Endress 333363, Translation Of The Original Operating Manual

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: ...yright 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 Notes on printing All descriptions technical details and illustrations refer to the version of the gen erator for printing We reserve the right to make modifications in terms of ong...

Page 3: ...d battery side components 28 6 3 Components on the maintenance side 29 6 4 Components for operating panel and switch box 30 7 Commissioning 32 7 1 Transporting and preparing your generator 34 7 2 Refuelling your generator 35 7 3 Starting the generator 36 7 4 Low load diesel engine operation 37 7 5 Turning off your power generator 38 7 6 Turn off your generator in the event of an EMERGENCY 38 7 7 C...

Page 4: ...ance 64 10 1 Maintenance plan 64 10 2 Maintenance work 64 10 3 Starter battery 65 10 3 1 Replacing the battery 65 10 4 Engine oil 66 10 4 1 Changing the engine oil 66 10 5 Checking the coolant 68 11 Storage 69 12 Disposal 70 13 Troubleshooting 71 14 Technical data 73 15 Replacement parts 75 Keyword index 77 ...

Page 5: ...ontrol module s control panel 47 Fig 8 3 Operating display on the control module 48 Fig 8 4 Sample from control module s display screen 50 Fig 8 5 TN system TT system version example 53 Fig 8 6 Insulation monitoring 55 Fig 8 7 Refuelling device connection 57 Fig 8 8 Remote starting device with HARTING socket 59 Fig 9 1 POWERLOCK BOX 60 Fig 9 2 Display with dummy load operating 61 Fig 9 3 230 V fee...

Page 6: ...ubject to a contin uous improvement process In doing this we ensure that the full product is com pliant with the current safety requirements and the current state of the art The respective most up to date language version of the operating manual and the original operating manual can be found on our website www endressparts com 2 1 Constituent parts of the documentation Apart from this operating ma...

Page 7: ...mbols These warning notices are usually used in a safety symbol which also emphasis es the type of danger see next example A list of the safety symbols used in this operating manual can be found in Chapter Fig 3 1 The safety symbols never stand alone Notices on avoidance of damage to the device According to DIN ISO 3864 notices which warn against false operation and pos sible damage to the device ...

Page 8: ...ed with the adjacent symbol NOTICE The adjacent symbol is situated anywhere where the supplier documenta tion must be read and observed and refers to appropriate information tasks or action steps References to details and components in figures are made with blue bordered position numbers in the text such as the example of CE signs on the type plate demonstrates see Fig 3 1 ...

Page 9: ...Customer service Tel 49 0 7123 9737 44 Email service endress stromerzeuger de You will find competent contact persons there also concerning original spare parts and wear parts see also Chapter 15 Type plate The type plate shown below is a representation of the adhesive label placed on the device Please be prepared when contacting our service team to assist us in exactly identifying your device Ref...

Page 10: ... Fig 6 4 The generator is only to be used outdoors within the indicated voltage output and nominal RPM ranges see type plate The power generator must never be used for direct feed into other power distri bution systems e g public power supply or be used with other power generation systems e g other power generators The generator is not to be used in explosion prone environments The generator is no...

Page 11: ... not permitted by In both cases this will inevitably lead to severe damage and possibly also severe injury Never place the generator in explosion prone environments The individual components of the generator are not designed to be EX protected Never operate the generator in rooms narrow pits or vehicles The combus tion exhaust gases contain poisonous substances including the odourless but deadly g...

Page 12: ...umentation 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: ...ices 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 The following figures and tables show the stipulated attachment point and a brief explanation of the labels Fig 3 3 Labels on the device ...

Page 14: ...ower 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 Type plate Example Note 2 way fuel valve External tank Internal tank Note Fuel quality and tank contents Prohibition signs No smoking Open flame prohibited ...

Page 15: ...IT networks and for earthing right with TN networks DGUV instruction on Generators of Version C Death hazard Live parts when opening the cover The EMERGENCY STOP switch turns off the power generator immediately if there is an emergency Warning symbols Dangerous voltage For electricians only Brief operating manual Warning notices Do not use starting aids Explosion hazard Item label Meaning ...

Page 16: ...nd rapid understanding of these safety and warning notices They describe their systematic structure as well as the meaning of markings and symbols 4 1 Safety symbols The safety symbol indicates graphically that a source of danger exists We use the internationally valid safety symbols from ISO 7010 for rapid and unique classification of the respective dangerous situation In the follow ing there is ...

Page 17: ...nvi ronment exists possibly with catastrophic consequences Warning of hot surfaces This warning symbol indicates activities during which there is the danger of burns possibly with lasting consequences Warning of a suspended load This warning symbol indicates activities where the danger of falling loads exists possibly with lethal consequences Warning of automatically starting machines This warning...

Page 18: ...Generators that are not described in this manual are prohibited misuse beyond the legally defined limits of the manufacturer s liability In return all claims for damages and warranty claims against ENDRESS Elektrogerätebau GmbH that are associated with mis use are null and void 4 3 Residual risks As a manufacturer of EU compliant machines ENDRESS make great ef forts to create designs which already...

Page 19: ...le level CAUTION CAUTION describes a danger which represents a low level of risk which can lead to minor or medium level injurieswhen not avoided The individual points provide instructions and notices as aids to avoid the danger or to reduce the risk to an acceptable level NOTICE ATTENTION describes a situation or action that might result in damage to equipment and or malfunctions if it is not pre...

Page 20: ...out Never open the tank cover during operation or when it is hot Remove leaked operating fluids immediately and appropriately Never use an additional starting aid Smoking naked flames and sparks are forbidden DANGER Hot parts can ignite flammable and explosive materials A risk of suffering severe even deadly burns Never operate the generator in the vicinity of combustible or flammable ma terials N...

Page 21: ...ing op eration or transport Only lift the generator with the aid of all handles provided or by using a suit able hoist During transport on vehicles ensure that there is the prescribed load secur ing in place With it in a raised condition never come close to or stand under the genera tor NOTICE Leaking engine oil and operating fluids can contaminate the soil and groundwater Ensure that the generato...

Page 22: ...he 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 Never allow water to find its way inside the generator ...

Page 23: ...e technical documentation concerning their respon sibilities tasks and activities on the Generators and be able to implement these in practice 4 5 Danger zones and work areas In order to be able to consider all of a machine s safety aspects and to com ply with the safety and health protection requirements of the applicable standards and EU directives we have assessed the use of your Generators in ...

Page 24: ...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 ...

Page 25: ...ential equalization device The ter minal Fig 6 4 is connected with this Potential equalization device connected An earthing device is not needed in the on site operation mode Your Generators corresponds to a Version A generator according to DGUV Infor mation 032 203 issued in May 2016 when it is in on site operation mode A cor responding marking can be found on the device see Fig 3 3 We strongly r...

Page 26: ...conjunction with the device We recommend the following checks and intervals as general guideline values Tab 5 1 Recommended test intervals When What how Who First start up at the op erating location See Chapter 7 and follow the operating manual in the supplier documentation Visual inspection for externally visible defects such as transport damage Operating personnel Start up on a daily basis See C...

Page 27: ...rther understand the de scribed functions and operating steps and to be able to perform them safely Ignoring this manual can cause severe injury or death and or dam age to the power generator and connected consumers To make it easy to find the operating elements and components the individual views of the power generator are designated throughout the following descrip tions and instructions as can ...

Page 28: ...6 2 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: ...3 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: ...n RCD 30 mA for socket RCD residual current circuit breaker 30 mA for sockets Circuit breaker 63A 4 pin for socket not on IT TN EMERGENCY STOP switch Remote start socket HARTING Terminal strip 5 pin 63A POWERLOCK BOX optional Socket 230V 16A Connection terminal Potential equaliza tion earthing CEE socket 400V 63A 6h red OR CEE socket 400V 125A 1h white CEE socket 400V 32A 16A 6h red Operating hour...

Page 31: ...31 Description of the device NOTES ...

Page 32: ...eutsche Gesetzliche Unfallversicherung DGUV in DGUV Information 203 032 the May 2016 edition requires observance of special protective measures and behaviour regulations Be sure to refer to the following section for a summary of this DGUV infor mation It supplements the operating manual for this special application We also urgently advise observance of relevant DGUV information under comparable op...

Page 33: ...33 Commissioning Fig 7 1 Setting up personal protection measures source DGUV ...

Page 34: ...ng NOTICE Leaking engine oil and operating fluids can contaminate the soil and groundwater Ensure that the generator is transported horizontally and mounted Make all efforts at all costs to prevent escaping of operating fluids Dispose of contaminated soil immediately and according to regulations Transporting by lift ing forks 1 Align the lifting forks e g forklift with the position of the forklift...

Page 35: ...NOTICE Leaking fuel can contaminate soil and groundwater Take note of the residual quantity in the tank and its maximum filling capacity Always bear in mind that the fuel gauge reacts only after a time delay Fill the tank to a maximum of 95 Always use a filling aid e g funnel NOTICE Use of wrong or outdated fuel damages or destroys the engine Only use the fuel displayed on the sign Tab 3 1 Observe...

Page 36: ...fore first start up for this see the engine s operating and maintenance manual The oil level is adequate fill with engine oil before initial use see the engine operating and maintenance manual There is adequate air supply and air removal The main battery switch must be in the ON position DANGER Leaking engine oil and fuel can burn or explode A risk of suffering severe even deadly burns Prevent eng...

Page 37: ...ower generator see Chapter 8 1 NOTICE Do not apply load to the generator immediately after a cold start Allow the generator engine to warm up for a few minutes before switching on a load when the generator has not been operating for more than eight hours or for very low external temperatures 7 4 Low load diesel engine operation Internal combustion engines normally run most economically and environ...

Page 38: ...witching the gen erator off 1 Press the Fig 7 2 button once a If the button Fig 7 2 is pressed a second time after Step 1 the engine stops immediately without a cool down phase not recommend ed The engine will go into the cool down phase Cool down on the display and shuts off automatically in about two minutes 2 Use the Fig 7 2 switch to switch the controls to 0 The generator is switched off and s...

Page 39: ...ain after the hazard has been eliminated and if the EMERGENCY STOP switch is unlocked manually How to unlock the EMER GENCY STOP switch Conditions The hazard or cause of the EMERGENCY STOP process has been eliminat ed All of the connected consumers are disconnected or switched off Removing the EMERGENCY STOP 1 Gently turn the red button on the EMERGENCY STOP switch left or right The red button unl...

Page 40: ...c Never operate the device with wet hands DANGER There will be no RCD personal protection during operation if the earthing of the Generators is faulty Mortal danger from electrocution The use of an RCD FI circuit breaker for personal protection requires proper earthing of the Generators and this must be undertaken by a qualified elec trician before the initial commissioning The effectiveness of th...

Page 41: ...A ONLY on site operation RCD CEE socket 400V 32A 3 6h 30mA CEE socket 230V 16A 3 6h 30mA CEE socket 400V 63A 3 6h 300 mA CEE socket 400V 16A 3 6h 30mA Schuko attachment sockets 230 V 16 A 1 30mA Terminal strip 5 pin ACCESS FOR ELECTRICIANS ONLY 300 mA POWERLOCK BOX option see Chapter 9 1 300 mA NO PERSONAL PROTECTION ...

Page 42: ...rs are supplied with voltage Connecting con sumers 1 Turn the locking ring on the socket s splash guard anti clockwise to the stop 2 Fold the splash guard aside with one hand 3 Use your other hand to insert the plug from the consumer to be connected into the socket to the stop 4 Firmly screw the locking ring clockwise on the consumer s plug The consumer is connected to the power generator and read...

Page 43: ...work We strongly recommend that you also comply with the requirements of DGUV In formation 203 032 for other purposes DANGER There will be no RCD personal protection during operation if the earthing of the Generators is faulty Mortal danger from electrocution The use of an RCD FI circuit breaker for personal protection requires proper earthing of the Generators and this must be undertaken by a qua...

Page 44: ... the test button The switch position indicates the result The device has been tested in compliance with DIN VDE 0100 551 1 Move the circuit breaker back into POS I to be able to operate consumers from the generator again Symbol Meaning POS I Circuit breaker does not trip FI circuit breaker is defective POS 0 Circuit breaker trips FI circuit breaker is working correctly ...

Page 45: ...0100 551 1 Move the circuit breaker back into POS I to be able to operate consumers from the generator again In building supply mode the white feed socket Fig 7 3 Connecting consum ers is secured against overload and short circuit by the main switch The inte grated differential current release is only for protecting the system Due to its electrical design it offers NO PERSONAL PROTECTION For this ...

Page 46: ...eserved for mainte nance and configuration work or if starting the Generators must be prevented un der all circumstances NOTICE Automatic grid switching is deactivated in the control mode The power generator will not start if the power supply has failed Use only the control mode for temporary purposes and only if starting the Generators must be prevented After you have finished accessing the unit ...

Page 47: ...s are completely shut off The power generator cannot be started neither automatically nor manually in this mode DANGER Dangerous electrical voltage is still present even when the power genera tor is switched off Mortal danger from electric shock if live parts are touched Access only for electricians in areas marked with an adjacent warning sym bol Maintenance on the generator is only to be done af...

Page 48: ...of the active alarms changes to acknowledged so that this will be faded out immediately af ter the cause is eliminated RESETTING THE HORN Press this button to deactivate the horn output without acknowledging the alarm SELECTING A CONTROL MODE Pressthis button to switch between the or control modes The buttons will only be functional if Fig 8 4 is displayed in the main window on the control screen ...

Page 49: ...dge the alarm The character will disappear The entry will only disappear after the error has been eliminated 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 t...

Page 50: ... 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 Operation for supplying a mobile distribution system Building supply for supplying a stationary system Selection of the right operating mode is specified based on the purpose ...

Page 51: ...consumables or make cable connections to the sockets Follow the working steps for starting the generator described in Chapter 7 3 Follow the work steps for connecting consumers described in Chapter 7 7 8 2 2 Building supply operating mode The building supply operating mode is used to supply stationary systems such as residential houses or public facilities The generator serves as the emergency pow...

Page 52: ...ibutor over to emergency power Take note of the instructions in the supply distributor s operating manual NOTICE Ensure that there is a clockwise rotating field applied to the feed distributor at the sides of the emergency power infeed The rotational field must be checked by a qualified electrician if there is no appropriate direction of ro tation indicator on the supply distributor see Fig 8 5 Cr...

Page 53: ...53 The device in use Fig 8 5 TN system TT system version example ...

Page 54: ...warning tone a There is an insulation fault with transfer resistance lower than 23 kΩ in a current circuit of the power generator the cable network or a connected consumer Result Operation is no longer possible and insulation monitoring trips the main line circuit breaker The power generator cannot be operated again until the cause of the insulation fault is fixed If the insulation fault occurs on...

Page 55: ...d the circuit breaker must be put into POS 1 in order to operate the device again Insulation monitor ing during opera tion With the following instructions you will learn how your generator detects an insu lation fault of a connected consumable during operation and how it protects you Conditions The generator has started and is running Line circuit breaker is in POS I 1 Use a socket to connect a co...

Page 56: ...vely against reuse by third parties Replace the consumer or have it repaired by a qualified electrician 8 4 2 way fuel valve When supplying fuel you can choose between the internal tank and an ex ternal refuelling device To change refuelling methods there is a 2 way tap behind the maintenance hatch on the maintenance side of the power gen erator Do as follows to operate the power generator with an...

Page 57: ...nect refuelling device 1 Remove the stoppers from the hose holes on the base frame 2 Make sure the 2 way tap s lever is in internal tank position INSIDE 3 Remove the dummy plugs from the feed and return connections 4 Guide the ready made fuel hoses for the refuelling device though the holes and screw them as follows to the connections on the 3 way tap a Connect the fuel feed hose b Connect the fue...

Page 58: ...ions with the dummy plugs 4 Insert the stoppers back into the base frame s hose holes The refuelling device is disconnected 8 5 HARTING remote starting device The optionally installed HARTING socket allows you to turn your power generator on and off remotely in connection with a suitable external instal lation such as a control station WARNING Beware of machines starting in automatic mode Risk of ...

Page 59: ... starting device is ready to operate NOTICE Further steps for starting and stopping the power generator are in the op erating manual for the external component or installation NOTICE If the remote starting device is connected the power generator CANNOT be turned off from the control module see Chapter 8 1 Use the EMERGENCY STOP switch if an emergency occurs see Chapter 7 6 Disconnecting the remote...

Page 60: ...gize the POWERLOCK BOX before inserting or removing the plugs Fig 9 1 POWERLOCK BOX Do as follows to connect consumers through the POWERLOCK BOX to the pow er generator Conditions The circuit breaker for the POWERLOCK BOX see power generator operat ing manual is in 0 or OFF position The consumer to be connected is shut off Step by step 1 Turn the locks left and right of the cover flap using the in...

Page 61: ...rator has a dummy load with an output adapted to the drive engine This is electrical load resistance that automatically creates a base load as soon as the engine is running below the specified load limit During extended operation at low load deposits form in the engine that with time cause increased wear and possibly severe engine damage Au tomatic switch on of the dummy load increases the burn te...

Page 62: ...uffering severe or even deadly burns Only work with acid resistant protective equipment Clean surfaces covered in acid immediately using adequate amounts of wa ter Only charge the starter battery in a well ventilated environment WARNING During the charging process never undo the cable connections to the starter battery Before you start the power generator you must end the charging process and let ...

Page 63: ...ction ca ble to an existing 230 V AC network The The battery charger turns on automatically The starter battery is charged NOTICE The battery charger automatically transitions to charge retention when the set end of discharge voltage is reached When the charging system is in tact overcharging is not possible and the charge connection to the Gen erators can remain until next use ...

Page 64: ...e allowed to carry out maintenance tasks Carry out all of the maintenance work listed in the maintenance plan ac cording to the instructions given in the accompanying operating and main tenance instructions provided by the engine manufacturer This operating manual merely describes the instructions that differ from or go beyond those instructions DANGER Mortal danger from unintentional generator st...

Page 65: ... Wear acid resistant protective clothing Fig 10 1 Starter battery illustration similar Conditions Change the starter battery as follows Power generator is switched off 7 3 switch is in the OFF position Battery disconnection switch is in OFF position You are wearing personal safety equipment Feed plug disconnected from the integrated battery charger 1 Interrupt the battery circuit from the main swi...

Page 66: ...ing and inner cooling It is also very important to use the correct engine oil both for refilling and when chang ing the oil and to adhere the stipulated maintenance intervals Refer to the accompanying operating and maintenance instructions provided by the engine manufacturer for all necessary information 10 4 1 Changing the engine oil In contrast to the operating and maintenance manual for the eng...

Page 67: ... approx 30 C 50 C Let the cold engine appropriately warm up Do as follows to suction up the used oil 1 Open the shut off valve by pressing the valve anti clockwise and down ward 2 Guide the hose into a suitable oil collection container 3 Move the suction pump s hand grip Fig 10 2 up and down until no more used oil comes from the engine 4 Move the hand grip Fig 10 2 to the bottom position The engin...

Page 68: ...ICE Follow the engine s operating and maintenance manual for all work on the cooling system In deviation from this follow these instructions Check the coolant level only from the surge tank Fig Fig 10 3 near the ra diator The fluid level should always be between the Maximum and Mini mum marks If the tank is empty the cooling system must be ventilated CAUTION Hot surfaces and hot pressurized fluid ...

Page 69: ...dust Protect your device with a cover made out of breathable material Ensure that the storage temperature and air humidity lie within the specified limits see Technical data NOTICE Due to the limited shelf life of the different operating fluids it is important for decommissioning for more than one month that additional measures for storage are taken While doing this observe the instructions given ...

Page 70: ...k 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...

Page 71: ...s please exactly follow the instructions in the existing and delivered documentation See the event and error lists in the Appendix Malfunction Possible cause Correction The engine turns but does not start electrical start The controller is being operated incor rectly Look at the operating instruc tions Maintenance of the engine was inade quate Look at the engine mainte nance instructions The oil l...

Page 72: ...ive Contact your service partner Strong voltage fluctua tions occur The engine runs irregularly Contact your service partner Speed controller working erratically or insufficiently Contact your service partner The engine smokes Too much oil in the engine Drain off an excess oil Paper element of the air filter is dirty or oil soaked Clean paper element or re place if necessary Foam element of the ai...

Page 73: ...890 2 000 kg EngineOil quantity including oil filter 12 8 l Internal tank content 430 l Fuel consumption at a 75 load 2 13 0 15 4 18 5 l h Running time at 75 load approx 2 33 1 27 9 23 2 h Length 2 900 mm Width 1 090 mm Height 1 925 mm Noise pressure level at the workplace LpA 3 83 86 85 db A Sound pressure level at a distance of 7m LpA 4 66 69 69 db A Sound power level LWA 3 91 94 94 db A Protect...

Page 74: ...s Power reduction The following table shows you the applicable Operating conditions for running the generator ambient conditions Name Value Unit Set up height above sea level 100 m Ambient temperature 25 C Relative Air humidity 30 Reference value Power output reduction for each ad ditional Set up height above sea level 1 100 m Ambient temperature 4 10 C Name Value Unit Set up height above sea leve...

Page 75: ...39737 44 by email service endress stromerzeuger de Have the item and serial number of your device ready for identification As a registered user you can obtain rapid and uncomplicated access to a range of services over our home page to obtain suitable original spare parts for main tenance and repair work Using your internet browser please go to https endressparts com and click on the area Documenta...

Page 76: ...76 Replacement parts NOTES ...

Page 77: ... 75 I Imprint 2 Included with delivery 12 L label 13 13 Low load operation 61 M Main battery switch 29 Maintenance hatch 28 misuses 11 O Oil dipstick 28 Oil quantity 73 operating manual 7 Operating personnel 18 23 P Potential equalization 25 30 power connectors 60 Power reduction 74 Prohibition signs 14 R Refuelling device 56 Resetting an error message 48 S safety instructions 16 Safety symbols 16...

Page 78: ...rätebau 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 ...