OPERATING INSTRUCTIONS ESE 604 DBG DIN Article No. 151002 ESE 604 DBG ES DIN Article No. 151012 ESE 604 DBG ES FS DIN Article No. 151022 ESE 954 DBG DIN Article No. 151004 ESE 954 DBG ES DIN Article No. 151014 ESE 954 DBG ES FS DIN Article No.
Table of Contents Table of Contents Operating Instructions ....................1 ENDRESS ........................2 Elektrogerätebau GmbH .................... 2 E132569 ........................2 General information ..................9 Further documents ................... 10 Used signs and symbols .................. 11 1.2.1 General signs / symbols ..................11 Advanced Organizer ....................
Page 4
Table of Contents 2.1.3 Residual risks .....................17 Operating personnel – qualifications and obligations ........19 Personal protective equipment ................. 19 Danger zones and work areas ................. 20 Signs on the generator ..................21 General safety instructions ................23 Notes......................... 27 Description of the ESE 604 / 954 DBG DIN generator ........
Page 5
Table of Contents Switch the consumer off as follows:..............43 Disconnect a consumer from the control panel as follows: ........ 43 Check the protective conductor (valid for devices up to year of construction 12/2015) ......................44 Monitoring the operating status using the multifunction display ......46 Putting the generator out of service ..............
Page 6
Table of Contents Disconnect the battery charge conservation device as follows: ......61 Disconnect the battery charge conservation device as follows: ......62 Disconnect the battery charge conservation device as follows: ......63 3-way fuel valve / Refuelling device ..............64 Connect up fuelling device as follows: ..............
Page 7
Table of Contents Generator and electronics ................87 Fuses ....................... 89 Accessories and markings ................90 List of illustrations Figure 2-1: Signs on the generator ........21 Fig. 3-1: Views of the generator ..........28 Fig. 3-2: Components of the operating and generator side .29 Figure 3-3: Exhaust and engine side components ....30 Fig.
Page 8
Table of Contents List of tables Table 2.1: Danger zones and work areas on the generator 20 Table 2.2: Signs on the generator........22 Table 4.1: Protective conductor test lamp ......45 Table 5.1: FI protection switch test ........52 Table 5.2: Insulation monitoring without switching off ..53 Table 5.3: Insulation monitoring whilst running without switching off ..............54 Table 5.4: Insulation monitoring plus switching off ....55...
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 Further documents 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 Used signs and symbols The signs and symbols in these operating instructions help you to use the operating instructions and the device quickly and safely. 1.2.1 General signs / symbols Advanced Organizer The Advanced Organizer informs you briefly about the con- tents of the following chapter.
General information 1.2.2 Safety symbols The safety warning symbol indicates that a source of danger exists. The safety warning symbols used in the work area of the machine/plant and the entire technical documentation correspond to the Council Directive 92/58/EEC - Minimum requirements for the provision of safety and/or health signs at work.
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 is not to be connected up to other energy dis- tribution systems (e.g. public power supply) or to other ener- gy generation systems (e.g. other generators). The generator is not to be used in explosion-prone environ- ments. The generator is not to be used in fire-prone environments. The generator must be operated according to the specifica- tions in the technical documentation.
Unintended use 2.1.3 Residual risks The points analysed and evaluated before beginning the design and planning of the ESE 604 / 854 (ES) ( FS) DBG DIN generator were the residual risks using a risk analysis tool according to EN 1050. Structurally unavoidable residual risks during the entire ser- vice life of the ESE 604 / 854 (ES) ( FS) DBG DIN DIN gen- erator include:...
Page 18
Transport Hot components Recoiling starter rope on the engine Environmental hazards Environmental hazards involving the generator may be caused by: Inappropriate handling Operating fluids (fuel, lubricants, engine oil, etc.) Exhaust gas emission Noise emission ...
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. ...
2.4 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 Transport in the vehicle Radius of 1.0 m none by the operating per-...
2.5 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 Abridged operating instructions (inside Nameplate cover) Reference note - read operating in- Reference note - three-way valve structions Reference note - no naked flames Maintenance note...
Sign Name Short operating in- structions (inner side of the flap) Read the operating manual Reference note - no naked flames Fuel note Note on engine speed set at the works Note Line extension Nameplate External refuelling Reference note - en- gine maintenance Hot surfaces Motor model plate...
2.6 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 clear- ly legible condition.
Page 24
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. Transport The generator is only be transported after it has cooled down.
Page 25
Do not operate the generator without a sound damper. 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 26
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 ignition key and the spark plug sockets before beginning maintenance and/or repair work.
3 Description of the ESE 604 / 954 DBG DIN generator The components and functionality of the generator are de- scribed in this section. 3.1 Components of the ESE 604 / 954 DBG DIN generator The generator components are distributed on all four sides. Fig.
3.1.1 Components of the operating and generator side Fig. 3-2: Components of the operating and generator side Alternator Cover flaps Oil filter Cold start (choke), engine Fuel filter Spark plug connector 3-way fuel valve (optional) Status at: January 2013 ESE 604 / 954 DBG DIN...
3.1.2 Exhaust and engine side components Figure 3-3: Exhaust and engine side components Air filter Spark plug connector Carrying handle Oil filling screw Starter grip for the engine Exhaust Potential equalization (earthing for FI) Tank Oil drain screw Fixing points according to DIN14685 ESE 604 / 954 DBG DIN Status at: January 2013...
3.1.3 Control panel components Fig. 3-4: Control panel components Frame for fuse boxes Multi-functional display Fuses CEE 400V/16A according to DIN49462 Insulation monitoring test socket Schuko 230V according to DIN49442 (valid for devices up to year of con- struction 12/2015) Status at: January 2013 ESE 604 / 954 DBG DIN...
3.1.4 Accessory components 3.1.4.1 Standard accessories Figure 3-5: Components of the standard accessories Spark plug wrench Test probes (valid for devices up to year of con- struction 12/2015) User information (operating instruc- Spark plugs (2x) tions for the engine, as well as these operating instructions) Testing cable (valid for devices up to year of con-...
3.1.4.2 Special accessories Fig. 3-6: Components of the special accessories Exhaust hose DN 50 – 1500 mm Fuelling device 20 litre standard container according to DIN 14572 3.2 Function and mode of operation The synchronous generator is firmly coupled to the drive engine.
4 Operating the ESE 604 / 954 DBG DIN generator The operation of the generator is described in this section. 4.1 Transporting the generator Proceed as follows to transport the generator. Requirements The following requirements must be met: The generator must be turned off ...
Requirements The following 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. ...
Requirements The following requirements must be met: Electrical safety check (see 6.3) 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) ...
Figure 4-1: Started by hand: HAND START 1. Pull on the choke ) (completely for a cold (Figure 4-1-(1) engine / appropriately less for a warm engine) and hold firmly. in Pos. “I“. 2. Place the red engine switch (Figure 4-1-(2)) 3.
Figure 4-2: Electrical start 1. Pull on the choke (completely for a cold ELECTRICAL (Figure 4-1-(1)) START engine / appropriately less for a warm engine) and hold firmly. 2. Bring the key-operated switch into pos. (Figure 4-2-(1)) Start (Figure 4-2-(4)) Note Only activate the starter briefly (max.
Devices with a remote start device are fitted with an automatic choke. You do not need to use the manual choke (on the engine). 4.5 Switching the generator off Proceed as follows to shut down the generator. WARNING! Hot parts can ignite flammable and explosive materials. ...
4.6 Connecting up to consumers Proceed as follows to connect appliances to the generator. Requirements The following requirements must be met: generator started protective earthing conductor tested device switched off WARNING! Electric shocks cause injury or death. ...
1. Switch consumer on. Consumer is connected. Switching the consumer Switch the consumer off as follows: 1. Switch consumer off. Consumer is switched off. Disconnecting an Disconnect a consumer from the control panel as fol- appliance lows: 1. Remove plug. 2.
4.7 Check the protective conductor (valid for devices up to year of construction 12/2015) Proceed as follows to check the protective conductor con- nection between the generator and the consumer. Requirements The following requirements must be met: generator has been started (see 4.4) ...
Test lamp Significance 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 604 / 954 DBG DIN...
4.8 Monitoring the operating status using the multifunction display Manual start / Electrical The display is only activated after the generator has been start started. Electrical start with All LEDs light up for about 2 seconds to allow checking as soon as the START-STOP switchis set to the position “ON”.
Page 47
Oil pressure: If the display is red whilst the generator is (see Figure 4-55-(15)) running then the oil pressure is too low and the generator switches off automatically or the buzzer sounds, this can be acknowledged using the acknowledgement button. (Buzzer only active for the ordered “Insulation monitoring“, “Firecan“) spe- cial fitting Engine temperature:...
Page 48
If the “high” display is red then the frequency is too high. If the “low” display is red then the frequency is too low. L1, L2 & L3 phases: The single L1 to L3 phases are displayed (see Figure 4-5-(18)) separately: Voltage (U) (see Figure 4-5-(17)):...
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.
5 Special fittings / using accessories 5.1 FI protection switch The FI circuit breaker (RCD) is a protective measure against dangerous body currents according to DIN VDE 0100-551. Earthing requirements: 1. The assembly's earthing connection clamps must be connected to the earthing spike by at least 16mm² of earthing cable (green/yellow).
Figure 5-1: FI protection switch Checking the FI protection 1. The generator must be started. switch: 2. Put the protection switch into position 1. (seeFigure 5-1-(20)) 3. Activate the test switch (seeFigure 5-1-(10)) The switch position displays the result (seeFigure 5-1-(20)) Symbol Significance...
5.2 Insulation monitoring using E-MCS 4.0 The insulation monitoring option can only be supplied by the factory. Figure 5-2: Insulation monitoring using E-MCS 3.0 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 device and switch on. whilst running: The displayed symbol indicates the re- (see Figure 4-5-(8)) sult: Symbol Significance Insulation fault (≤ 23 kΩ) Yellow stays off Connected unit is OK Table 5.3: Insulation monitoring whilst running without switching off ...
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 ...
5.3 Speed lowering in idle Proceed as follows to operate the generator with idle down. Requirements The following requirements must be met: generator is ready for operation generator has been started (see 4.4) Switching the idle down Figure 5-3: Switching the idle down on pressure switch Switch on idle speed reduction as follows: pressure switch until it engages (LED...
5.4 Remote start device Standard for type no.: 151022 / 151024 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 plug by turning to the left and then pull the remote start operating status / generator connecting ca- ble plug out. 2. Screw protective cap onto the remote start socket (Figure 5-4-(1)) ...
Switching the device off The device is switched off as follows: Electrical start 1. Switch off or disconnect devices. 2. Continue to run the engine for about two minutes. 3. Place operating switch in Pos. OFF. (Figure 5-5-(3)) WARNING! In an emergency, the generator can be stopped by pressing the “EMERGENCY-OFF switch”...
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 Figure 5-6: Connecting up an external start device Connect up the external start device as follows: 1.
5.6 Battery charge retention Proceed as follows to charge the starter battery for the gen- erator over the battery charge retention 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 retention device 1. Unscrew cover for socket (Figure 5-7-(2)) (Figure 5-7-(1)) the starter battery charge conservation device.
Connect up the battery charge conservation device Connecting up the battery charge conservation (MagCode socket) as follows: device Fig. 5-9: Connecting up the battery charge retention device 1. Put plug for the external energy source (e.g. a battery charging device) / charge retention device socket con- necting cable in place.
5.7 3-way fuel valve / Refuelling device Proceed as follows to use the refuelling device with the gen- erator. Requirements These requirements must be fulfilled: generator is ready for operation 3-way fuel valve In the course of supplying fuel you can select between the device's own tank and the refuelling device.
WARNING! Using the wrong fuel will destroy the engine. Only refuel with lead-free regular grade petrol RON 91. Connect up fuelling device Figure 5-11: Connect up fuelling device Note The canister may stand at a maximum of 0.5 m below the level of fuel pump.
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. ...
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 604 / 954 DBG DIN Status at: January 2013...
6 Servicing and maintaining the ESE 604 / 854 DBG DIN generator Generator maintenance 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 are allowed to carry out mainte- nance 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- (Figure 3-5-(2)) tions of the engine manufacturer are an integral component of these operating instructions.
Checking the oil Check the oil level as follows: 1. Pull out the dipstick and wipe it off with a (Figure 6-1-(2)) clean cloth. 2. Reinsert the dipstick and take it out again. Drain off some of the oil if the level is above the upper mark and refill with oil if the level is under the lower mark (see below).
Page 72
Changing the oil 1. Remove the oil filling screw (Figure 6-1-(1)) 2. Prepare the oil collecting tray. 3. Unscrew oil drainage screw carefully and (Figure 6-2-(1)) wait until oil has completely run off into the collection container. 4. Screw on oil drainage screw again.
6.2.2 Replacing the starter battery 1. Unscrew the battery holder (Figure 6-3-(1)) 2. Remove the battery from the battery com- (Figure 6-3-(2)) partment. 3. Unscrew the battery cable. Push the protective terminal caps back for this purpose and loosen the screws. Al- ways disconnect the cable from the NEGATIVE terminal first and then disconnect the cable from the POSITIVE terminal.
The Endress battery is maintenance-free throughout its entire service life. Never open the battery — this may destroy it. 6.2.3 Replacing fuses Replacing fuses (only for the special accessory external start socket, socket, charging retention and/or remote start de- vice) 1.
6.3 Checking the electrical safety Only specifically authorised personnel may check the electri- cal 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.
Page 77
Malfunction Possible cause Correction The battery connecting cables Clamp or screw on the battery are unclamped. connecting cables. Starter battery has no power. 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.
8 Technical specifications The technical specifications concerning use of the generator are described in this section. Fig. 8-1: Generator dimensions ESE 604 / 954 DBG DIN Status at: January 2013...
Technical specifications Name Value Unit ESE 604 DBG ESE 954 DBG (ES) (FS) DIN (ES) (FS) DIN Nominal output [kVA] Nominal output factor [cosφ] Nominal frequency [Hz] Nominal speed 3000 3000 [min Nominal voltage 3~ Nominal voltage 1~ Rated current 3~ 12.3 Rated current 1~ 18.0...
Ambient conditions Name 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 power Power reduction for each addi- Unit tional [°C] Table 8.3: Generator power reduction dependent on ambient conditions Distribution network Line max.
9 Replacement parts The replacement parts needed to run the generator are de- scribed in this section. The generator 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 Item Part number Quantity Article name E503828/10 Frame complete, yellow E502064/90 Carrying handle, black E130579 Inset handle made of soft PVC E133316 Plastic end cap for pipe, 25×2 E130186 Polyamide expansion rivets E130692 12.8-18-3 spacer sleeve E133023...
9.2 Generator and electronics Fig. 9-3: Replacement parts Generator and electronics Item Part number Quanti- Article name E130959 Gen syn. 7 kVA IP 54 50Hz (for ESE 604) E130960 Gen syn. 9 kVA IP 54 50Hz (for ESE 854) Battery, 12V – 18h 163040 E130422 Hinged window No.
Item Part number Quanti- Article name (valid for devices up to year of construction 12/2015) 162314 Multi-functional display with a circuit board and con- necting cable E130424 CEE panel mounting socket E131799 EFXY3R2 interference elimination filter E133007 Schuko attachment socket Table 9.2: Replacement parts for an engine with an exhaust and fuel sys- When placing an order, please also enter the serial number on the model plate.
9.3 Fuses Only for the devices remote start, battery charge retention or external start. Figure 9-4: Replacement parts for fuses Item Part number Quantity Article name 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...
9.4 Accessories and markings Fig. 9-5: Replacement parts accessories Item Part number Quantity Article name E130472 Champion 12YC spark plugs (no other type may be used) E130545 Test probes (valid for devices up to year of con- struction 12/2015) E130446 100 cm measuring line (valid for devices up to year of construction 12/2015)
Item Part number Quantity Article name (special accessory) Table 9.4: Replacement parts for accessories / special accessories Fig. 9-6: Replacement parts forspecial accessories Status at: January 2013 ESE 604 / 954 DBG DIN...
This manual is also suitable for:
Ese 954 dbg dinEse 604 dbg es fs dinEse 954 dbg es dinEse 954 dbg es fs din
Need help?
Do you have a question about the ESE 604 DBG DIN and is the answer not in the manual?
Questions and answers