Endress ESE 1107 DBG DIN Operating Instructions Manual Download Page 10

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ESE 807 / 1107 / 1307 / 1407 DBG (ES) DIN

Status at:

February 2013

Notes

Summary of Contents for ESE 1107 DBG DIN

Page 1: ...CTIONS ESE 807 DBG DIN Article No 151203 156203 ESE 807 DBG ES DIN Article No 151213 156213 ESE 1107 DBG DIN Article No 151215 156215 ESE 1307 DBG DIN Article No 151216 156216 ESE 1407 DBG DIN Article No 151219 156219 ...

Page 2: ...4022 February 2013 2013 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 Manufa...

Page 3: ...Description of the generator ESE 807 1407 DBG ES DIN 26 Views of the generator 26 3 1 3 1 1 Components on the operating and engine side 27 3 1 2 Components on the exhaust and generator side 28 3 1 3 Control panel components 29 3 1 4 Accessory components 30 Function and mode of operation 31 3 2 4 Operating ESE 807 1407 DBG ES DIN 33 Transporting the generator 33 4 1 Setting up the generator 33 4 2 ...

Page 4: ...il 63 6 2 2 Replacing the starter battery 66 6 2 3 Replacing fuses 67 Checking the electrical safety 68 6 3 7 Troubleshooting 69 8 Technical specifications 73 List of illustrations Fig 2 1 Signs on the generator 18 Fig 3 1 Views of the generator 26 Fig 3 2 Components on the operating and engine side 27 Fig 3 3 Components on the exhaust and generator side 28 Fig 3 4 Control panel components 29 Fig ...

Page 5: ...he generator 17 Table 2 2 Signs on the generator 20 Table 4 1 Protective conductor test lamp 42 Table 5 1 FI protection switch test 49 Table 5 2 Insulation monitoring without switching off 50 Table 5 3 Insulation monitoring whilst running without switching off 51 Table 5 4 Switchingpositions of the 3 way fuel tap 58 Table 6 1 Generator maintenance plan 62 Table 6 2 Location of the fuses 67 Table 7...

Page 6: ...Table of Contents 6 ESE 807 1107 1307 1407 DBG ES DIN Status at February 2013 These instructions do not include technical modifications that occurred after printing ...

Page 7: ...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 ______________________________________...

Page 8: ...nerator Operating instructions and maintenance instructions for the engine Briggs Stratton Corporation Important safety information and instructions for engine selection engine installation engine operation Briggs Stratton Corporation Briggs Stratton Service Germany Briggs Stratton Corporation Test protocol for the power generator Maintenance instructions for the battery Circuit diagram for the ge...

Page 9: ...erials 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 conse quences Poisonous substances This warning symbol indicates activities during which there is the danger of poisoning possibly ...

Page 10: ...General information 10 ESE 807 1107 1307 1407 DBG ES DIN Status at February 2013 Notes ...

Page 11: ...ors 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 The gene...

Page 12: ...r early damage identifica tion Failure to replace wearing parts Incorrectly performed maintenance or repair work Defectively performed maintenance or repair work Unintended use Intended use 2 2 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 indicat ed voltage output and nominal rpm r...

Page 13: ... in these operating instructions is considered for bidden incorrect use and is outside the legal limits of the manufacturer s liability 2 2 1 Residual risks The points analysed and evaluated before beginning the design and planning of the ESE 807 1407 DBG ES DIN generator were the residual risks identified using a risk anal ysis tool Structurally unavoidable residual risks during the entire ser vi...

Page 14: ...ersons 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 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 handli...

Page 15: ...ncorrect 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 Material damage to other property Limits to performance or f...

Page 16: ...neral 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 generator be trained and instructed in his responsibilities tasks and activities on the alternator have understood the technical documentation concerning his res...

Page 17: ...es 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 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 ...

Page 18: ... Fig 2 1 Signs on the generator 1 Reference note noise emission 6 Cable extension 2 Reference note maintenance inter vals inner side 7 Reference note read operating in structions 3 Reference note three way valve 8 Reference note no naked flames 4 Reference note Hot surface 9 Short operating instructions 5 Potential equalisation screw earthing for an optional FI 10 Nameplate ...

Page 19: ...07 DBG ES DIN 19 Sign Name Reference note noise emission Reference note maintenance intervals External refuelling Potential equalization earthing for FI Note Line extension Reference note read operating instructions Reference note no naked flames ...

Page 20: ...20 ESE 807 1107 1307 1407 DBG ES DIN Status at February 2013 Sign Name Short operating in structions Note EMERGENCY STOP Nameplate Table 2 2 Signs on the generator ...

Page 21: ...n the generator s danger zone 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 personn...

Page 22: ...ndles pro vided The generator is to be carried by at least one person per carrying 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 sta...

Page 23: ...structions 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 ...

Page 24: ... this instruction manual The packaging material must be recycled according to the environmental protection regulations applicable at the place of use The workplace must be protected against contamination by leaking operating fluids Used or leftover fuels and lubricants must be recycled ac cording to the environmental regulations applicable at the place of use Environmental protection ...

Page 25: ...Status at February 2013 ESE 807 1107 1307 1407 DBG ES DIN 25 Notes ...

Page 26: ...ES DIN The components and functionality of the generator are de scribed in this section Views of the generator 3 1 The generator components are distributed on all four sides The standard equipment is described here Fig 3 1 Views of the generator 1 Control side 3 Exhaust gas side 2 Engine side 4 Generator side ...

Page 27: ...ting and engine side Fig 3 2 Components on the operating and engine side 1 Upper flap 5 Mounting holes according to DIN 14685 2 Hinged window circuit breaker 6 Filler neck 3 Storage compartment for operating instructions standard accessories 7 Engine spark plug 4 Carrying handle 8 Side flap ...

Page 28: ... exhaust and generator side Fig 3 3 Components on the exhaust and generator side 1 Air filter cover 6 Storage compartment 2 Oil filler neck 7 Spark plug connector 3 Recoil starter 8 Oil dipstick 4 Carrying handle 9 Exhaust 5 Connection for external refuelling 3 way valve 10 Upper flap ...

Page 29: ...ol panel components 1 Circuit breaker hinged window un der the upper flap 5 EMERGENCY STOP switch 2 Socket for protective earthing con ductor test 6 Schuko socket 230V 3 Multifunction display E MCS 3 0 7 Potential equalization connection for optional FI to earthing 4 START STOP switch 8 CEE socket 400 V 3 ...

Page 30: ... 1 Spark 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 Figure above Oil channel 3 1 4 2 Special accessories Fig 3 6 Components of the special accessories 1 Fuelling device 3 Exhaust hose DN 50 1500 mm 2 20 litre standard container according to DIN 14572 ...

Page 31: ...50 Hz supply the power On some models the engine rotational speed control cen trifugal governor is supported at high loads by a special performance management module Maxdrive An integrated voltage regulator controls the voltage of the generator in the nominal speed range of the generator The generator is designed for mobile operation with one or several electrical consumers safety separated circui...

Page 32: ...32 ESE 807 1107 1307 1407 DBG ES DIN Status at February 2013 Notes ...

Page 33: ...haust hose a special 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 Take the weight into account about 130 150 kg Carry the alternator using at least one person per carry ing handle Only lift the alternator by the carrying handles Lift lower the alternator evenly Walk slowly 1 Unfold carrying handles 2 Lift...

Page 34: ...ite WARNING Leaking engine oil and petrol can contaminate the soil and groundwater Prevent leaking of engine oil and petrol Set up the generator as follows 1 Prepare the work site 2 Transport the generator to the work site 3 Attach the exhaust hose if necessary a special accesso ry see 3 1 4 2 The generator is set up and ready for use Refuelling the generator 4 3 Proceed as follows to refuel the g...

Page 35: ... engine oil can contaminate the soil and groundwater Do not fill the tank completely Use a filling aid WARNING Using the wrong fuel will destroy the engine 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 tank cover 3 Insert filler aid into the filler neck 4 Add petrol 5 Remove filler aid 6 Screw on tank cap Th...

Page 36: ...ds 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 asphyxiation Provide for sufficient ventilation Use an exhaust gas pipe 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 37: ... 1 Open the flap side see Fig 4 1 2 2 Pull on the manually operated choke Fig 4 1 2 com pletely for a cold engine appropriately less for a warm engine and hold firmly 3 Turn the START STOP switch Fig 4 2 2 completely to the right into the position START until the engine starts and then release The motor starts ELECTRICAL START NOTE ...

Page 38: ...1 4 Advance engine at the handgrip of the reversing starter Fig 3 3 3 Support oneself with one hand on the device grip in order to simplify advancing the engine The motor starts 5 Move the choke slowly back into its start position The engine has started WARNING Devices with a remote start device are fitted with an automatic choke You do not need to use the manual choke on the engine 1 Set the STAR...

Page 39: ...Status at February 2013 ESE 807 1107 1307 1407 DBG ES DIN 39 The motor starts 5 Release the choke The engine has started ...

Page 40: ...or to cool down The device is switched off as follows 1 Switch off or disconnect devices 2 Continue to run the engine for about two minutes 3 Set the START STOP switch Fig 4 2 1 to position 0 We request that you only switch off the device using the EMERGENCY STOP switch in an emergency Switch off using the EMERGENCY STOP switch only interrupts the ignition so it is still possible for fuel to ignit...

Page 41: ...ective earthing conductor tested see 4 7 device switched off WARNING Electric shocks cause injury or death Do not earth the generator except for special option FI Do not connect protective conductor 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 3 Connecting up to consumers Requiremen...

Page 42: ...ductor 1 Insert test cable into socket Fig 4 4 2 2 Hold a test tip an a metallic blank location on the device The test lamp Fig 4 4 1 on the multifunction display shows the result Test lamp Significance 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 equalization for this dev...

Page 43: ...in the START STOP switch must first be turned into the position STOP The display intensity is dependent on the ambient brightness sensor see Figure 4 5 5 Fig 4 5 Multi functional display Displayed see Fig 4 55 1 when the generator has started or is activated for 30 seconds when the START STOP switch is turned to the Operate position If the display is red see Fig 4 55 16 whilst the generator is run...

Page 44: ...red then the charge voltage of the al ternator is too high If the display lights up red see Fig 4 55 9 or if the buzzer sounds then there is an insulation fault present see Chapter 5 Insulation monitoring Only active for an ordered insulation monitoring standard for DIN If the display glows green see Fig 4 55 10 during the protec tive earth lead test see chapter 4 7 Protective earth lead test the ...

Page 45: ...tilisation will be displayed in 10 steps for 3 phase loads 10 80 green 80 100 yellow and 100 110 red If the display is red for single phase utilisation asymmetric load then the load should be distributed evenly over the 3 existing phases Load P see Figure 4 5 7 For a 1 and 3 phase load the total load on the generator is displayed in steps of 10 10 80 green 80 100 yellow and 100 110 red If the OFF ...

Page 46: ...etc cannot 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 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 dispo...

Page 47: ...Status at February 2013 ESE 807 1107 1307 1407 DBG ES DIN 47 Notes ...

Page 48: ...earthing device conforming to VDE 0100 540 can be used such as the main earthing 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 ...

Page 49: ...on 1 3 Activate the test switch seeFig 5 1 10 The switch position displays the result seeFig 5 1 20 Symbol Significance Position I Switch does not trigger FI protection switch is defec tive Position 0 Switch triggers FI protection switch is working proper ly Table 5 1 FI protection switch test The device has been tested in compliance with DIN VDE 0100 551 Checking the FI protection switch ...

Page 50: ...tarted see 4 4 1 Unplug the device 2 Press the test button see Fig 5 2 2 The displayed symbol see Fig 4 5 8 indicates the result Symbol Significance lights up red The buzzer sounds Insulation monitoring is OK stays off Insulation monitoring is defective Table 5 2 Insulation monitoring without switching off The insulation monitoring test has been run 3 The reset button see Fig 5 2 1 must be pressed...

Page 51: ...ected unit is OK Table 5 3 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 insula tion monitoring above the insulation fault has been caused by the device 2 The reset button see Fig 5 2 1 must be pressed after switching off and disconnecting the device so that the unit can be operated...

Page 52: ...ngages 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 engaged to about 1800 rpm The engine speed will be increased to the nominal speed as soon as a load is switched on The engine always runs within the nominal speed range if the rocker switch is in th...

Page 53: ...ectrical 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 start device 1 Fold away any protective caps on the remote start socket after unlocking the clip Fig 5 4 2 2 Plug the remote start operating status generator con necting cable into the remote s...

Page 54: ...start device 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 start socket and lock in place by turning to the right Remote start device is ready for use Disconnect the remote start device as follows 1 Release the plug by turning to the left and then...

Page 55: ...or the 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 engine can be started using the electrical start Disconnect the external start device as follows 1 Release the plug by turning to the left and then pull the external energy source external start ...

Page 56: ...nnecting up the battery charge retention device 1 Unscrew cover Fig 5 7 2 for socket Fig 5 7 1 for the starter battery charge conservation device 2 Insert plug for the external energy source e g a battery charging device charge retention device socket con necting cable and lock in place by turning to the right The battery charge conservation device is ready to oper ate Connect up the battery charg...

Page 57: ...device socket con necting cable and lock in place by turning to the right The battery charge conservation device is ready to oper ate Connect up the battery charge conservation device MagCode socket as follows Fig 5 9 Connecting up the battery charge retention device 1 Put plug for the external energy source e g a battery charging device charge retention device socket con necting cable in place Th...

Page 58: ...operation 3 way fuel valve In the course of supplying fuel you can select between the device s own tank and the refuelling device Fig 5 10 3 way fuel valve Switch position Operation 1 EXTERNAL REFUELLING 2 OWN TANK 3 CLOSED Table 5 4 Switchingpositions of the 3 way fuel tap Establish a connection to the fuel supply system as follows 1 Set the fuel valve to the required fuelling mode The fuel suppl...

Page 59: ... up fuelling device as follows 1 Pull off cover plugs from quick action coupling 2 Place the quick action coupling on the external refuelling connection 3 The quick action coupling engages The fuelling device is attached Disconnect fuelling device from the generator by 1 Pull back the knurled sleeve on the quick action coupling The coupling is released 2 Pull off quick action coupling with hose fr...

Page 60: ...e full canister next to the empty canister 2 Open sealing cap on the full canister 3 Set the fuel cock to the internal tank Fig 5 10 2 The engine is supplied with fuel over its own tank 4 Loosen the fuelling device latch on the canister 5 Remove hose 6 Introduce hose into the full canister 7 Engage catch on the fuelling device The canister is attached 8 Set the fuel cock to external fuelling Fig 5...

Page 61: ...the generator outdoors Fig 5 11 Connecting the exhaust hose Connect up the exhaust hose as follows 1 Push the exhaust hose s grip with the larger opening onto the muffler s connection 2 Turn the exhaust hose to the right to lock it in place Exhaust hose is now plugged in Disconnect the exhaust hose from the generator by 1 Turn the exhaust hose grip to the left 2 Pull the exhaust hose off the muffl...

Page 62: ...l ly every 50 h annual ly every 100 h annual ly annual ly Checking the electrical safety before each start up Checking the oil X Changing the oil X 1 X Change oil filter X Cleaning the air filter X2 Clean area around mufflers linkages and springs X Exchange spark plugs X Change the fuel filter X Check fit of screws nuts and bolts X Check condition and tightness of the fuel hoses and connec tions X...

Page 63: ...ions 6 2 1 Motor oil WARNING Leaking engine oil can contaminate soil and groundwa ter Use an oil collection container Recycle used motor oil WARNING Engine oil can be hot risk of burns Allow motor to cool The following requirements must be met The engine should ideally be slightly warm allow a cold engine to run for 5 min then stop it and allow it to cool for 2 min Fig 6 1 Oil dipstick Check the o...

Page 64: ...per mark and refill with oil if the level is under the lower mark The oil level has been checked Pour in oil as follows 1 Remove oil screw plug Fig 6 1 1 Pull out the dipstick for easier filling Fig 6 1 2 2 Fill with oil using a filling aid 3 Check oil level and add oil if necessary The engine has been refilled with oil Fig 6 2 Change the oil Refilling with oil ...

Page 65: ...s off completely 4 Screw in the oil drainage screw again Attach the side plate again 5 Then pour in new oil as already described The engine oil has been changed WARNING The oil escapes immediately after opening the oil drain age valve The procedure is as described in the operating instructions for the engine To do this the side plate on the generator must be unscrewed and the flap must be opened C...

Page 66: ...minal Battery is disconnected Fig 6 3 Replacing the battery 4 Prepare a new battery 5 The battery cables must first be screwed onto the POSI TIVE terminal then onto the NEGATIVE terminal and then put on the terminal caps 6 Put the battery back into the battery compartment 7 Put the battery holder back The battery has been replaced WARNING A highly explosive electrolytic gas mixture develops from g...

Page 67: ...ing fuses Replacing fuses only for the special accessory external start 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 needed for 2 20 Control system 2 15 Charging retention socket 1 150 External start Nato socket Table 6 2 Location of the fuses ...

Page 68: ...l safety 6 3 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 69: ...r 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 does not start The engine is being operated incorrectly Follow the engine operating manual instructions Maintenance of the engine was inadequate Follow the engine mainte nance instructions The oil lev...

Page 70: ... The fuel filter is clogged Replace the fuel filter The engine splutters The 20 litre standard contain er is empty Change the canister The refuelling device s sieve is blocked Clean the sieve Carburettor fuel filter tank are covered with resin Call service staff The power output is insuffi cient The electronic controller has been altered Call service staff The electronic controller is defective Ca...

Page 71: ...in external start mode The external start equipment plug is not inserted properly Insert the external start equipment plug correctly The high performance exter nal start fuse is defective Replace the fuse The battery is not charging in charge retention mode The charge retention plug is not inserted properly Insert the charge retention plug correctly The charge retention fuse is defective Replace t...

Page 72: ...72 ESE 807 1107 1307 1407 DBG ES DIN Status at February 2013 Notes ...

Page 73: ...tus at February 2013 ESE 807 1107 1307 1407 DBG ES DIN 73 8 Technical specifications The technical specifications concerning use of the generator are described in this section Fig 8 1 Generator dimensions ...

Page 74: ...ed current 1 21 7 26 1 A Voltage tolerance idling nominal out put 5 5 Weight ready for use 130 150 kg Tank capacity lead free normal ROZ91 fuel 22 22 l Length 820 820 mm Width 440 440 mm Height 580 580 mm Sound power level LWA 94 95 db A Sound pressure level LPA at a distance of 7 m 69 70 Sound pressure at the work place LPA 1 6m above the machine 1m distance 86 87 db A Protection Class IP 54 IP 5...

Page 75: ...17 3 19 1 A Rated current 1 30 4 30 4 A Voltage tolerance idling nominal out put 5 5 Weight ready for use 150 150 kg Tank capacity lead free normal ROZ91 fuel 22 22 l Length 820 820 mm Width 440 440 mm Height 580 580 mm Sound power level LWA 94 94 db A Sound pressure level LPA at a distance of 7 m 69 69 Sound pressure at the work place LPA 1 6m above the machine 1m distance 86 86 db A Protection C...

Page 76: ...nt on ambient conditions Line max line length Unit HO 7 RN F NSH öu 1 5 mm2 60 m HO 7 RN F NSH öu 2 5 mm2 100 m Table 8 3 Maximum line length of the distribution network as a function of the cable cross section The general limitation of 100 m for the overall length was selected in the interest of safe handling during practical use Larger dimensioning of the distribution network is only to be under...

Page 77: ...Status at February 2013 ESE 807 1107 1307 1407 DBG ES DIN 77 Notes ...

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