Endress ESE 1104 DBG ES FS DIN Operating Instructions Manual Download Page 17

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Status at:

January 2013

ESE 904 - 1304 DBG DIN

2.5 Danger zones and work areas

The danger zones work places (work areas) on the genera-
tor are determined by the activities to be performed within
the individual life cycles:

Life cycle

Activity

Danger zone

Work area

Transport

in the vehicle

Radius of 1.0 m

none

by the operating per-

sonnel

Radius of 1.0 m

Operation

Setting up

Operating

Radius of 5.0 m

Refuelling

Radius of 2.0 m

Service and

maintenance

Cleaning

Radius of 1.0 m

Shutting down

Maintenance

Table 2.1: Danger zones and work areas on the generator

Summary of Contents for ESE 1104 DBG ES FS DIN

Page 1: ...No 151003 ESE 904 DBG ES DIN Article No 151013 ESE 904 DBG ES FS DIN Article No 151023 ESE 1104 DBG ES DIN Article No 151015 ESE 1104 DBG ES FS DIN Article No 151025 ESE 1304 DBG ES DIN Article No 15...

Page 2: ...099 January 2013 2013 ENDRESS Elektroger tebau 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...

Page 3: ...ESE 904 1304 DBG DIN 25 3 1 Components of generator ESE 904 1304 DBG DIN 25 3 1 1 Components of the operating and alternator side 26 3 1 2 Exhaust and engine side components 27 3 1 3 Control panel com...

Page 4: ...nal start device 56 5 6 Battery charge conservation 57 5 7 3 way fuel tap fuelling device 60 5 8 Exhaust hose 63 6 Maintenance 65 6 1 Maintenance plan 65 6 2 Maintenance work 66 6 2 1 Charge battery 6...

Page 5: ...53 Fig 5 4 Remote start device with Harting plug 54 Fig 5 5 Remote start device with CAN plug 55 Fig 5 6 Connecting up an external start device 56 Fig 5 7 Connecting up the battery charge conservatio...

Page 6: ...able 8 2 Ambient conditions for the generator 78 Table 8 3 Generator performance reduction dependent on the ambient conditions 78 Table 8 4 Maximum line length of the distribution network as a functio...

Page 7: ...on 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 Ho...

Page 8: ...e generator Operating instructions and maintenance instructions for the engine Briggs Stratton Corporation Briggs Stratton Service Germany Briggs Stratton Corporation Circuit diagram for the generator...

Page 9: ...ol 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 dang...

Page 10: ...General information 10 ESE 904 1304 DBG DIN Status at January 2013 Notes...

Page 11: ...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 da...

Page 12: ...intenance 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 dist...

Page 13: ...nalysed and evaluated before beginning the design and planning of the ESE 804 1104 1304 DBG DIN generator were the residual risks identified using a risk anal ysis tool Structurally unavoidable residu...

Page 14: ...tor may be caused by 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 oc...

Page 15: ...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...

Page 16: ...afety Regulations in practice be trained and instructed according to the rules of con duct in the event of malfunctions occurring have the physical and mental abilities to carry out his responsibiliti...

Page 17: ...rformed within the individual life cycles Life cycle Activity Danger zone Work area Transport in the vehicle Radius of 1 0 m none by the operating per sonnel Radius of 1 0 m Operation Setting up Opera...

Page 18: ...equalization earthing for FI 6 Reference note read operating in structions 2 Motor model plate 7 Short operating instructions interior Reference note regarding short oper ating instructions exterior...

Page 19: ...tential equalization earthing for FI Reference note hot surface Reference note ca ble extension Reference note fuel note Reference note read operating instructions Short operating in structions inner...

Page 20: ...s on the generator must be in place and in a clearly legible condition The operational reliability and functionality must be checked before and after each use operation The generator must only be used...

Page 21: ...tor s danger zone Open flames and light are prohibited in the generator s dan ger zone Consumption of alcohol drugs medications or other mind altering substances is prohibited The authorised personnel...

Page 22: ...and or equipment components safety separated circuit The entire drawn output must not exceed the maximum nom inal output of the generator Do not operate the generator without a sound damper It is pro...

Page 23: ...t 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...

Page 24: ...24 ESE 904 1304 DBG DIN Status at January 2013 Notes...

Page 25: ...N The components and functionality of the generator are de scribed in this section 3 1 Components of generator ESE 904 1304 DBG DIN The generator components are distributed on all four sides Fig 3 1 V...

Page 26: ...ents of the operating and alternator side Fig 3 2 Components of the operating and alternator side 1 Generator lid 5 Tank 2 Generator 6 Electrical compartment 3 Potential equalisation screw for an opti...

Page 27: ...side components Fig 3 3 Exhaust and engine side components 1 Air filter 7 Spark plug connector 2 Tool pouch 8 Oil dipstick 3 Briggs Stratton engine 9 Exhaust 4 Carrying handle 10 Exhaust heat shield...

Page 28: ...rol panel components 1 Hinged window 6 START STOP switch 2 Line circuit breaker 7 Emergency OFF button 3 Multi function control display 8 Signal tone speaker 4 Shockproof attachment sockets 230 V AC 9...

Page 29: ...plug wrench 4 Test probes 2 User information operating instruc tions for the engine as well as these operating instructions 5 Spark plugs 2x 3 Testing cable Fig ure abo ve Oil channel 3 1 4 2 Special...

Page 30: ...kproof and CEE sockets with a nominal voltage of 230V and or 400V 50 Hz supply the power An integrated voltage regulator controls the voltage of the alternator in the nominal speed range of the altern...

Page 31: ...Status at January 2013 ESE 904 1304 DBG DIN 31 Notes...

Page 32: ...accessory see 3 1 4 2 is not attached At least one person per carrying handle WARNING A slipping or falling device can crush hands or feet Keep the device s weight in mind about 125 to 155 kg dependin...

Page 33: ...follows 1 Prepare the work site 2 Transport the generator to the operating site 3 Attach the exhaust hose if necessary a special accesso ry see 3 1 4 2 The alternator is set up and ready for use 4 3...

Page 34: ...ely Use a filling aid WARNING The wrong fuel destroys the motor Use only lead free ROZ 95 premium petrol Refuel the generator as follows 1 Set the fuel cock to closed Fig 5 10 1 as necessary 2 Unscrew...

Page 35: ...disconnected WARNING Operating fluids can burn or explode Prevent leaking of engine oil and petrol Do not use starting aids Avoid open flames and sparks WARNING Exhaust gases can cause fatal asphyxia...

Page 36: ...36 ESE 904 1304 DBG DIN Status at January 2013 Fig 4 1 Actuate manual choke Fig 4 2 Standard design of operating panel Fig 4 3 Emergency starting the pump...

Page 37: ...warming up phase of about one minute WARNING Devices with a remote start device are fitted with an automatic choke You do not need to use the manual choke on the motor 1 Covering hood Fig 3 3 13 compl...

Page 38: ...the fuel cock to closed Fig 5 10 1 as necessary 5 Allow the device to cool down The generator is switched off WARNING In an emergency the generator can be stopped by pressing the emergency OFF switch...

Page 39: ...ductor to an existing po tential equalisation line Do not connect the generator to an existing electrical grid You can connect devices using Schuko or CEE sockets Fig 4 4 Connecting up consumers appli...

Page 40: ...y or death Do not earth the generator Do not connect protective conductor to an existing po tential equalisation line Do not connect the generator to an existing electrical grid Fig 4 5 Check the prot...

Page 41: ...IN 41 Test lamp Meaning lights up green protective conductor is OK stays off Protective conductor defective not present Table 4 1 Protective conductor test lamp The protective conductor potential equa...

Page 42: ...or goes dark To bring the E MCS 4 0 back into a ready to operate condition again the START STOP switch must first be turned into the position STOP The display intensity is dependent on the ambient bri...

Page 43: ...the genera tor must be switched off Only active if the special Warning signal II Firecan option is fitted If the display glows red see Fig 4 6 12 then the generator s recharging function is not workin...

Page 44: ...h display is red then the frequency is too high If the low display is red then the frequency is too low The single L1 to L3 phases see Fig 4 6 18 are displayed separately Voltage U see Fig 4 6 17 If t...

Page 45: ...of 10 10 80 green 80 100 yellow and 100 110 red If the OFF symbol glows red see Fig 4 6 4 and the buzzer sounds the EMERGENCY OFF button has been pressed The buzzer can be acknowledged using the ackn...

Page 46: ...ot simply be thrown into the refuse bin Observe all local laws and regulations concerning correct disposal of such parts and substances Your author ised ENDRESS generator dealer is happy to advise you...

Page 47: ...Status at January 2013 ESE 904 1304 DBG DIN 47 Notes...

Page 48: ...ce conforming 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 safe...

Page 49: ...te the test switch seeFig 5 1 10 The switch position displays the result seeFig 5 1 20 Symbol Meaning Position I Switch does not trigger FI protection switch is defec tive Position 0 Switch triggers F...

Page 50: ...st button see Fig 5 2 1 The displayed symbol see Fig 4 6 9 indicates the re sult the buzzer also sounds for insulation monitoring with this and it can be acknowledged over the acknowledge ment button...

Page 51: ...sed by the device 2 The reset button see Fig 5 2 2 must be pressed after switching off and disconnecting the device so that the unit can be operated again Action Operation Press once Acknowledge the b...

Page 52: ...can be used again 1 Plug in the consumer and switch on The displayed symbol see Fig 4 6 8 and the position of the circuit breaker indicate the result Symbol Significance lights up red Insulation faul...

Page 53: ...LED lights up green Idle down is activated The idling speed reduction is active for about 5 minutes after engine start and then lowers the rotational speed of the en gine in as far as no load is enga...

Page 54: ...start Connect up the remote start device as follows with the Harting socket Fig 5 4 Remote start device with Harting plug Battery charging retention might occur simultaneously when using the remote s...

Page 55: ...with CAN plug 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 s...

Page 56: ...external energy source connecting cable e g starter battery external start socket into the external start socket and lock in place by turning to the right External start device is ready for use The en...

Page 57: ...for the starter battery charge conservation device 2 Insert plug for the external energy source e g a battery charging device charge conservation device socket connecting cable and lock in place by t...

Page 58: ...ttery charging device charge conservation device socket connecting cable and lock in place by turning to the right The battery charge conservation device is ready to oper ate Disconnect the battery ch...

Page 59: ...battery charging device charge conservation device socket connecting cable in place The battery charge conservation device is ready to oper ate Disconnect the battery charge conservation device as fol...

Page 60: ...e devices own tank and the fuelling device Fig 5 10 3 way fuel tap Switch position Operation 1 CLOSED 2 OWN TANK 3 EXTERNAL FUELLING Table 5 6 Switchingpositions of the 3 way fuel tap Establish a conn...

Page 61: ...ling device as follows 1 Pull off cover plugs from quick action coupling 2 Place the quick action coupling Fig 5 11 1 on the exter nal fuelling connection Fig 5 11 2 3 The quick action coupling engage...

Page 62: ...ister is attached Change an empty canister during operation as follows 1 Place the full canister next to the empty canister 2 Open sealing cap on the full canister 3 Set the fuel cock to the internal...

Page 63: ...s can cause fatal asphyxiation Provide for sufficient ventilation Use an exhaust gas hose Only operate the alternator outdoors Fig 5 12 Connecting the exhaust hose Connect up the exhaust hose as follo...

Page 64: ...January 2013 Disconnect the exhaust hose from the generator by 1 Turn the exhaust hose grip to the left 2 Pull the exhaust hose off the muffler s exhaust hose con nection Exhaust hose is now disconnec...

Page 65: ...l ly every 100 h annual ly annual ly Checking the electrical safety before each start up Checking the oil X Change the oil X3 X 1 Change oil filter X Cleaning the air filter X 2 Clean area around muff...

Page 66: ...Charge battery Charge the battery according to the handling regulations supplied by the manufacturer see 1 1 in order to maximise service life 6 2 2 Replacing the starter battery 1 Unscrew the batter...

Page 67: ...assing when charging batteries Flames sparks an open light and smoking are prohibit ed Avoid sparks when handling cables and electrical devic es as well as electrostatic discharge Avoid short circuits...

Page 68: ...clean cloth 2 Reinsert the dipstick and take it out again Drain off some of the oil if the level is above the upper mark and refill with oil if the level is under the lower mark see below The oil leve...

Page 69: ...at an angle of 30 5 Unscrew the oil drainage screw Fig 6 3 1 and allow the oil to drain completely Engine oil has been drained 6 Screw in the oil drainage screw again 7 Then refill with fresh oil The...

Page 70: ...tart socket socket charging retention and or remote start de vice 1 Open the fuse holder 2 Replace a fuse 3 Close the fuse holder The fuse has been replaced Fig 6 4 Replacing a fuse Fuse type Amperes...

Page 71: ...ety Only appropriately authorised personnel may check the elec trical reliability The electrical reliability must be checked in accordance with the applicable VDE regulations EN and DIN standards and...

Page 72: ...is defective Call service staff Strong voltage fluctuations occur The engine runs irregularly Call service staff The speed control works er ratically or insufficiently Call service staff The engine d...

Page 73: ...ov er are clogged Clean ventilation holes The oil level is too low Add oil The fuel filter is clogged Replace the fuel filter The engine splutters The 20 litre standard contain er is empty Change the...

Page 74: ...art equipment fuse is defective Replace the fuse The engine does not start in external start mode The external start equipment plug is not inserted properly Insert the external start equipment plug co...

Page 75: ...Status at January 2013 ESE 904 1304 DBG DIN 75 Notes...

Page 76: ...76 ESE 904 1304 DBG DIN Status at January 2013 8 Technical specifications The technical specifications concerning use of the generator are described in this section Fig 8 1 Generator dimensions...

Page 77: ...30 230 V Rated current 3 11 5 15 9 17 3 A Rated current 1 21 7 26 1 30 4 A Voltage tolerance idling nominal output 5 5 5 Weight ready for use 124 147 148 kg Tank capacity lead free normal ROZ91 fuel 1...

Page 78: ...on the ambient conditions Line max line length Unit HO 7 RN F NSH u 1 5 mm2 60 m HO 7 RN F NSH u 2 5 mm2 100 m Table 8 4 Maximum line length of the distribution network as a function of the cable cro...

Page 79: ...Status at January 2013 ESE 904 1304 DBG DIN 79 Notes...

Page 80: ...generator are de scribed in this section The alternator is divided into these component groups Frame with covers tank and engine Generator and electronics Standard accessories Special accessories Spec...

Page 81: ...andle black E130579 4 Inset handle made of soft PVC E133316 4 Plastic end cap for pipe 25 2 40 151003 1 Generator tank yellow 50 151003 2 Earth strap copper 60 E133301 4 Vibration dampers D40x40 M8 70...

Page 82: ...Protective cap for battery terminal 140 163040 1 Battery 12V 18A for electrical starting only 150 151003 1 Generator 160 E502114 90 1 Air baffle plate 170 E502085 10 1 Manual compartment 180 E502111 1...

Page 83: ...ngine Vanguard 16HP for ESE 804 DBG ES DIN E131589 1 Engine Vanguard 20HP for ESE 1104 DBG ES DIN E131590 1 Engine Vanguard 22HP for ESE 1304 DBG ES DIN 310 692519 1 Paper filter 692520 1 Pre filter 3...

Page 84: ...rator fan blade 600 E131433 1 Generator regulator for 8 5kVA 13kVA 610 E134151 E134152 2 conductor through clamp 4 conductor through clamp 620 E130975 Mini changer relay 630 E131799 1 Noise filter 700...

Page 85: ...1 Line circuit breaker ESE 1304 DBG ES DIN E134046 3 Line circuit breaker E134047 1 Line circuit breaker 780 E500762 90 1 Mounting rail housing 1 RAL 9005 E500763 90 1 Mounting rail housing 2 RAL 900...

Page 86: ...9 5 Replacement parts for fuses Position Part number Quantity Item designation 800 E132672 1 Flat fuse holder E132680 1 Flat fuse insert 20 A DIN 72581 Part 3 E132735 1 Flat fuse insert 15 A DIN 72581...

Page 87: ...used 910 E130545 1 Test probes 920 E130446 1 100 cm measuring line 930 1 Engine operating manual B S 940 E130534 1 Spark plug wrench 1000 E100592 1 Fuelling device special accessory 1010 E100593 1 20...

Page 88: ...88 ESE 904 1304 DBG DIN Status at January 2013 Fig 9 7 Replacement parts forspecial accessories...

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