and in clearly legible condition.
  • Page 18 Open flames and light are prohibited in the generator's dan- ger 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. The generator may only be transported after it has cooled Transport down.
  • Page 19 It is prohibited to operate the generator without air filters and with an open air filter cover. The generator must always be operated with the hood clo- sed. Refuelling It is prohibited to refill the fuel tank of the generator during operation.
  • Page 20 Operating personnel may only carry out maintenance or re- Maintenance and repair pair work described in these operating instructions. work All other maintenance or repair tasks may only be carried out by specially trained and authorised specialists. Always unclamp the starter battery before beginning maintenance and/or repair work.
  • Page 21 Notes Version: Jan. 2011...

  • Page 22: Components Of The Ese 608 Dhg Es Di Duplex

    3 Components of the ESE 608 DHG ES DI DUPLEX 3.1 Operation/engine side Fig. 31: Components on the operating and engine side Engine Cap for external refuelling Tank cover Feed air to the engine (always keep free) Recoil starter Flap for engine below Oil level Version: Jan.

  • Page 23: Rear / Generator Side

    3.2 Rear / generator side Fig. 32: Electrical compartment components Flap for engine below Feed air to the engine (always keep free) Exhaust Carrying handle Version: Jan. 2011...

  • Page 24: Control Panel

    3.3 Control panel Fig. 33: Control panel components Circuit breaker (under hinged window) Oil pressure indicator light START/STOP switch Battery indicator light Operating hour counter Earth CEE socket Protected plug sockets Version: Jan. 2011...

  • Page 25: Function And Mode Of Operation

    3.4 Function and mode of operation Function and mode of operation The synchronous alternator is firmly coupled to the drive engine. The aggregate is installed in a stable frame and equipped with flexible, low-vibration suspension elements. Splash-proof, shockproof and CEE sockets with a nominal voltage of 230V and/or 400V / 50 Hz supply the power.
  • Page 26 Notes: Version: Jan. 2011...
  • Page 27 Version: Jan. 2011...

  • Page 28: Operating The Ese 608 Dhg Es Di Duplex

    4 Operating the ESE 608 DHG ES DI DUPLEX The operation of the generator is described in this section. 4.1 Transport Proceed as follows to transport the generator. These requirements must be fulfilled: Requirements • The generator must be turned off •...

  • Page 29: Fig. 41: Ring Screw For Loading

    Fig. 41: Ring screw for loading 1. Screw on the ring screw for loading / check for firm sea- Transporting with a crane ting. 2. Hook in hook for the crane onto the eye of the generator. 3. Transport the with crane to the use location. 4.

  • Page 30: Fuelling

    4.2 Fuelling Proceed as follows to refuel the generator. Requirements These requirements must be fulfilled: • The device must be shut off. • The device must be cooled down. • Sufficient ventilation must be available. CAUTION! Escaping motor oil or diesel fuel can burn. •...

  • Page 31: Fig. 42: External Refuelling

    Fig. 42: External refuelling A max. suction height of 1 m is allowed. Refuelling the device externally 1. Remove cover plug (see Fig. 42-(2)) 2. Place hose for external refuelling canister with quick- connect coupling LP-006 on coupling (see Fig. 42-(1)). (see Fig.

  • Page 32: Commissioning

    4.3 Commissioning These requirements must be fulfilled: Requirements • Electrical reliability has been checked (see 5.3) • Full fuel tank • An adequate oil level (for this, see the engine's operating and maintenance manual (see Fig. 11-(5)) • Sufficient ventilation must be available. •...

  • Page 33: Fig. 43: Started By Hand

    Starting the engine Start the engine as follows: Fig. 43: Started by hand: 1. Move START-STOP switch into the “RUN” HAND START (Fig. 43-(2)) position. 2. Advance engine at the handgrip of the reversing starter (Fig. 43-(1)) Support oneself with one hand on the device grip in order to NOTE simplify advancing the engine.
  • Page 34 The electrical consumers can be connected and/or hooked NOTE up after a warming-up phase of about one minute. 1. Move START-STOP switch into the “Start” ELECTRICAL (Fig. 43-(2)) position. Only activate the starter briefly (max. 5-10 seconds). Never Note start or run the engine with the battery disconnected. The engine starts.

  • Page 35: Connecting Appliances

    4.4 Connecting appliances Proceed as follows to connect appliances to the generator. Requirements These requirements must be fulfilled: • Generator started • Appliance switched off CAUTION! Electric shocks cause injury or death. • Do not earth the generator. • Do not connect protective conductor to an existing potential equalisation line.

  • Page 36: Special Options

    4.5 Special options 4.5.1 Monitoring the operating condition using the multifunctional display The display is only activated after the generator has been started. All LEDs light up for about 2 seconds to allow checking as soon as the START-STOP switch is set to the position "RUN“.
  • Page 37 If the display is red whilst the generator is run- Oil pressure: (seeFig. 44-(3)) ning then the oil pressure is too low and the generator must be switched off. Engine temperature: (see Fig. 44-(4) not active). Fuel temperature: (see Fig. 44-(5) not active). If the display is red )) then the generator’s phase Phase sequence:...

  • Page 38: Insulation Monitoring Plus Switching Off

    4.5.2 Insulation monitoring plus switching off The following requirements must be fulfilled: Requirements • Generator started Testing the insulation 1. Unplug the consumer monitoring: 2. The circuit breaker must be in Pos. 1. 3. Press the test knob The displayed symbol and the position of (see Fig.

  • Page 39: Decommissioning

    4.6 Decommissioning In new condition, the generator can be stored for up to a year. For a longer period, please contact a Hatz service facility (also see the engine operating see Fig. 11-(4)) Version: Jan. 2011...
  • Page 40 Notes Version: Jan. 2011...
  • Page 41 Version: Jan. 2011...

  • Page 42: Maintenance

    5 Maintenance Maintenance of the generator is described in this section. Only personnel from the manufacturer or an authorised spe- cialist workshop may carry out maintenance or repair work not described in this section. 5.1 Maintenance plan Perform maintenance according to the information in the motor manual.

  • Page 43: Fig. 51: Drain The Oil

    Fig. 51: Drain the oil. 1. Lift the device using a crane Drain the oil. Remove the plate for the oil drain (see Fig. -(2)) 3. Guide the drain hose through the opening (seeFig. (8)) in the frame and set the oil collection pan in place. 4.

  • Page 44: Check The Electrical Safety

    5.3 Check the electrical safety Only appropriately authorised personnel may check the electrical safety. 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.

  • Page 45: Troubleshooting

    6 Troubleshooting This section describes problems during operation that autho- rized personnel can repair. Inform yourself further in the en- gine operating manual. Each occurring problem is described with its possible cause and the respective corrective measure. Malfunction Possible cause Correction No or insufficient voltage avai- The engine's rpm was subse-...
  • Page 46 Notes: Version: Jan. 2011...
  • Page 47 Version: Jan. 2011...

  • Page 48: Technical Specifications

    7 Technical specifications The technical specifications concerning use of the generator are described in this section. Fig. 71: Generator dimensions Version: Jan. 2011...
  • Page 49 Technical specifications Designation Value Unit Type ESE 608 DHG ES DI DUPLEX Nominal output 400V / 3~ [kVA] Nominal output 230V / 1~ [kVA] Nominal power factor V3~ [cosφ] Nominal power factor V1~ [cosφ] Nominal frequency [Hz] Nominal speed 3000 [min Nominal voltage 3~ Nominal voltage 1~...

  • Page 50: Table 7.4: Maximum Conduit Length Of The Distribution Network As A Function Of The Cable Cross-Section

    Distribution network Line max. conduit Unit length HO 7 RN-F (NSH öu) 1,5 mm HO 7 RN-F (NSH öu) 2.5 mm Table 7.4: Maximum conduit length of the distribution network as a function of the cable cross-section Version: Jan. 2011...

  • Page 51: Replacement Parts

    8 Replacement parts This section contains the replacement parts needed to run the generator. 8.1 Frame with engine and generator Fig. 81: Replacementparts for the exhaust or generator side Version: Jan. 2011...

  • Page 52: Fig. 82: Engine And Exhaust Side Replacement Parts

    Fig. 82: Engine and exhaust side replacement parts Position Part number Quantity Item designation E506100/99 Frame E505716/99 Engine hood E133683 1B50/10HP engine E130959 Gen syn. 7 kVA IP 54 50Hz E133301 Shock mounts E505724/99 Engine air duct E133823 Inset handle made of soft PVC E133316 27x0.8-3 ribbed insert E133023...

  • Page 53: Electronics

    Position Part number Quantity Item designation E505235/92 Rear muffler E505709/11 Protective plate E505732/11 Protective plate 8.2 Electronics Fig. 83: Electrical junction box spare parts Position Part number Quantity Item designation E130422 Hinged window E503857/96 Control panel E131540 ON/OFF switch E130470 Operating hour counter E131851 CEE socket 400V/16A 5P...
  • Page 54 Position Part number Quantity Item designation E133940 LED signalling lamps E130564 Hexagon bolt M 8 x 40 E100418 Hexagon nut M 6 E131862 M6 wingnut E100039 250V / 16A shockproof socket Version: Jan. 2011...
  • Page 55 Version: Jan. 2011...

  • Page 56: Replacement Parts

    9 Replacement parts Version: Jan. 2011...

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