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Endress ESE 1008 LG ES DIESEL DUPLEX SILENT, User Manual, Page: 49 / 57

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Endress ESE 1008 LG ES DIESEL DUPLEX SILENT User Manual Download Page 49

 

 

Maintenance

 

Checking

 the electrical safety 

 

 

Status at: April 2016

 

 

49

 

 

WARNING! 

The Endress battery is maintenance-free throughout its 
entire service life. 

 

Never open the battery 

— this may destroy it. 

 
 

 

7.3

 

Checking the electrical safety 

Only specifically authorised personnel may check the electri-
cal reliability. 

The electrical reliability must be checked in accordance with 
the applicable VDE regulations, EN and DIN standards and 
especially the current version of the BGV A3 accident pre-
vention regulations.

Summary of Contents for ESE 1008 LG ES DIESEL DUPLEX SILENT

Page 1: ...ESE 1008 LG ES DIESEL DUPLEX SILENT Article No 113035 ESE 1408 LG ES DIESEL DUPLEX SILENT Article No 113032 ...

Page 2: ...l 2016 2016 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 Manufacturer and p...

Page 3: ...panel components 24 3 4 Function and mode of operation 25 4 1 Transporting and setting up the generator 27 4 2 Fuelling 28 4 3 Start the device 30 4 4 Stop the device 31 4 5 Connecting up to consumers 31 4 6 Putting the generator out of service 32 4 7 Disposal 32 5 1 Insulation monitoring 33 5 2 FI circuit breaker 35 5 3 EcoTronic speed reduction 37 5 4 Radio impulse remote start remote start with...

Page 4: ...47 Figure 7 2 Replacing the battery 48 Fig 9 1 Generator dimensions 52 Fig 10 1 Replacementparts for the exhaust or generator side 55 Fig 10 2 Spare parts for the exhaust and or alternator side 56 List of tables Table 2 1 Danger zones and work areas on the generator 14 Table 5 1 Insulation monitoring plus switching off 33 Table 5 2 Insulation monitoring whilst running without switching off 34 Tabl...

Page 5: ...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 ____________________________________________...

Page 6: ...nd accessories In addition to the operating manual there are also the follow ing documents and standard accessories for the generator Motor operating manual see Figure 1 1 1 Oil drain hose see Figure 1 1 2 Exhaust gas adapter see Fig 1 1 3 Figure 1 1 Delivery documentation Accessories 1 2 3 ...

Page 7: ...aterials 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 a risk of an electric shock possibly with lethal consequenc es Poisonous substances This warning symbol indicates activities during which there is a risk of poisoning possibly with l...

Page 8: ...enerators are designed to operate electrical equipment with appropriate power output requirements Oth er applications can lead to injury to the operating personnel and to damage to the generator as well as other damage to equipment The majority of injuries and damage to equipment can be avoided if all instructions given in this manual and all instruc tions attached to the generator are followed Th...

Page 9: ... 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 2 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 outdo...

Page 10: ...ion of Con formity 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 confined areas Operation without the necessary safety redundancies Operation in existing power supply networks Refuelling when hot Refuelling during operation Spraying with high pre...

Page 11: ...age to the generator Material damage to other property Limited performance or functionality You can avoid existing residual risks by observing and fol lowing these guidelines The special warning notices on the generator The general safety instructions in this manual The special warnings in this manual Risk of death to persons at the generator can be caused by Incorrect use Inappropriate handling M...

Page 12: ...table 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 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 ...

Page 13: ...apter General Safety Regulations has understand the content of the chapter General Safe ty Regulations be able to use and implement the content of the chapter General Safety Regulations in practice be trained and instructed according to the rules of con duct in the event of a malfunction occurring have the physical and mental abilities to carry out his responsibilities tasks and activities on the ...

Page 14: ...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 person nel Radius of 1 0 m Operation Setting up Operating Radius of 5 0 m Refuelling Radius of 2 0 m Service and mainte nance Cleaning Radius of 1 0 m Shutting down Maintenance Table 2 1 Danger zones and work areas on the generator ...

Page 15: ...e fitted on the generator and be kept in a clearly legible condition Fig 2 1 Signs on the generator 1 Noise emission 5 Note on the hot surface 2 Generator model plate 6 Oil drainage note 3 Open flame prohibited note Fuel note 7 Reference note engine maintenance 4 Reference note read operating instruc tions 1 2 3 4 7 5 6 ...

Page 16: ...the generator 16 Version April 2016 Sign Name Noise emission Open flame prohibited Fuel note Reference note read operating instructions Generator model plate Motor maintenance note Note on the hot surface Table 2 2 Signs on the generator ...

Page 17: ...ices in the danger area of the generator 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 authori...

Page 18: ... 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 pow er network It is prohibited to establish a connection between existing neutral conduc...

Page 19: ...e generator s fuel tank during opera tion It is prohibited to refill the fuel tank on the generator when it is still hot Use filling aids for refuelling To prevent overflow do not fill the tank to the upper edge of the filler neck It is prohibited to clean the generator during operation It is prohibited to clean the generator when it is still hot Refuelling Cleaning ...

Page 20: ... manual for the engine should always 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 decommissioned if it is not required for more than 1 year see 4 6 Store the generator in a dry locked room A copy of these operating instructions must always be kept together with the generator ___________...

Page 21: ...General Safety Regulations General safety instructions Status at April 2016 21 Notes ...

Page 22: ...16 3 Description of the ESE 1008 LG 1408 DLG ES DIESEL DUPLEX SILENT 3 1 Components of the operating side Figure 3 1 Components of the operating and generator side 1 Control panel 4 Air intakes cooling vents always keep clear 2 Tank filler neck 5 Flap for engine below 3 Control panel flap 6 Transportation 1 2 3 4 5 6 ...

Page 23: ...L DUPLEX SILENT Components of the rear side Status at April 2016 23 3 2 Components of the rear side Figure 3 2 Components of the rear side 1 Flap engine 4 Air intakes cooling vents 2 Air filter 5 Cover battery 3 Oil filler neck 6 Exhaust outlet rear ...

Page 24: ...ircuit breaker 6 Operating hours counter 2 Schuko shockproof power sockets 7 Earthing 3 Oil pressure indicator light 8 3 pin CEE socket 4 Battery indicator light 9 3 pole CEE socket 1008 2x 5 pole CEE socket 1408 5 START STOP switch Figure above CON for remote start emergency power automatic control Figure above EMERGENCY STOP only for re mote start emergency power auto matic control ...

Page 25: ...ssembly is installed in a stable frame and equipped with a flexible low vibration suspension Splash proof earthed power and CEE sockets with a nominal voltage of 230 and or 400 V 50 Hz supply the power The generator is designed for mobile operation with one or several electrical consumers safety separated circuit ac cording to VDE 100 Part 551 The protective conductor of the ground contact socket ...

Page 26: ...Description of the ESE 1008 LG 1408 DLG ES DIESEL DUPLEX SILENT Function and mode of operation 26 Version April 2016 Notes ...

Page 27: ...ng device can crush hands or feet Take the weight of about 320kg into account Transport the device only with a crane or forklift as de scribed below Hang the crane s hooks in the generator s transport 1 hooks see Figure 3 1 5 Transport with the crane to the use location 2 Slowly lower the device and remove the hooks 3 The generator has been transported 4 Insert the fork on the device s long side 1...

Page 28: ...tched off Generator has cooled down Avoid open flames and sparks WARNING Leaking diesel fuel can contaminate soil and groundwa ter Do not fill the tank completely Use a filling aid WARNING Using the wrong fuel will destroy the engine Use only diesel fuel exact specification See engine operating manual Refuel the generator as follows Unscrew the fuel cap see Figure 3 1 2 from the filler neck 1 Guid...

Page 29: ...e see 1 Figure 4 1 3 Place hose for external refuelling canister with quick 2 connect coupling LP 006 see Figure 4 1 1 on coupling see Figure 4 1 2 External refuelling is activated Fuel delivery takes place in the area 1 3 1 2 of the whole volume of the tank Overfilling of the tank for a defect in the pump circuit is de tected by a second safety circuit This circuit operates for about 2 3 of the t...

Page 30: ... or disconnected WARNING Fuel can burn Prevent engine oil and diesel fuel from leaking Do not use starting aids Avoid open flames and sparks WARNING Exhaust gases can cause fatal asphyxiation Provide for sufficient ventilation Only operate the generator outdoors WARNING Hot parts can ignite flammable and explosive materials Avoid flammable materials at the operating site Avoid explosive materials ...

Page 31: ...as started 4 4 Stop the device Turn the START STOP switch seeFigure 3 3 8 all the 1 way to the left until the engine stops The generator is off 4 5 Connecting up to consumers Proceed as follows to connect appliances to the generator These requirements must be met generator started device switched off WARNING Electric shocks cause injury or death Do not earth the generator Do not connect protective...

Page 32: ...erve 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 Do not throw away used engine oil into the re f...

Page 33: ...bol Result Significance lights up red Circuit breaker jumps to Pos 0 and the generator cuts out Insulation monitoring is OK stays off Circuit breaker stays in Pos 1 and the generator continues to run Insulation monitoring is defective Table 5 1 Insulation monitoring plus switching off The insulation monitoring test has been run 4 The circuit breaker must be returned to Pos 1 after the test has bee...

Page 34: ...ult 34 5 kΩ stays off Circuit breaker stays in Pos 1 and the generator continues to run Connected unit is OK Table 5 2 Insulation monitoring whilst running without switching off If an insulation fault exists and the unit was previously OK when tested without a device connected see above the insulation fault has been caused by the device 2 After the device has been switched off and unplugged the ci...

Page 35: ...nforming to VDE 0100 540 can be used such as the main earth ing line in buildings WARNING The generator must be earthed In this special case the generator must be earthed The above mentioned safety warnings with other wording are not relevant for this special fitting 1 The effectiveness of this protective measure must be checked at least once a month by an electrical expert or if suitable measurin...

Page 36: ...ctivate the test switch seeFigure 5 2 10 The switch position displays the result seeFigure 5 2 20 Symbol Significance Position I Switch does not trigger FI circuit breaker defective Position 0 Switch triggers FI circuit breaker is working properly Table 5 3 Checking the FI circuit breaker The device has been tested in compliance with DIN VDE 0100 551 Checking the FI protection switch ...

Page 37: ...follows The following requirements must be met generator is ready for operation Fig 5 3 Speed reduction 1 Press the ECOTRONIC button Fehler Verweisquelle konnte nicht gefunden werden 1 once The green button lights up and is activated 2 The speed reduction is deactivated by pressing again Requirements Activate speed reduction ...

Page 38: ...supply Connect up the remote start device as follows with the CAN plug Fig 4 1 remote impulse start emergency power supply with CON Battery charging retention might occur simultaneously when using the remote start device 1 Insert plug for the remote start operating status genera tor connecting cable into the remote start socket and lock in place by turning to the right Remote start device is ready...

Page 39: ... cable remote operation The function of the multifunctional display E MCS 5 0 is de scribed in this section In order now to switch on the E MCS 5 0 the START button Figure 11 1 must be pressed once Fig 5 1 Multifunction display E MCS 5 0 The value can be read off in the lower part of the display The battery charging is monitored by the E MCS 5 0 and a fault message appears on the upper right in th...

Page 40: ...s be available Appliances switched off or disconnected 1 Press the START button Figure 11 1 once The E MCS 5 0 is started This is only necessary when the power supply was interrupted or the E MCS 5 0 is in Sleep mode 2 Press the START button Figure 11 1 a second time the green LED begins to flash 3 The engine starts after the preheating phase The engine has started The electrical devices can be co...

Page 41: ...D begins to flash The engine stops after the cooling run on period 3 Press the STOP button Figure 11 1 a second time the engine stops immediately without a cooling run on period not recommended The engine is stopped The generator cannot be started manually in AUTO mode WARNING We request that you only switch off the device using the EMERGENCY STOP switch in an emergency NOTE ...

Page 42: ... status using the multifunction display Switch off generator with E MCS 5 0 42 Version April 2016 6 2 1 Status query E MCS 5 0 Fig 6 1 Status query E MCS 5 0 Various values can be queried by pressing the arrow keys Figure 12 1 ...

Page 43: ...il level Battery too weak the battery charging has stopped functioning Call service staff Battery is defective Exchange the battery Alternator protection GCB fault Call service staff Alternator voltage is too high Call service staff Alternator voltage is too low Call service staff Alternator frequency is too high Call service staff Alternator frequency is too low Call service staff Generator start...

Page 44: ... 1 2 Adequate ventilation must always be available Appliances switched off or disconnected Remote start mode is activated as follows 1 Connect up the cable remote start 2 Press the AUTO button see Fig 11 1 so that remote start mode is activated Remote start mode is active 1 turn the switch on the cable remote start into Pos I the generator start the green RUN LED on the cable remote operation begi...

Page 45: ... 1 2 Adequate ventilation must always be available Appliances switched off or disconnected Remote start mode is activated as follows 3 Connect up the radio receiver 4 Press the AUTO button see Fig 11 1 so that remote start mode is activated Remote start mode is active 1 press the button on the radio impulse remote opera tion once the generator starts 1 press the button again The generator is off I...

Page 46: ...he engine manual 7 2 Maintenance work Only authorised personnel are allowed to carry out mainte nance tasks Perform all work in the maintenance plan according to the information in the motor s operating and maintenance manu al see Figure 1 1 2 7 2 1Drain the oil WARNING Leaking engine oil can contaminate soil and groundwa ter Use an oil collection container Recycle used motor oil WARNING Engine oi...

Page 47: ...e device Guide the drain hose seeFigure 7 1 1 through the open 3 ing in the frame and set the oil collection pan in place If present screw down the oil drain valve cap on the un 4 derside of the engine seeFigure 7 1 1 Put the oil collection pan in place Screw the drain hose 5 onto the oil drain valve on underside of the engine The valve opens and the motor oil flows into the collection tray The mo...

Page 48: ...attery back into the battery compartment 7 The battery cables must first be screwed onto the POSI TIVE terminal then onto the NEGATIVE terminal and then put on the terminal caps 8 Put the battery holder back 9 Put the cover plate back on The battery has been replaced WARNING A highly explosive electrolytic gas mixture develops from gassing when charging batteries Flames sparks an open light and sm...

Page 49: ... Never open the battery this may destroy it 7 3 Checking the electrical safety Only specifically authorised personnel may check the electri cal reliability The electrical reliability must be checked in accordance with the applicable VDE regulations EN and DIN standards and especially the current version of the BGV A3 accident pre vention regulations ...

Page 50: ...ntenance instructions The oil level monitor actuates Check oil level and refill if neces sary Too little fuel in the tank Refuel The fuel filter is clogged Replace the fuel filter Bad fuel in the tank Call service staff The engine does not rotate Engine defective Call service staff The engine smokes also see the motor manual Figure 1 1 2 Too much oil in the engine Drain excess oil Air filter cartr...

Page 51: ...Troubleshooting Checking the electrical safety Status at April 2016 51 Notes ...

Page 52: ...pecifications Checking the electrical safety 52 Version April 2016 9 Technical specifications The technical specifications concerning use of the generator are described in this section Fig 9 1 Generator dimensions ...

Page 53: ... capacity diesel fuel 35 35 l Length 1110 1110 mm Width 700 700 mm Height 870 870 mm Sound power level LWA 96 96 db A Sound power level LPA at 7 m 71 71 db A Sound power level at work loca tion LpA 88 88 db A Protection Class IP54 IP54 Table 9 1 Generator technical data Name Value Unit Setting up height above sea level 100 m Temperature 25 C Relative air humidity 30 Table 9 2 Ambient conditions fo...

Page 54: ...max line length Unit HO 7 RN F NSH öu 2 5 mm 2 100 m Table 9 4 Maximum line length of the distribution network as a function of the cable cross section measured in accordance with ISO 3744 Part 10 measured at a distance of 1 m and a height of 1 6 m in accordance with ISO 3744 Part 10 ...

Page 55: ...Generator Fig 10 1 Replacementparts for the exhaust or generator side Item Part number Quantity Article name 10 E505530 31 1 Frame centre beam 20 E505512 31 1 Generator hood 30 E130510 1 Bayonet tank cap size 40 40 E505528 31 1 Hinged lid for E box 50 E505987 31 1 Upper hood flap 60 E506715 00 1 Heat shield 70 E135411 1 Engine Lom12LD477 2 Die ES E133750 1 Alternator for IP54 10 20 30 40 50 60 70 ...

Page 56: ...2Electronics Fig 10 2 Spare parts for the exhaust and or alternator side Item Part number Quantity Article name 100 E130422 3 Hinged window 110 E131540 1 EMERGENCY STOP switch 120 E100039 3 250V 16A shockproof socket 130 ESE 1008 HG ES The Silent E130618 1 CEE socket 230V 16A 5P E132058 1 CEE socket 230V 32A 3P ESE 1408 DHG ES The Silent E130619 1 CEE socket 400V 16A 5P E130620 1 CEE socket 400V 3...

Page 57: ...gon bolt M 8 x 40 E130565 1 Hexagon nut M 8 E130563 1 Wing nut M 8 E130566 1 U washer 8 4 for M 8 E130567 1 Lock washer M 8 ESE 1008 LG ES DIESEL DUPLEX SILENT E130177 2 Circuit breaker 2B 16 2 pin E131914 1 Circuit breaker 2B 32 2 pin E133613 1 Circuit breaker 1B 40 1 pin ESE 1408 DLG ES DIESEL DUPLEX SILENT E132195 1 Circuit breaker 4B 20 4 pin 415V A C E134047 1 Circuit breaker similar to C16T4...

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