Endress ESE 406 HG-GT ES DUPLEX Operating Instructions Manual Download Page 73

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Replacement parts

Status at: August 2017

ESE 406 - 606 (D)HG-GT (ES) Duplex

Item

Article name

Engine

Silencer

Hinged window No. 40978

Gen syn.

G gram BG2

110

G tank V02

120

M-side panel R

130

M-side panel L

180

Carrying handle, black

Inset handle made of soft PVC

KAPSTO sealing cap

350

Vibration damper Form B

400

12V/20Ah battery

690

Operating instructions for the 406-606

Table 9.1: Replacement parts for the frame / engine / generator

Summary of Contents for ESE 406 HG-GT ES DUPLEX

Page 1: ...6 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...

Page 2: ...er de E135793 August 2017 i04 2017 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...

Page 3: ...ation 203 032 before performing the first commissioning In cases of doubt consult a qualified electrician Operation of the generator on construction and assem bly locations according to DGUV Informati...

Page 4: ...ction 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...

Page 5: ...alifications 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 generat...

Page 6: ...ent 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...

Page 7: ...ure 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 gen...

Page 8: ...do not always comply completely with the actual design in particular with re gard to the colour and are to be considered a representation of basic principles We reserve the right to make modification...

Page 9: ...void 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 stan...

Page 10: ...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...

Page 11: ...ances 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...

Page 12: ...General information Safety symbols 12 ESE 406 606 D HG GT ES Duplex Status August 2017 Notes...

Page 13: ...ning 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 ge...

Page 14: ...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...

Page 15: ...dling Foreseeable incorrect use or inappropriate handling of the generator nullifies the manufacturer s EC Declaration of Con formity and automatically thereby the operating licence Foreseeable incorr...

Page 16: ...e or functionality You can avoid existing residual risks by observing and follow ing these guidelines the special warning notices on the generator the general safety instructions given in these operat...

Page 17: ...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 Inappropri...

Page 18: ...lations 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 a...

Page 19: ...etermined 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 per sonnel Radius...

Page 20: ...early 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 pla...

Page 21: ...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 cur...

Page 22: ...cing 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 T...

Page 23: ...g 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 grou...

Page 24: ...ried 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 i...

Page 25: ...t be recycled according to the en vironmental protection regulations applicable at the place of use The workplace must be protected against contamination by leaking operating fluids Used or leftover f...

Page 26: ...the potential equalization device The terminal Figure 3 2 3 is connected with this potential equalization device Protective earthing is not required In addition to the details given above the electric...

Page 27: ...facturer Visual inspection for externally visible defects such as dam aged insulation connectors ca ble leaks noise Operating per sonnel After starting the gen erator and before connecting up con sume...

Page 28: ...General Safety Regulations Checking the electrical safety 28 ESE 406 606 D HG GT ES Duplex Status August 2017 Notes...

Page 29: ...9 3 The generator ESE 406 606 D HG GT ES Duplex The components and functionality of the generator are de scribed in this section Views of the generator The generator components are distributed on all...

Page 30: ...st side Figure 3 2 Components on the operating and exhaust side 1 Tank filling opening 2 Tank fill level indicator 3 Retainer bracket for loading by crane 4 Terminal for potential equalization earthin...

Page 31: ...6 D HG GT ES Duplex 31 Engine and maintenance side components Figure 3 3 Engine and maintenance side components 1 Fuel valve 2 Oil filling and checking screw 3 Oil drain screw 4 Engine 5 Recoil starte...

Page 32: ...ine start switch 4 Choke switch 5 Multi functional display 6 Schuko shockproof power sockets 230 V 1 7 CEE socket 400V 3 8 Reset button for ISO monitoring 9 Test button for ISO monitoring 10 Insulatio...

Page 33: ...and low vibration suspension elements Splash proof earthed power and CEE sockets with a nominal voltage of 230 and or 400 V 50 Hz supply the power An integrated voltage regulator controls the voltage...

Page 34: ...The generator ESE 406 606 D HG GT ES Duplex Control panel components 34 ESE 406 606 D HG GT ES Duplex Status August 2017 Notes...

Page 35: ...ipping or falling device can crush hands or feet Take the weight of about 94 113kg into account Carry the device with one person on carrying handle Only lift the device using the carrying handles Rais...

Page 36: ...rea of swivel of the lifting device Use all suitable measures to prevent the suspended load from swaying Figure 4 1 Attachment of the carrying straps 1 Lead a suitable carrying strap through the brack...

Page 37: ...um outdoors There are no inflammable materials at the operating site There are no explosive materials at the operating site WARNING Leaking engine oil and petrol can contaminate the soil and groundwat...

Page 38: ...ol can ignite or explode on hot parts of the device Prevent leaking of engine oil and petrol Never refuel when the engine is running Allow device to cool off before refuelling Avoid open flames and sp...

Page 39: ...ating and maintenance instructions there must be an adequate air supply and air removal Fit push on exhaust gas pipe special accessory if needed Appliances switched off or disconnected WARNING Operati...

Page 40: ...s follows to start the generator in the hand start ver sion Figure 4 2 Hand start operating controls Figure 4 3 Hand choke position 1 Turn fuel cock clockwise into the uppermost position Fig ure 4 2 1...

Page 41: ...oked up af ter a warming up phase of about one minute Proceed as follows to start the generator in the Electrostart version Figure 4 4 Electrical start 1 Turn fuel cock clockwise into the uppermost po...

Page 42: ...us August 2017 4 Release the engine start switch Figure 4 4 2 the switch springs into the RUN position 5 Release choke button Figure 4 4 1 The engine has started The electrical devices can be connecte...

Page 43: ...ad for about two minutes 3 Turn engine switch Figure 4 2 3 downwards into the OFF position The engine comes to a standstill and the generator is switched off 1 Switch off or disconnect consumers 2 Con...

Page 44: ...r to a building in Chapter 4 7 if your genera tor with this option Select the required operating mode The following requirements must be met The correct operating mode on the changeover switch Fig ure...

Page 45: ...his is how you connect the consumer to the 12 V power sockets on the control panel 1 Fold up the cover of the power socket upwards for power socket from IP54 and turn latch counterclockwise and take o...

Page 46: ...tion must be selected before start ing the generator 4 7 1 Incident scenes operation In the operating mode 1st on site operation the generator is designed for manual or automatic operation remote star...

Page 47: ...ording to VDE 0100 Part 410 and VDN The fault protection must in particu lar be secured by an on site RCD DANGER The power feed in socket with the 7h position may ONLY be used for supplying power to a...

Page 48: ...5 1 4 Connect the flexible connection line with the power socket to the on site installed feed distributor DANGER Ensure that there is a clockwise rotating field applied to the feed distributor at the...

Page 49: ...Operation Changeover of operating mode II TN S Status at August 2017 ESE 406 606 D HG GT ES Duplex 49 Figure 4 7 Equipment specification example Main distribution TN system TT system...

Page 50: ...ed as soon as the motor starts and it re duces the motor speed to approx 1 800 revs min The en gine speed will be increased to the nominal speed as soon as a load is switched on The motor will continu...

Page 51: ...inated V symbol for Volt 2 Press the button once see Figure 4 9 2 and the current fre quency Hz will be displayed shown by means of the illu minated Hz symbol for Hertz The display has been switched o...

Page 52: ...mply 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 Plea...

Page 53: ...Operation Disposal Status at August 2017 ESE 406 606 D HG GT ES Duplex 53 Notes...

Page 54: ...C and is fitted with the following marking It is essential to observe the regulations and safety instruc tions of the DGUV information 203 032 mentioned in order to achieve body protection for all pe...

Page 55: ...seeFigure 5 1 2 The switch position displays the result seeFigure 5 1 1 Symbol Significance Position I Protection switch does not trigger Fi protection switch is defective Position 0 Protection switch...

Page 56: ...eck The following requirements must be met for the test generator has been started see 4 4 Figure 5 2 Insulation monitoring 1 Unplug the device 2 The circuit breaker must be in Pos 1 3 Press the test...

Page 57: ...indicates the result Lamp Result Significance lights up red Circuit breaker jumps to Pos 0 Insulation fault 23 k stays off Circuit breaker stays in Pos 1 Connected unit is OK Table 5 3 Insulation moni...

Page 58: ...d off or disconnected from the generator Figure 5 3 Remote start device Proceed as follows to connect a cable remote control not in the scope of delivery 1 Remove protective cap of the CPC remote star...

Page 59: ...art device using cable remote control The following requirements must be met Generator is ready for operation Engine start switch Figure 5 3 3 is in the OFF position The cable remote control is fitted...

Page 60: ...tuation or if there is a fault over the clearly marked EMERGENCY STOP switch Figure 5 3 1 on the device Proceed as follows to switch off the generator in an emer gency using the EMERGENCY STOP switch...

Page 61: ...weekly every 200 h monthly every 300 h every 500 h Checking the electrical safety before each start up Check and top off motor oil Check fit of screws nuts and bolts Changing the oil X 1 X every 100 h...

Page 62: ...and maintenance instructions of the engine manufacturer are an integral component of these operating instructions 6 2 1 Motor oil WARNING Leaking engine oil can contaminate soil and groundwa ter Use a...

Page 63: ...The oil level has been checked Refill with oil as follows 1 Unscrew the grey oil level gauge Figure 6 1 1 2 Fill with oil using a filling aid 3 Check oil level and add oil if necessary The engine has...

Page 64: ...ion in the control circuit of the generator Always remove the starter battery before charging see Chapter 6 2 3 Exactly observe the handling instructions provided by the battery manufacturer WARNING A...

Page 65: ...he pos itive cable of the battery and loosen the cable 4 Remove the battery from the battery compartment Battery is disconnected Figure 6 2 Replacing the battery 5 Prepare a new battery 6 Put the batt...

Page 66: ...roller is de fective for ESE 606 DHG GT ES Duplex Call service staff Strong voltage fluctuations occur The engine runs irregularly Call service staff The speed control works er ratically or insufficie...

Page 67: ...inals and if necessary apply terminal grease The power output is insuffi cient The electronic controller has been altered for ESE 606 DHG GT ES Duplex Call service staff The electronic controller is d...

Page 68: ...Troubleshooting 68 ESE 406 606 D HG GT ES Duplex Status August 2017 Notes...

Page 69: ...urrent 17 4 21 7 8 7 3 17 4 1 A Weight ready for use 94 103 102 111 104 113 kg Tank capacity 33 33 33 l Fuel consumption at a 75 load 1 1 6 2 1 2 1 l h Length 780 780 780 mm Width 550 550 550 mm Heigh...

Page 70: ...dependent on 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 3 Maximum line length of the distribution network as a function of the cab...

Page 71: ...Technical specifications Maintenance work Status at August 2017 ESE 406 606 D HG GT ES Duplex 71 Notes...

Page 72: ...e to obtain original replacement parts for your device at Tel 49 0 7123 9737 44 service endress stromerzeuger de Note the article number and serial number of your device be forehand to exactly identif...

Page 73: ...d window No 40978 80 Gen syn 90 G gram BG2 110 G tank V02 120 M side panel R 130 M side panel L 180 Carrying handle black Inset handle made of soft PVC KAPSTO sealing cap 350 Vibration damper Form B 4...

Page 74: ...breaker 90 230 V 16 A Schuko power socket 100 400V 16 A 5P CEE socket 110 EMERGENCY STOP switch 120 Idle controller for BG 112 130 Rocker switch green 1 pin 140 FPG1 fuse holder 150 5 x 20 mm fine wi...

Page 75: ...Written guarantee Status at August 2017 ESE 406 606 D HG GT ES Duplex 75 10 Written guarantee...

Page 76: ...Written guarantee 76 ESE 406 606 D HG GT ES Duplex Status August 2017...

Page 77: ...Written guarantee Status at August 2017 ESE 406 606 D HG GT ES Duplex 77 Notes...

Page 78: ...Proof of maintenance 78 ESE 406 606 D HG GT ES Duplex Status August 2017 11 Proof of maintenance...

Page 79: ...ebau GmbH Neckartenzlinger Str 39 D 72658 Bempflingen Telephone 49 0 71 23 9737 0 Telefax 49 0 71 23 9737 50 Email info endress stromerzeuger de www www endress stromerzeuger de 2017 ENDRESS Elektroge...

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