Endress ESE 807 DBG DIN Operating Instructions Manual
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Endress ESE 807 DBG DIN Operating Instructions Manual

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OPERATING INSTRUCTIONS
ESE 807 DBG DIN
ESE 807 DBG ES DIN
ESE 1107 DBG DIN
ESE 1307 DBG DIN
ESE 1407 DBG DIN
Article No. 151203 / 156203
Article No. 151213 / 156213
Article No. 151215 / 156215
Article No. 151216 / 156216
Article No. 151219 / 156219

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Summary of Contents for Endress ESE 807 DBG DIN

  • Page 1 OPERATING INSTRUCTIONS ESE 807 DBG DIN Article No. 151203 / 156203 ESE 807 DBG ES DIN Article No. 151213 / 156213 ESE 1107 DBG DIN Article No. 151215 / 156215 ESE 1307 DBG DIN Article No. 151216 / 156216 ESE 1407 DBG DIN...
  • Page 2 E134022 Publication date February 2013 Copyright © 2013, 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: Table Of Contents

    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 .................
  • Page 4 Table of Contents 4.10 Disposal ......................46 Special fittings / using accessories ............... 48 FI protection switch ..................48 Insulation monitoring using E-MCS 4.0 (without switching off) ......50 Speed lowering in idle ..................52 Remote start device ..................53 External start device ..................
  • Page 5 Table of Contents Fig. 5-2: Insulation monitoring using E-MCS 4.0 ....50 Fig. 5-3: Switching the idle down on pressure switch ..52 Fig. 5-4: Remote start device with Harting plug ....53 Fig. 5-5: Remote start device with CAN plug ......54 Fig. 5-6: Connecting up an external start device ....55 Fig.
  • Page 6 Table of Contents These instructions do not include technical modifications that occurred after printing. ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN Status at: February 2013...

  • Page 7: General Information

    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.

  • Page 8: Documentation And Accessories

    General information 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)  Important safety information and instructions for: engine selection, engine installation, engine operation (Briggs &...

  • Page 9: Safety Symbols

    General information 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.
  • Page 10 General information Notes ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN Status at: February 2013...

  • Page 11: 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. Oth- er applications can lead to injury to the operating personnel and to damage to the generator as well as other damage to equipment.

  • Page 12: Intended Use

    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 ...

  • Page 13: Residual Risks

    The methods that will be used to install the generator on these vehicle platforms require written approval from the distributor that supplied the generator. 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.
  • Page 14  The specific standing instructions (the relevant opera- tional conditions) issued by fire-brigades, civil defence and other relief organisations Risk of death Risk of death to persons at the generator can be caused by:  Incorrect use  Inappropriate handling ...
  • Page 15 Material damage to other Material damage to other equipment in the operating area of property the generator can be caused by:  Inappropriate handling  An overvoltage or an undervoltage  Incorrect installation in a vehicle Limits to performance or The generator's performance or functionality can be limited functionality ...

  • Page 16: Operating Personnel - Qualifications And Obligations

    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 17: 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 Transport in the vehicle Radius of 1.0 m none by the operating per-...

  • Page 18: Signs On The Generator

    Signs on the generator These signs must be fitted on the generator and be kept in a clearly legible condition: Fig. 2-1: Signs on the generator Reference note - noise emission Cable extension Reference note - maintenance inter- Reference note - read operating in- vals (inner side) structions Reference note - three-way valve...
  • Page 19 Sign Name Reference note - noise emission Reference note - maintenance intervals External refuelling Potential equalization (earthing for FI) Note Line extension Reference note - read operating instructions Reference note - no naked flames Status at: February 2013 ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN...

  • Page 20: Table 2.2: Signs On The Generator

    Sign Name Short operating in- structions Note EMERGENCY- STOP Nameplate Table 2.2: Signs on the generator ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN Status at: February 2013...

  • Page 21: 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 clear- ly legible condition.
  • Page 22 Open flames and light are prohibited in the generator's dan- ger zone. Consumption of alcohol, drugs, medications, or other mind- altering 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 23 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 24 The operating instructions and the maintenance instructions for the engine (Briggs & Stratton Corporation) are integral parts of this instruction manual. Environmental protection The packaging material must be recycled according to the environmental protection regulations applicable at the place of use. The workplace must be protected against contamination by leaking operating fluids.
  • Page 25 Notes Status at: February 2013 ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN...

  • Page 26: Description Of The Generator Ese 807 - 1407 Dbg (Es) Din

    3 Description of the generator ESE 807 - 1407 DBG (ES) DIN 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. The standard equipment is described here. Fig.

  • Page 27: Components On The Operating And Engine Side

    3.1.1 Components on the operating and engine side Fig. 3-2: Components on the operating and engine side Upper flap Mounting holes according to DIN 14685 Hinged window circuit breaker Filler neck Storage compartment for operating Engine spark plug instructions / standard accessories Carrying handle Side flap Status at: February 2013...

  • Page 28: Components On The Exhaust And Generator Side

    3.1.2 Components on the exhaust and generator side Fig. 3-3: Components on the exhaust and generator side Air filter cover Storage compartment Oil filler neck Spark plug connector Recoil starter Oil dipstick Carrying handle Exhaust Connection for external refuelling, 3- Upper flap way valve ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN...

  • Page 29: Control Panel Components

    3.1.3 Control panel components Fig. 3-4: Control panel components Circuit breaker / hinged window (un- EMERGENCY-STOP switch der the upper flap) Socket for protective earthing con- Schuko socket 230V / ~ ductor test Multifunction display E-MCS 3.0 Potential equalization connection (for optional FI to earthing) START-STOP switch CEE socket 400 V 3~...

  • Page 30: Accessory Components

    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 Figure Oil channel above 3.1.4.2 Special accessories Fig.

  • Page 31: Function And Mode Of Operation

    Function and mode of operation The synchronous generator is firmly coupled to the drive engine. 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. On some models the engine rotational speed control (cen- trifugal governor ) is supported at high loads by a special performance management module (Maxdrive).
  • Page 32 Notes ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN Status at: February 2013...

  • Page 33: Operating Ese 807 - 1407 Dbg (Es) Din

    4 Operating ESE 807 - 1407 DBG (ES) DIN 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 34: Refuelling The Generator

    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.

  • Page 35: Starting The Generator

    Requirements The following requirements must be met:  The generator must be switched off (see 4.5).  The device must be cooled down.  Adequate ventilation must always be available  Appliances switched off or disconnected WARNING! Leaking engine oil and petrol can burn or explode! ...
  • Page 36  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  a connected and operational starter battery ...

  • Page 37: Fig. 4-1: Actuate Manual Choke

    Fig. 4-1: Actuate manual choke Fig. 4-2: Standard design of operating panel ELECTRICAL START 1. Open the flap side (see Fig. 4-1-(2)) 2. Pull on the manually-operated choke (com- (Fig. 4-1-(2)) pletely for a cold engine / appropriately less for a warm engine) and hold firmly.
  • Page 38 Only activate the starter briefly (max. 5-10 seconds). Never start or run the engine with the battery disconnected. 4. Bring the choke into the basic position again. (Fig. 4-1-(1))  The engine has started. NOTE The electrical devices can be connected and/or hooked up after a warming-up phase of about one minute.
  • Page 39  The motor starts. 5. Release the choke.  The engine has started. Status at: February 2013 ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN...

  • Page 40: 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.  Allow the generator to cool down. Switching the device off The device is switched off as follows: Electrical start...

  • Page 41: Connecting Up To Consumers

    Connecting up to consumers Proceed as follows to connect appliances to the generator. Requirements The following requirements must be met:  generator has been started (see 4.4)  protective earthing conductor tested (see 4.7)  device switched off WARNING! Electric shocks cause injury or death. ...

  • Page 42: Check The Protective Conductor

    Check the protective conductor 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)  device is connected (see 4.6) ...

  • Page 43: Monitoring The Operating Status Using The Multifunction Display

    Monitoring the operating status using the multifunction display 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“. The normal operational lighting is then shown after- wards for about 30 seconds.
  • Page 44 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: If the display is red whilst the generator is (see Fig. 4-55-(14)) running then the engine temperature is too high and the generator must be switched off.
  • Page 45 Frequency: If the display glows green , the frequency is (see Fig. 4-55-(8)) within the correct range (47.5–52.5 Hz). 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 &...

  • Page 46: 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 47 Notes Status at: February 2013 ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN...

  • Page 48: Special Fittings / Using Accessories

    5 Special fittings / using accessories FI protection switch The FI circuit breaker option can only be supplied by the fac- tory. The FI circuit breaker (RCD) is a protective measure against dangerous body currents according to DIN VDE 0100-551. Earthing requirements: 1.

  • Page 49: Fig. 5-1: Fi Protection Switch

    Fig. 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. (seeFig. 5-1 -(20)) 3. Activate the test switch (seeFig. 5-1 (10))  The switch position displays the result (seeFig.

  • Page 50: Insulation Monitoring Using E-Mcs 4.0 (Without Switching Off)

    Insulation monitoring using E-MCS 4.0 (without switching off) The insulation monitoring option can only be supplied by the factory. Fig. 5-2: Insulation monitoring using E-MCS 4.0 Requirements The following requirements must be met:  Generator has been started (see 4.4) Testing the insulation 1.

  • Page 51: Table 5.3: Insulation Monitoring Whilst Running Without Switching Off

    Insulation monitoring 1. Plug in the device and switch on. whilst running:  The displayed symbol indicates the result: (see Fig. 4-5-(8)) Symbol Significance Insulation fault (≤ 23 kΩ) lights up red The buzzer sounds stays off Connected unit is OK Table 5.3: Insulation monitoring whilst running without switching off ...

  • Page 52: Speed Lowering In Idle

    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 Fig. 5-3: Switching the idle down on pressure switch Switch on idle speed reduction as follows: pressure switch until it engages (LED...

  • Page 53: Remote Start Device

    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.

  • Page 54: Fig. 5-5: Remote Start Device With Can Plug

    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 the protective cap (if fitted) onto the remote start socket and lock in place using the clip.

  • Page 55: External Start Device

    External start device Proceed as follows to operate the generator using the exter- nal start device. Requirements The following requirements must be met:  generator is ready for operation Connecting up an external start device Fig. 5-6: Connecting up an external start device Connect up the external start device as follows: 1.

  • Page 56: Battery Charge Retention

    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...

  • Page 57: Fig. 5-8: Connecting Up The Battery Charge Retention Device

    Fig. 5-8: Connecting up the battery charge retention device 1. Unscrew cover for socket for the (Fig. 5-7-(2)) (Fig. 5-7-(1)) starter battery charge conservation device. 2. Insert plug for the external energy source (e.g. a battery charging device) / charge retention device socket con- necting cable and lock in place by turning to the right.

  • Page 58: 3-Way Fuel Valve / Refuelling Device

    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.
  • Page 59 WARNING! Leaking engine oil and petrol can contaminate the soil and groundwater.  Do not fill the canister completely.  Allow the fuelling device to drain off. WARNING! Using the wrong fuel will destroy the engine.  Use only lead-free ROZ 95 premium petrol. Note The canister may stand at a maximum of 0.5 m below the level of fuel pump.
  • Page 60 Connect up canister Connect the canister to the fuelling device as follows: 1. Open sealing cap on the canister. 2. Introduce hose. 3. Engage catch on the fuelling device.  The canister is attached. Changing the canister Change an empty canister during operation as follows: during operation 1.

  • Page 61: Exhaust Hose

    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.  Use an exhaust gas hose.

  • Page 62: Maintain Generator Ese 807 - 1407 Dbg (Es) Din

    6 Maintain generator ESE 807 - 1407 DBG (ES) DIN 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. Maintenance plan The maintenance work specified in this summary must be carried out after the indicated time intervals.

  • Page 63: Motor Oil

    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. 6.2.1 Motor oil WARNING! Leaking engine oil can contaminate soil and groundwa- ter.

  • Page 64: Fig. 6-2: Change The Oil

    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.  The oil level has been checked. Refilling with oil Pour in oil as follows: 1.
  • Page 65 Changing the oil 1. Disassemble the side plate on the operating side of the generator. 2. Attach oil drain channel as shown. (Fig. 6-2-(3)) 3. Remove oil drain screw so that engine oil runs (Fig. 6-2-(2)) off completely. 4. Screw in the oil drainage screw again. Attach the side plate again.

  • Page 66: Replacing The Starter Battery

    6.2.2 Replacing the starter battery 1. Disassemble plate on the exhaust side. 2. Remove the battery from the battery compartment. 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.

  • Page 67: Replacing Fuses

    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.

  • Page 68: Checking The Electrical Safety

    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.

  • Page 69: 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 70 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.

  • Page 71: Table 7.1: Problems Arising During Generator Operation

    Malfunction Possible cause Correction The protective conductor is Disconnect the device from defective. the generator. The protective conductor is Select the device with a pro- missing. tective earth. Faults on the special equipment The engine does not start in The remote start equipment Insert the remote start equip- remote start mode.
  • Page 72 Notes ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN Status at: February 2013...

  • Page 73: Technical Specifications

    8 Technical specifications The technical specifications concerning use of the generator are described in this section. Fig. 8-1: Generator dimensions Status at: February 2013 ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN...
  • Page 74 Technical specifications Name Unit Type ESE 807 DBG DIN ESE 1107 DBG ES DIN Nominal output 11.0 [kVA] Nominal output factor [cosφ] Nominal frequency [Hz] Nominal speed 3000 3000 [min Nominal voltage 3~ Nominal voltage 1~ Rated current 3~ 11.5 15.9...
  • Page 75 Name Unit ESE 1307 DBG ES DIN ESE 1407 DBG ES DIN Type Nominal output 12.0 13.2 [kVA] Nominal output factor [cosφ] Nominal frequency [Hz] Nominal speed 3000 3000 [min Nominal voltage 3~ Nominal voltage 1~ Rated current 3~ 17.3 19.1 Rated current 1~ 30.4...

  • Page 76: Table 8.1: Ambient Conditions For The Generator

    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 Line max.

  • Page 77: Status At: February 2013 Ese 807 / 1107 / 1307 / 1407 Dbg (Es) Din

    Notes Status at: February 2013 ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN...

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