Related Manuals for Endress ESE 67 IW
Summary of Contents for Endress ESE 67 IW
- Page 1 ESE power generator TRANSLATION OF THE ORIGINAL OPER- ATING MANUAL ESE 67 IW/RS Item No. 333363 / 333373 ESE 90 IW/RS Item No. 333364 / 333374 ESE 110 IW/RS Item No. 333365 / 333376...
- Page 2 This documentation and parts thereof are subject to copyright. Any use or modi- fication beyond the restrictions of the Copyright Act is forbidden and subject to penalty without the consent of ENDRESS Elektrogerätebau GmbH. This applies in particular to copies, translations, microfilming, as well as storage and processing in electronic systems.
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Page 3: Table Of Contents
Welcome to ENDRESS! ........ - Page 4 Optional fittings ............. .60 Powerlock-Box.
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Page 5: Directories
Directories Directories List of illustrations Fig. 3-1 Example of a type plate Fig. 3-2 Included with delivery Fig. 3-3 Labels on the device Fig. 6-1 Views of the generator Fig. 6-2 Components on the connecting side Fig. 6-3 Components on the maintenance side Fig. -
Page 6: About This Manual
About this manual About this manual We would like to explain to you the safe and correct use of your generator in the best possible way through this operating manual. To do this we have oriented ourselves to the new European standard DIN EN 82079-1 for preparing the user manuals. - Page 7 About this manual signs warning about dangers to life and limb Safety and warning notices are necessary at all locations where there is potential danger from the device which cannot be eliminated by design or operational measures. We restricted ourselves to the permitted minimum in order to place the required distinctive warning notices at the correct point in time without impair- ing the legibility and comprehensibility of the operating manual.
- Page 8 About this manual Results of the action which should be achieved after performing the sequence of action. Additional notices for operation or for function of a unit are marked with the adjacent symbol. NOTICE! The adjacent symbol is situated anywhere where the supplier documenta- tion must be read and observed and refers to, ►...
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Page 9: Product Identification
Product identification Product identification Welcome to ENDRESS! We are pleased that you have made the decision to purchase a ENDRESS power generator. You have purchased a high-performance product into which we have embodied decades of our experience and have integrated many functions oriented on daily use. -
Page 10: Foreseeable Misuse
Product identification Your power generator has been designed for manual or automatic operation (re- mote start) with one or more electrical consumers. To protect against electric shock (i.e. current flowing through your body), automatic switch-off according to DIN VDE 0100-551: 2017-02 is used as the protective separation measure. The protective conductor system from the attached consumers will take over the earthing function. - Page 11 Product identification • software was modified or changes were made to the generator's factory set- tings • use of the generator by inadequately instructed operating personnel Furthermore at all costs avoid the following Misuses: • Never refuel the generator’s own tank when the engine is running. The vibra- tions and strong exhaust streams during operation can lead to fuel spillage.
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Page 12: Scope Of Delivery Of Your Generator
Product identification Scope of delivery of your generator Apart from the technical documentation mentioned in Chapter 2.1 the following items are Scope of delivery of your generator: Fig. 3-2 Included with delivery Item Name Earth stake with connection cable Key for POWERLOCK BOX (optional) Universal key for access hatch Filling aid with hopper Technical documentation, see Chapter 2.1... -
Page 13: Labels On The Generator
Product identification Labels on the generator An important part of the operating manual is the labelling and notices on your generator. These labels must not be removed and must always be maintained in legible condition. If there is damage to a Labels can be ordered from our custom- er service team. - Page 14 Product identification Item label Meaning Mandatory sign Read the operating manual before starting up Note Operate the power genera- tor only with the mainte- nance hatches closed. Note Crane loading lug Example of maximum de- vice weight Note Noise emissions Warning Burn hazard Hot surfaces...
- Page 15 Product identification Item label Meaning POWERLOCK sticker Open, connect and discon- nect only when de-ener- gized. The connection terminal is for potential equalization (left) with IT networks and for earthing (right) with TN networks. DGUV instruction on Generators of Version C Death hazard Live parts when opening the cover...
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Page 16: For Your Safety
For your safety For your safety The following chapter describes basic Safety instructions for safe operation of your generator. Your device is a very high-performance electrical machine which is potentially dangerous when operated if it has not been installed, commis- sioned, used, serviced and repaired according to the operating manual. - Page 17 For your safety Warning of corrosive substances This warning symbol indicates activities where a risk of chemical burns to the en- vironment as well as people exists, possibly with lethal consequences. Warning of environmentally damaging substances This warning symbol indicates activities where a risk of contaminating the envi- ronment exists, possibly with catastrophic consequences.
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Page 18: General Safety Instructions
Residual risks As a manufacturer of EU-compliant machines, ENDRESS make great ef- forts to create designs which already eliminate possible risk potentials at the design stage. If this is not possible without significantly impairing the functions of a device, we implement suitable protective measures protect the user from injury. - Page 19 For your safety four different danger levels in order to be able to reliably assess the dan- gers associated with the individual operating states and action steps when reading the operating manual. DANGER! DANGER describes a danger which represents a high level of risk,which can lead to death or severe injuries,when not avoided.
- Page 20 For your safety DANGER! Engine exhaust gases contain poisonous and partially invisible gases such as carbon monoxide (CO) and carbon dioxide (CO2). Risk of death due to poisoning or asphyxiation. ► Ensure that there is good ventilation during the whole period of operation. ►...
- Page 21 For your safety WARNING! Escaping corrosive acid fumes or sulphuric acid during and after the charging process. A risk of suffering severe or even deadly burns. ► Only work with acid-resistant protective equipment. ► Clean surfaces covered in acid immediately using adequate amounts of wa- ter.
- Page 22 For your safety NOTICE! Excessive heat or moisture can destroy the device. ► Always ensure that there is a good supply of air and heat removal. ► Never operate the generator in rooms or narrow pits. ► Never clean the device with the aid of a strong jet of water or high pressure cleaner.
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Page 23: Authorised Operating Personnel - Qualifications And Obligations
For your safety Authorised operating personnel – qualifications and obligations Your Generators is a complex machine, the operation and maintenance of which requires exact knowledge of its functions and danger potentials. Therefore any work with or on the device, of any kind, may only be per- formed by authorised and instructed operating personnel. - Page 24 For your safety Product's service life phase Danger zone Transport and installation within a radius of 1m around or below the de- vice Operation within the outer limits of the device Service and maintenance Within the outer limits of the device when switched on Generators Tab.
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Page 25: Checking The Electrical Safety
Checking the electrical safety Checking the electrical safety Checking electrical safety requires different measures that are only to be taken by authorized personnel. In doing so the pertinent VDE provisions, EN and DIN standards, in their valid versions, must be observed. For use at construction or assembly sites, the DGUV Information 203-032 edition of May 2016 must be observed. - Page 26 Checking the electrical safety In addition to the details given above, the electrical safety of the Generators is to be checked by a qualified electrician at regular intervals. The periods between testing must be established in such a way that the Generators and all work equip- ment to be connected can, based on current general knowledge, operational ex- perience or specific evidence, be safe to use in the period between the two inspections.
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Page 27: Description Of The Device
Description of the device Description of the device Views The following section provides an overview of the designation and location of the most important components of your generator. It is important to en- sure that you are familiar with these in order to further understand the de- scribed functions and operating steps and to be able to perform them safely. -
Page 28: Exhaust Gas And Battery Side Components
Description of the device Exhaust gas and battery side components Fig. 6-2 Components on the connecting side Compartment for device documentation Maintenance hatch Drain screw for collection pan Tank filling port Engine air filter Oil dipstick Pre-filter... -
Page 29: Components On The Maintenance Side
Description of the device Components on the maintenance side Fig. 6-3 Components on the maintenance side FPT drive engine Synchronous generator Base frame with tank and collection pan Starter battery Main battery switch Forklift pockets with edge protection... -
Page 30: Components For Operating Panel And Switch Box
Description of the device Components for operating panel and switch box Fig. 6-4 Components for operating panel and external switch box Control module E-MCS 7.0 Test button for 300 mA differential cur- rent release Controls ON/OFF switch Insulation monitoring Main switch Circuit breaker 16 A/4-pin for socket (with IT/TN 32A) Circuit breaker 1-pin RCD (30 mA) for... - Page 31 Description of the device NOTES...
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Page 32: Commissioning
Commissioning Commissioning The following chapter explains the basic procedure for initial or repeated generator start-ups in “direct supply" mode. Perform the following de- scribed steps when you put your generator into operation for the first time or again after transport. NOTICE! For start-up and operation of a Generators on building and assembly sites, Deutsche Gesetzliche Unfallversicherung (DGUV) in DGUV Information... - Page 33 Commissioning Fig. 7-1 Setting up personal protection measures (source: DGUV)
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Page 34: Transporting And Preparing Your Generator
Commissioning Transporting and preparing your generator Choose the transport vehicle and lifting gear so that the generator can be moved safely at all times according to its total mass (see Chapter 14 ). The unit's solid base frame allows it to be lifted and transported by a forklift. Alternatively, loading by crane is also possible after the crane eyes have been installed correctly. -
Page 35: Refuelling Your Generator
Commissioning 7. Unhook the lifting device. The unit has been transported and positioned at its work site. Refuelling your generator Proceed as follows to the generator. Conditions The generator is turned off. The generator has cooled down. There must be an adequate air supply and air removal. ... -
Page 36: Starting The Generator
Commissioning Starting the generator Power generator start-up in manual control mode (see Chapter 8.1 ) is de- scribed here. Proceed as follows to start the power generator from the E-MCS 7.0 control mod- ule of the operating panel. Fig. 7-2 Manually starting and stopping the power generator Conditions ... -
Page 37: Low Load Diesel Engine Operation
Commissioning DANGER! Engine exhaust gases contain poisonous and partially invisible gases such as carbon monoxide (CO) and carbon dioxide (CO2). Risk of death due to poisoning or asphyxiation. ► Ensure that there is good ventilation during the whole period of operation. ►... -
Page 38: Turning Off Your Power Generator
Commissioning NOTICE! Avoid, as far as possible, short-term operation or operation without a load or with a basic load that is too low. Follow these recommendations if the engine manufacturer does not provide detailed information or he provides different information: ►... - Page 39 Commissioning The horn gives off a continuous warning tone. The control module locks the power generator against further operation. The EMERGENCY STOP switch's latching function is blocking the Generators against restart. The EMERGENCY STOP switch is locked in its actuated state. The generator can only be switched back on again after the hazard has been eliminated and if the EMERGENCY STOP switch is unlocked manually.
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Page 40: Connection Of Power Consuming Equipment
Commissioning Connection of power consuming equipment DANGER! Mortal danger due to an electric shock if live parts are touched. ► Never operate the device if it is in a damaged condition. ► Never operate the electrical consumers and connecting cable (power con- suming equipment) in a damaged condition. - Page 41 Commissioning Fig. 7-3 Connecting consumers ONLY supplying power to a building CEE socket 400V / 125A / 3~ / 1h 300 mA* ONLY on-site operation CEE socket 400V / 32A / 3~ / 6h 30mA CEE socket 230V / 16A / 3~ / 6h 30mA CEE socket 400V / 63A / 3~ / 6h 300 mA*...
- Page 42 Commissioning Connect a consumer to the power generator as follows: Conditions The generator is started and brought up to operating temperature (see Chap- ter 7.3 ). All power consuming equipment is disconnected or switched off. All circuit breakers in the fusebox are in “ON” position. ...
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Page 43: Residual Current Circuit Breaker (Rcd)
Commissioning Residual current circuit breaker (RCD) The residual current circuit breaker (RCD) protects against dangerous body currents in compliance with DIN VDE 0100-551. This version of the generator according to DGUV information 203-032 is classified as a Version C generator for commissioning and operation on building and installation sites and it has the following marking: It is essential to observe the regulations and safety instructions of the DGUV in- formation 203-032 mentioned in order to achieve protection for all people work-... - Page 44 Commissioning Fig. 7-4 Built-in types of residual current circuit breaker (RCD) Testing the RCD The generator is running 1. Move the FI circuit breaker into POS I. 2. Press the test button. The switch position indicates the result: Symbol Meaning POS I Circuit breaker does not trip.
- Page 45 Commissioning Fig. 7-5 Differential current release Testing the differ- Do as follows to test that the differential current release is responding correctly: ential current re- The generator is running. lease 1. Move the main switch into POS I. 2. Press the differential current release test switch. The circuit breaker position shows the test result.
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Page 46: The Device In-Use
The device in-use The device in-use Operating the E-MCS 7.0 control module We will explain in detail how to operate the power generator from the con- trol module in the following chapter, 7.3 and under various operating con- ditions. You will also learn how to display and edit various operating parameters and error messages. -
Page 47: Operating Panel For Control Module E-Mcs 7.0
The device in-use Control mode - Automatic The Automatic control mode is indicated by “ “ being displayed in the top line of the display. The generator will start automatically in this mode as soon as the integrated mains monitoring system detects a power grid fault. However, some functions such as resetting the warning tone can still be used. - Page 48 The device in-use Item Button Description START ENGINE Press this button to start the power generator if control mode is selected (also see SWITCH OFF ENGINE Press this button oncein control mode and the control module will start the power generator’s cool-down phase, and it will be switched off afterwards.
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Page 49: Display Window On The Control Module's Screen
The device in-use Item Description GENERATOR STATUS DISPLAY There are two statuses: Unit OK (display is green), and Unit Fault (display is red). The green LED lights up if voltage from the generator is present and the voltage parameters are within the limit values. After the button is pressed (FAULT RESET), it starts to glow continuously (if an alarm is still active) or goes out (if no alarm is still active). -
Page 50: Select Operating Mode (Ii / Tn-S)
The device in-use Fig. 8-4 Sample from control module’s display screen Select operating mode (II / TN-S) The following section explains the precise procedure for operating the gen- erator under different operating conditions. Your generator has a change- over device that allows you to use the generator in two different modes: •... -
Page 51: Direct Supply Mode
The device in-use NOTICE! Press the operating mode selection switch (Fig. 6-4 ) ONLY when the power generator is not running! ► The correct operating mode (building supply or on-site operation) must be selected before you start the generator. 8.2.1 Direct supply mode The generator is designed for use with one or more electrical consumers (as per VDE 100, Part 551) in “on-site operation". - Page 52 The device in-use The supply into the stationary system is through a flexible connection line (H07RN-F or comparable) in the supply distributor installed on-site through the CEE power socket (Fig. 7-3 with white colour marking). All other sockets are not usable in this operating mode.
- Page 53 The device in-use Fig. 8-5 TN system / TT system version example...
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Page 54: Insulation Monitoring
The device in-use Insulation monitoring “On-site operation” mode is equipped with insulation monitoring with shut-off. The insulation monitoring provides electrical safety to the gener- ator and to all connected consumers and cable connections during contin- uous operation. A possible insulation fault is displayed in two stages: 1. - Page 55 The device in-use Fig. 8-6 Insulation monitoring Test the insulation monitoring function as follows: Conditions The generator has started and is running. 1. Disconnect all of the consumers from the generator's sockets. 2. Make sure all circuit breakers are turned on (switch in POS-I). 3.
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Page 56: 2-Way Fuel Valve
The device in-use Lamp Result Meaning No signal Line circuit breaker remains No insulation fault detected lamp goes on in POS 1 Consumer has an insulation fault (≤ 23kΩ) YELLOW Line circuit breaker remains Insulation fault (≤ 46 kΩ > 23 signal lamp in POS 1 kΩ) - Page 57 The device in-use DANGER! Fire and explosion hazard from leaking fuel Risk of severe to deadly burns. ► Prevent fuel from leaking. ► Keep the refuelling device’s fuel cannister firmly closed. ► When changing the fuel cannister, stay as far away as possible from the pow- er generator.
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Page 58: Harting Remote Starting Device
The device in-use NOTICE! When the lever of the 2-way fuel tap is in “OUTSIDE” position with the en- gine running, without the refuelling device connected, air can get into the engine’s fuel system. The drive engine shuts off for lack of fuel. ►... - Page 59 The device in-use Setting up the re- Do as follows to operate the power generator from the remote starting de- mote start connec- vice: tion Fig. 8-8 Remote starting device with HARTING® socket Conditions The power generator is ready for operation. ...
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Page 60: Optional Fittings
Optional fittings Optional fittings Powerlock-Box The POWERLOCK BOX allows secure connection of powerful consumers through individual cores with current strength up to 660 A. It therefore has comparable output data to a traditional terminal strip, but it has the advan- tage of tool-free connection without an electrical expert. -
Page 61: Dummy Load
Optional fittings 6. Then secure all locks by turning the lock with the square wrench anti-clock- wise to the stop. 7. Switch the circuit breaker for the POWERLOCK BOX to position “1” or “ON”. The consumer is securely connected and can be operated. NOTICE! If one of the plug connections or the lock cannot be locked, one of the pre- vious plug connections has not been locked properly. -
Page 62: External Battery Charging
Optional fittings External battery charging The additional option for external battery charging ensures that the drive engine’s starter battery is permanently charged. This increases safety of use by enabling trouble-free engine start-up (if the starter battery is in per- fect condition). With this option, your Generators has an integrated auto- matically operated battery charger that is supplied with a 230 V AC connection. - Page 63 Optional fittings 1. Turn the locking ring on the feed plug clockwise to the stop to remove the plug’s cover. 2. Connect the feed plug using a commercially available Schuko connection ca- ble to an existing 230 V AC network. The The battery charger turns on automatically.
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Page 64: 10 Maintenance
Maintenance 10 Maintenance Generators maintenance is described in this section. It may only be per- formed by qualified specialist personnel. Maintenance and repair which is neither described in this operating manual nor in the possibly also delivered operating and maintenance instructions may only be undertaken by authorized service personnel from the manu- facturer. -
Page 65: Starter Battery
Maintenance 10.3 Starter battery 10.3.1 Replacing the battery WARNING! There is a risk of explosion and fire in the case of inappropriate handling and spark development when working with the battery. Danger from spraying sulphuric acid. Danger of suffering severe even deadly burns and chemical burns. -
Page 66: Engine Oil
Maintenance 4. Undo both fastening nuts and remove the battery’s holding bracket. Fig. 10-1 5. Remove the battery from the power generator. The starter battery is now removed. 6. Prepare a new starter battery (follow the battery manufacturer’s instructions). 7. Place the starter battery in the battery compartment. 8. - Page 67 Maintenance To suction out used oil, you also need an oil-resistant hose whose diameter cor- responds to the pump opening (see - ) a suitable oil collection pan (not included with delivery).Below, only the procedures that differ from the engine operating manual are explained.
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Page 68: Checking The Coolant
Maintenance 10.5 Checking the coolant We have filled your power generator’s cooling circuit with premium coolant that ensures long-term material compatibility, and protection from corrosion and frost. The specification G12+ additive is free of nitrite, amine, phosphate and silicate and is mixed to ensure frost protection to at least a –25°C ambient temperature. So as not to impair the protective effect, use only a maximum 50% mixture for refilling. -
Page 69: 11 Storage
Storage 11 Storage It is important to store the device at a suitable storage location as soon as your generator is no longer being used. • The storage location must be roofed and must not be subjected to standing water, aggressive vapours or soiling as well as major accumulation of dust. •... -
Page 70: 12 Disposal
Pure b2b devices (devices which, for appropriate use, or exclusively are only used the commercial area) must not be disposed of over public collecting points in Germany and further EU countries. Speak to your authorised ENDRESS gen- erator dealer about handing back your recycling waste electrical equipment. The dealer is also your point of contact for any differing regulations on the respective country of deployment. -
Page 71: 13 Troubleshooting
Troubleshooting 13 Troubleshooting The following table is an aid for you to use in a case where faults arise during use. Based on experience a number of malfunctions can already be removed by operating personnel or the possible causes limited. In all other cases contact your service partner as described in the table. - Page 72 Customer service: Tel. +49 7123 973744 Email: service@endress-stromerzeuger.de Have the item and serial number of your device ready for identification. You will find these details on the type plate (see Fig. 3-1 ).
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Page 73: 14 Technical Data
14 Technical data You can find the relevant technical data for your generator in the following table. Name Value Unit ESE 67 IW/RS ESE 90 IW/RS ESE 110 IW/RS Continuous power output [PRP] 3~ 60 / 48 80 / 64... - Page 74 Technical data The information given in the table applies to the following operating conditions (standard reference conditions): standard reference conditions Name Value Unit Set-up height above sea level Ambient temperature [°C] Relative Air humidity The usable power output can deviate from the nominal values depending on the actual operating conditions.
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Page 75: 15 Replacement Parts
Replacement parts 15 Replacement parts Maintenance and replacement parts can be obtained quickly and easily from your responsible ENDRESS service partner or ENDRESS dealer. You can alternatively obtain support from our central customer service by telephone: +49 (0) 71239737-44 by email: service@endress-stromerzeuger.de Have the item and serial number of your device ready for identification. - Page 76 Replacement parts NOTES...
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Page 77: Keyword Index
Replacement parts Keyword index Air filter 28 Oil dipstick 28 Air humidity 74 Oil quantity 73 alarm list 49 operating manual 7 ambient conditions 74 Operating personnel 18 23 Ambient temperature 74 Potential equalization 25 30 Base frame 29 power connectors 60 Battery charger 63 Power reduction 74 Brief operating manual 15... - Page 78 Elektrogerätebau GmbH Neckartenzlinger Str. 39 D-72658 Bempflingen, Germany Tel: +49 (0) 7123 /9737-0 Fax: +49 (0) 7123 /9737-50 Email: info@endress-stromerzeuger.de www: www.endress-stromerzeuger.de © 2021, ENDRESS Elektrogerätebau GmbH...
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