Endress ESE 606 DHG-GT DUPLEX operation manual

ORIGINAL OPERATING INSTRUCTIONS

ESE 406 HG-GT DUPLEX Article No.: 113552
ESE 406 HG-GT ES DUPLEX Article No.: 113553
ESE 506 HG-GT DUPLEX Article No.: 113554
ESE 506 HG-GT ES DUPLEX Article No.: 113555
ESE 606 DHG-GT DUPLEX Article No.: 113556
ESE 606 DHG-GT ES DUPLEX Article No.: 113557

Table of Contents

2 ESE 406 - 606 (D)HG-GT (ES) Duplex Status: August 2017

ENDRESS
Elektrogerätebau GmbH
Neckartenzlinger Str. 39

D-72658 Bempflingen
Telephone: + 49 (0) 71 23 / 9737 – 0

Telefax: + 49 (0) 71 23 / 9737 – 50
Email: [e-mail]
www: http://www.endress-stromerzeuger.de

E135793

August 2017 / i04
© 2017, 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.

This applies in particular to copies, translations, microfilming,
as well as storage and processing in electronic systems.

Publisher

Document number

Publication date / Version

Copyright

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Status at: August 2017 ESE 406 - 606 (D)HG-GT (ES) Duplex 3

Caution!

Important notes on commissioning and op­eration of the construction and assembly lo­cations.

For this operation special protective measures and rules
of behaviour for commissioning must be observed ac­cording to the DGUV Information 203-032 Mai 2016 Edi­tion.

The following pages 3 and 4, notes on the DGUV Infor­mation 203-032, supplement the operating manual for
this special application.

One is recommended to read the DGUV Information 203­032 before performing the first commissioning. In cases
of doubt consult a qualified electrician.

Operation of the generator on construction and assem­bly locations according to DGUV Information 203­032(BGI867).

The following notes should be observed:

Protective measures and rules of behaviour

 The operating instructions from the manufacturer and

the accident prevention regulations must be observed
and followed.

 Only instructed persons may work with electrical equip-

ment.

 If mobile generators of type A are only operated with

one consumer, no further protective measures needed

to be taken.

 If mobile generators of type A are operated with many

consumer, additional protective measures needed to be
taken:

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4 ESE 406 - 606 (D)HG-GT (ES) Duplex Status: August 2017

- residual current protection devices (RCDs) with a
rated differential current not greater than 30 mA
(0.03 A) for the second and every additional con­sumer.

or

- a separating transformer for the second and every
additional consumer for increased danger through
having a conductive environment with limited free­dom of movement.

 one may not use a PRCD-S here as a residual current

protection device since it cannot be switched on.

 for generators with an insulation monitoring device (IMD)

the same requirements apply.

 Only rubber-insulated flexible cables of the type H07RN-

F or H07BQ-F may be used on construction and assem­bly locations.

 Electrical equipment must be spray water protected and

meet the regulations for rough operation

The generators of type A are marked as follows.

The generators of type C (with integral RCDs) and their des­ignation, see Chapter 5.1.

Also observe the important information for connection of con-

sumers on the supplementary sheet “Important note for gen-

erators with a connection for potential equalization“.

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Table of Contents

Protective measures and rules of behaviour ..................................................................3

1. General information .......................................................................................... 9

Further documents and documentation ............................................................ 10

Safety symbols ................................................................................................ 10

2. General Safety Regulations............................................................................ 13

Important safety warning .................................................................................. 13

2.1.1 Intended use ...................................................................................................... 14

2.1.2 Foreseeable incorrect use or inappropriate handling ........................................ 15

2.1.3 Residual risks .................................................................................................... 16

Operating personnel – qualifications and obligations ....................................... 17

Personal protective equipment ......................................................................... 18

Danger zones and work areas ......................................................................... 19

Signs on the generator ..................................................................................... 20

General safety instructions ............................................................................... 22

Checking the electrical safety .......................................................................... 26

3. The generator ESE 406 - 606 (D)HG-GT (ES) Duplex ................................... 29

Views of the generator ..................................................................................... 29

Components on the operating and exhaust side .............................................. 30

Engine and maintenance side components ...................................................... 31

Control panel components ............................................................................... 32

4. Operation ......................................................................................................... 35

Transporting the generator ............................................................................... 35

Setting up the generator................................................................................... 37

Refuelling the generator ................................................................................... 38

Starting the generator ...................................................................................... 39

Switching the generator off .............................................................................. 43

Connect up to consumers ................................................................................ 44

Changeover of operating mode (II / TN-S) ....................................................... 46

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6 ESE 406 - 606 (D)HG-GT (ES) Duplex Status: August 2017

4.7.1 Incident scenes operation .................................................................................. 46

4.7.2 Supplying power to a building............................................................................ 47

ECOtronic (idle down) ...................................................................................... 50

Monitoring the operating status via the “ECD 02 control display” ..................... 51

Putting the generator out of service ................................................................. 52

Disposal ........................................................................................................... 52

5. Using special fittings / accessories ............................................................... 54

RCD fault current safety equipment / FI protection switch ................................ 54

Insulation monitoring with switch off ................................................................. 56

Remote start device ......................................................................................... 58

5.3.1 EMERGENCY-STOP switch ............................................................................. 60

6. Maintenance .................................................................................................... 61

Maintenance plan............................................................................................. 61

Maintenance work ............................................................................................ 62

6.2.1 Motor oil ............................................................................................................. 62

6.2.2 Charging the battery .......................................................................................... 64

6.2.3 Replacing the starter battery ............................................................................. 65

7. Troubleshooting .............................................................................................. 66

8. Technical specifications ................................................................................. 69

9. Replacement parts ................................................................ .......................... 72

Frame / engine / generator ............................................................................... 72

Electrical junction box ...................................................................................... 74

10. Written guarantee ............................................................................................ 75

11. Proof of maintenance ..................................................................................... 78

List of illustrations

Figure 1-1: Document compartment under the fuel tank ...... 9

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Figure 2-1: Signs on the generator .....................................20

Figure 3-1: Views of the generator......................................29

Figure 3-2: Components on the operating and exhaust side

....................................................................................30

Figure 3-3: Engine and maintenance side components ......31

Figure 3-4: Control panel components * .............................32

Figure 4-1: Attachment of the carrying straps .....................36

Figure 4-2: Hand start operating controls............................40

Figure 4-3: Hand choke position .........................................40

Figure 4-4: Electrical start ...................................................41

Figure 4-5: Connect up to consumers .................................45

Figure 4-6: Feed plug in the scope of delivery ....................47

Figure 4-7: Equipment specification example Main

distribution TN system / TT system..............................49

Figure 4-8: Idle down rocker switch ....................................50

Figure 4-9: Multi-functional display .....................................51

Figure 5-1: FI protection switch ..........................................55

Figure 5-2: Insulation monitoring ........................................56

Figure 5-3: Remote start device .........................................58

Figure 5-4: Cable remote control ........................................59

Figure 6-1: Oil dipstickand oil drain plug .............................62

Figure 6-2: Replacing the battery .......................................65

Figure 9-1: Replacement parts for the frame / engine /

generator .....................................................................72

Figure 9-2: Replacement parts Electrical junction box ........74

List of tables

Table 2.1: Danger zones and work areas on the generator 19

Table 2.2: Signs on the generator.......................................21

Table 5.1: FI protection switch test .....................................55

Table 5.2: Insulation monitoring plus switching off ..............56

Table 5.3: Insulation monitoring whilst running without

switching off ................................................................57

Table 6.1: Generator maintenance plan .............................61

Table 7.1: Troubleshooting during generator operation ......67

Table 8.1: Ambient conditions for the generator .................70

Table 8.2: Generator power reduction dependent on ambient

conditions ....................................................................70

Table 8.3: Maximum line length of the distribution network as

a function of the cable cross-section............................70

Table 9.1: Replacement parts for the frame / engine /

generator .....................................................................73

Table 9.2: Replacement parts Electrical junction box .........74

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8 ESE 406 - 606 (D)HG-GT (ES) Duplex Status: August 2017

General note: The illustrations in these operating instructions do not always

comply completely with the actual design, in particular with re­gard to the colour, and are to be considered a representation
of basic principles.

We reserve the right to make modifications in terms of ongoing

technical development.

These instructions do not include technical modifications that

occurred after printing.

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Status at: August 2017 ESE 406 - 606 (D)HG-GT (ES) Duplex 9

1. General information

These operating instructions must be read carefully and un­derstood 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.

Complying with this information helps to:

 avoid hazards
 reduce repair costs and downtime
 increase the reliability and service life of the generator.

However, not only these operating instructions but also the
laws, regulations, guidelines, and standards applicable in the
country of use and at the site of operation must be observed.

These operating instructions only describe the generator op­eration.

A copy of these operating instructions must stay with the de­vice and be available to the operating personnel at all times.
To do this there is a document compartment on the engine
side of the generator under the fuel tank (see Figure 1-1).

Figure 1-1: Document compartment under the fuel tank

General information

Further documents and documentation

10 ESE 406 - 606 (D)HG-GT (ES) Duplex Status: August 2017

Further documents and documentation

Apart from these operating instructions, there are further doc­uments for documentation of the generator. They must remain
on the device and be available to be viewed by operating per­sonnel:

 operating manual and maintenance instructions for the en-

gine

 regulations for handling the battery for the Electrostart ver-

sion

 supplementary sheet “Import note for generators with a

connection for potential equalization“.

 supplementary sheet “Installation of ENDRESS genera-

tors in vehicles, containers or other closed rooms“

All documents named are a constituent part of the operating
instructions. They describe appropriate use of the generator
and provide the prerequisites in order to

 safeguard operating personnel and users from dangers

and risks,

 to avoid damage to the device and equipment used with it,
 to secure your warranty and guarantee claims (see also

Chapter 10).

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.

Warning of a general hazard

This warning symbol indicates activities where several
causes can lead to risks.

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Status at: August 2017 ESE 406 - 606 (D)HG-GT (ES) Duplex 11

Potentially explosive materials

This warning symbol indicates activities during which there is
an explosive hazard, possibly with lethal consequences.

Dangerous electrical voltage

This warning symbol indicates activities during which there is
the danger of an electric shock, possibly with lethal conse­quences.

Poisonous substances

This warning symbol indicates activities during which there is
the danger of poisoning, possibly with lethal consequences.

Warning concerning falling loads

This warning symbol indicates activities during which there is
the danger of crushing or breakage of bones, possibly with
lethal consequences.

Environmentally damaging substances

This warning sign indicates activities during which the envi­ronment could be endangered, possibly with catastrophic
consequences.

Hot surfaces

This warning symbol indicates activities during which there is
the danger of burns, possibly with lasting consequences.

General information

Safety symbols

12 ESE 406 - 606 (D)HG-GT (ES) Duplex Status: August 2017

Notes

General Safety Regulations

Important safety warning

Status at: August 2017 ESE 406 - 606 (D)HG-GT (ES) Duplex 13

2. General Safety Regulations

This section describes the basic safety regulations for operat­ing the generator.

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. Other
applications can lead to injury to the operating personnel and
to damage to the generator as well as other damage to equip­ment.

The majority of injuries and damage to equipment can be
avoided if all instructions given in this manual and all instruc­tions attached to the generator are followed.

The generator must not be modified in any way. This can lead
to an accident occurring and damage to the generator as well
as devices.

WARNING!

General Safety Regulations
Important safety warning

14 ESE 406 - 606 (D)HG-GT (ES) Duplex Status: August 2017

The following actions are not permitted.

 Operation in explosion-prone environments
 Operation in fire-prone environments
 Operation in confined areas
 Operation in vehicles
 Operation without the necessary safety redundancies
 Operation in existing power supply networks
 Refuelling when hot
 Refuelling during operation
 Spraying with high-pressure cleaners or fire-extinguish-

ing equipment

 Safety equipment removal
 Incorrect vehicle installation
 Non-compliance with maintenance intervals
 Failure to measure and test for early damage identifica-

tion

 Failure to replace wearing parts
 Incorrectly performed maintenance or repair work
 Defectively performed maintenance or repair work
 Unintended use

2.1.1 Intended use

The generator produces electricity in place of the power grid,
in order to supply a mobile distribution system.

The generator is only to be used outdoors within the indicated
voltage, output, and nominal rpm ranges (see nameplate
Chapter 2.5).

You are also permitted to use it on a vehicle extension or swiv­elling platform in both extended and swung out states, provid­ing that the air circulation is uninterrupted on all sides of the
alternator and that the exhaust gases are dispersed correctly.
This is especially relevant as access to the side with the in­strument panel and the side with the exhaust gas connection
must be unrestricted.

The methods that will be used to install the generator on these
vehicle platforms require written approval from the distributor
that supplied the generator.

General Safety Regulations

Important safety warning

Status at: August 2017 ESE 406 - 606 (D)HG-GT (ES) Duplex 15

The generator is not to be connected up to other energy dis­tribution systems (e.g. public power supply) or to other energy
generation systems (e.g. other generators).

The generator is not to be used in explosion-prone environ­ments.

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.
Every inappropriate use or all activities on the generator which

are not described in these instructions are forbidden misuse
outside the legally defined limits of liability of the manufac­turer.

2.1.2 Foreseeable incorrect use or inappropriate handling

Foreseeable incorrect use or inappropriate handling of the
generator nullifies the manufacturer's EC Declaration of Con­formity and automatically thereby the operating licence.

Foreseeable incorrect use or inappropriate handling include:

 Operation in explosion-prone environments
 Operation in fire-prone environments
 Operation in rooms or narrow pits
 Operation from a vehicle platform that has not been swung

out

 Operation without the necessary safety redundancies
 Operation in existing power supply networks
 Refuelling when hot
 Refuelling during operation
 Spraying with high-pressure cleaners or fire-extinguishing

equipment

 Safety equipment removal
 Incorrect vehicle installation
 Non-compliance with maintenance intervals
 Failure to measure and test for early damage identification
 Failure to replace wearing parts
 Incorrectly performed maintenance or repair work
 Defectively performed maintenance or repair work
 Unintended use

General Safety Regulations
Important safety warning

16 ESE 406 - 606 (D)HG-GT (ES) Duplex Status: August 2017

2.1.3 Residual risks

The points were analysed and evaluated using a risk analysis
tool before beginning the design and planning of the generator
for residual risks according to DIN EN 60204, DIN EN ISO
12100 or 12601.

Residual risks which cannot be avoided by implementing de­sign measures during the whole life cycle of the generator can
be:

 Risk of death
 Risk of injury
 Environmental hazards
 Material damage to the generator
 Material damage to other property
 Limited performance or functionality

You can avoid existing residual risks by observing and follow­ing these guidelines:

 the special warning notices on the generator
 the general safety instructions given in these operating in-

structions

 the specific warnings given in these operating instructions

Risk of death to persons at the generator can be caused by:

 Incorrect use
 Inappropriate handling
 Missing protective equipment
 Defective or damaged electrical components
 Fuel vapours
 Engine exhaust
 Too large a distribution network configuration

Risk of injury to persons at the generator can be caused by:

 Inappropriate handling
 Transport
 Hot components
 Recoiling starter rope on the engine

Environmental hazards involving the generator may be
caused by:

Risk of death

Risk of injury

Environmental hazards

General Safety Regulations

Operating personnel – qualifications and obligations

Status at: August 2017 ESE 406 - 606 (D)HG-GT (ES) Duplex 17

 Inappropriate handling
 Operating fluids (fuel, lubricants, engine oil, etc.)
 Exhaust gas emission
 Noise emission
 Fire hazard
 Leaking battery acid

Material damage to the generator can occur through:

 Inappropriate handling
 Overloading
 Overheating
 Too low/high oil level of the engine
 Non-compliance with the operating and maintenance

specifications

 Unsuitable operating fluids
 Unsuitable hoisting gear

Material damage to other equipment in the operating area of
the generator can be caused by:

 Inappropriate handling
 An overvoltage or an undervoltage
 Incorrect installation in a vehicle

The generator's performance or functionality can be limited
by:

 Inappropriate handling
 Inappropriate maintenance or repair work
 Unsuitable operating fluids
 An installation altitude greater than 100 metres above sea

level

 An ambient temperature exceeding 25°C
 Too large a distribution network configuration

Operating personnel – qualifications

and obligations

All work performed on the generator may only be performed
by persons suitably qualified to do this.

An instructed person (hereinafter referred to as operating per­sonnel) is only such a person who

Material damage to the

generator

Material damage to other

property

Limits to performance or

functionality

General Safety Regulations
Personal protective equipment

18 ESE 406 - 606 (D)HG-GT (ES) Duplex Status: August 2017

 is at least 18 years old,
 is trained in first aid and able to provide it,
 is familiar with the accident prevention regulations and

generator safety instructions and is able to apply them,

 has read the chapter “General Safety Regulations”,
 has understand the content of the chapter “General Safety

Regulations”,

 is able to use and implement the content of the chapter

“General Safety Regulations” in practice,

 is trained and instructed according to the rules of conduct

in the event of a malfunction occurring,

 has the physical and mental abilities to carry out his re-

sponsibilities, tasks, and activities on the generator,

 is trained and instructed in his responsibilities, tasks and

activities on the alternator,

 has understood the technical documentation concerning

his responsibilities, tasks and activities on the alternator
and be able to implement these in practice.

Personal protective equipment

This personal protection equipment must be worn during all
activities at the generator described in these operating instruc­tions:

 hearing protection
 protective gloves
 safety shoes

General Safety Regulations

Danger zones and work areas

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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 m
none

by the operating per­sonnel

Radius of 1 m

Operation
Setting up

Refuelling

Radius of 2 m

Operating

Radius of 5 m

Service and mainte­nance

Cleaning

Radius of 1 m
Maintenance

Decommissioning

Table 2.1: Danger zones and work areas on the generator

General Safety Regulations
Signs on the generator

20 ESE 406 - 606 (D)HG-GT (ES) Duplex Status: August 2017

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

1

Note concerning fuel quality

2 Open flame prohibited

3

Reference note - noise emission

4 Potential equalization terminal

5

Generator model plate

6 Reference note - Hot surface

7

Note concerning version A (C) accord-

ing to DGUV

8 Warning for engine operation

9

Note concerning compartment with op­erating instructions

4

5

6 1 7

3 8 9

2

General Safety Regulations

Signs on the generator

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No.

Sign

Name

1

Note

Fuel quality

2

Note

No naked

flames

3

Note

Noise emission

4

Potential equal-

ization

(earthing for FI)

5

Nameplate

6

Warning

Hot

surface

7

Note

DGUV infor-

mation

8

Warning

Dangers in-

curred during

engine opera-

tion

9

Note

Compartment

for operating in-

structions

Table 2.2: Signs on the generator

General Safety Regulations
General safety instructions

22 ESE 406 - 606 (D)HG-GT (ES) Duplex Status: August 2017

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 clearly

legible condition.
The operational reliability and functionality must be checked

before and after each use/operation.
The generator is only be used outdoors and with sufficient

ventilation.
Do not use open flames, lights, or spark-inducing devices in

the generator’s danger area.
Protect the generator against moisture and precipitation (rain,

snow) during operation.
Protect the generator against dirt and foreign matter during

operation.
The authorised personnel are responsible for the operational

reliability of the generator.
The authorised personnel are responsible for safeguarding

the generator against unauthorised operation.
The authorised personnel are obligated to observe the appli-

cable accident prevention regulations.
The authorised personnel are obligated to obey the safety and

work instructions of superiors and/or safety officers.
The authorised personnel are obligated to wear personal pro-

tective equipment.
Only authorised personnel may remain in the generator's dan-

ger zone.
Smoking is absolutely prohibited in the generator's danger

zone.

General Safety Regulations

General safety instructions

Status at: August 2017 ESE 406 - 606 (D)HG-GT (ES) Duplex 23

Open flames and light are prohibited in the generator's danger
zone.

Consuming alcohol, drugs, medicines, or other conscious­ness-expanding and/or changing substances is prohibited.

The authorised personnel must be familiar with the generator
components and their function and know how to use them.

The generator is only be transported after it has cooled down.
The generator may only be transported in a vehicle after being

fastened in place correctly (on the transport device).
The generator is only be lifted by the carrying handles pro-

vided.
The generator is to be carried by at least one person per car-

rying handle.

The generator is only be set up on sufficiently firm ground.
The generator may only be set up on even ground.

The electrical safety must be checked before each start-up.
Do not cover the equipment during use.
Do not obstruct or block the air supply.
Do not use starting aids.
Devices must not be connected during start-up.
Only tested and authorised cables may be used for the power

network.
It is prohibited to establish a connection between existing neu-

tral conductors, potential equalisation conductors and/or
equipment components (safety-separated circuit).

The entire drawn output must not exceed the maximum nom­inal output of the generator.

Do not operate the generator without a sound damper.

Transport

Setting up

Generating electricity

General Safety Regulations
General safety instructions

24 ESE 406 - 606 (D)HG-GT (ES) Duplex Status: August 2017

It is prohibited to operate the generator without air filters and
with an opened air filter cover.

It is prohibited to refill the generator's fuel tank during opera­tion.

It is prohibited to refill the fuel tank on the generator when it is
still hot.

Use filling aids for refuelling.

It is prohibited to clean the generator during operation.
It is prohibited to clean the generator when it is still hot.
Operating personnel may only carry out the maintenance or

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.
The maintenance intervals specified in these operating in-

structions must be observed.
It is prohibited to service the generator during operation.
It is prohibited to service the generator when it is still hot.
The generator should be put out of service if it is not required

for more than 30 days.
Store the generator in a dry and locked room.
Use a petrol additive to prevent resinous residues in the fuel

system.

One copy of these operating instructions must always be kept
in the generator’s manual compartment.

The operating instructions and the maintenance instructions
for the engine are integral parts of this instruction manual.

Refuelling

Cleaning

Maintenance and repair

work

Decommissioning

Documentation