ESE Power Generator: Translation of The Original Oper-Ating Manual

ESE Power Generator
TRANSLATION OF THE ORIGINAL OPER-

ATING MANUAL
ESE 75-250 IW/AS

Article-No.: 339280 - 339287
Manufacturer ENDRESS Elektrogerätebau GmbH
Neckartenzlinger Str. 39
D-72658 Bempflingen, Germany
Tel: + 49 (0) 71 23 / 9737 - 0

Fax: + 49 (0) 71 23 / 9737 – 50
Email: [email protected]
www: http://www.endress-stromerzeuger.de
Document number / E136679 / i01

version
Publication date April 2020
Copyright   2020 ENDRESS Elektrogerätebau GmbH

This documentation and parts thereof are subject to copyright. Any use or modi-
fication 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.
Notes on printing All descriptions, technical details and illustrations refer to the version of the gen-
erator for printing.
We reserve the right to make modifications in terms of ongoing technical devel-
opment. This operating manual does not include technical modifications that oc-
curred after printing.
The colours in this operating manual do not always comply completely with the
actual designs due to technical printing reasons.
2
Table of Contents
1 Directories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2.1 Constituent parts of the documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.2 Using this operating manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3 Product identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.1 Welcome to ENDRESS! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.2 Your product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.2.1 A device description and intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3.2.2 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
3.3 included in delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
3.4 Labels on the generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
4 For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

4.1 Safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
4.2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
4.3 Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
4.4 Authorised operating personnel – qualifications and obligations. . . . . . . . . . . . . . . . . . . . .23
4.5 Danger zones and work areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
5 Checking the electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
6 Description of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

6.1 Power generator view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6.2 Components on the connecting side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
6.3 Components on the maintenance side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
6.4 Control panel components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
7 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
7.1 Transporting and preparing your generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
7.2 Refuelling your generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
7.3 Starting the generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
7.4 Operating the E-MCS 6.0 control module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
7.4.1 Descriptions of the operating and display buttons. . . . . . . . . . . . . . . . . . . . . . . . . .39
7.4.2 Display window on the control module’s screen . . . . . . . . . . . . . . . . . . . . . . . . . . .41
7.5 Low load diesel engine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
7.6 Turning off your power generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
7.7 Turn off your generator in the event of an EMERGENCY . . . . . . . . . . . . . . . . . . . . . . . . . .43
7.8 Connection of power consuming equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
8.1 Maintenance plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
8.2 Maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
8.3 Starter battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
8.3.1 Charging the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
8.3.2 Replacing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
8.4 Engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
8.4.1 Checking the oil level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
3
8.4.2 Changing the engine oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
9 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
10 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
11 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
12 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
13 Replacement parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Keyword index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
4
Directories
1 Directories
1.1 List of illustrations
Fig. 3-1 Example of a type plate .9

Fig. 3-2 included in delivery .12
Fig. 3-3 Labels on the device .13
Fig. 6-1 Views of the generator .27
Fig. 6-2 Components on the exhaust and operating side .28
Fig. 6-3 Components on the exhaust and maintenance side .29
Fig. 6-4 Components on the control panel .30
Fig. 7-1 Transporting with a forklift .32
Fig. 7-2 Top .33
Fig. 7-3 Manually starting and stopping the power generator .35
Fig. 7-4 Control module’s display .37
Fig. 7-5 Control module’s control panel .39
Fig. 7-6 Operating display on the control module .40
Fig. 7-7 Control module’s display screen .41
Fig. 7-8 EMERGENCY-STOP smash button .43
Fig. 8-1 Starter battery .49
Fig. 8-2 Viscosity grade engine oil .50
Fig. 8-3 Oil level checking and oil changing .51
Fig. 13-1 Spare parts over endressparts.com .60
1.2 List of tables
Tab. 3-1 Labels on the device .15

Tab. 4-1 Danger zone on Generators .24
Tab. 5-1 Recommended test intervals .26
Tab. 7-1 Control buttons on the control module .40
Tab. 7-2 Operating display on the control module .41
Tab. 8-1 FPT engine maintenance schedule, source FPT engine .46
operating and maintenance instructions
Tab. 11-1 Troubleshooting .57
Tab. 12-1 Power generator technical data .59
5
About this manual
2 About this manual

We would like to explain to you the safe and correct use of your generator in the
best possible way through this operating manual. To do this we have oriented
ourselves to the new European standard DIN EN 82079-1 for preparing the user
manuals.
It is absolutely essential for safe and appropriate use that you read through this
manual very carefully and understand it before using the device for the first time.
Your observance of it creates the foundation for,
• avoiding dangers for yourself and others,
• reducing repair costs and downtimes as well as
• increasing the reliability and service life of the generator.
Not only this manual but also the laws, regulations, guidelines, and standards ap-
plicable in the country of use must be observed.
This document only describes the safe operation of the generator when used as
a complete unit. The following also includes detailed technical operating instruc-
tions that are binding with regard to using the device's specific components.
This documentation and also the product described in it are subject to a contin-
uous improvement process. In doing this we ensure that the full product is com-
pliant with the current safety requirements and the current state-of-the-art. The
respective most up to date language version of the operating manual and the
original operating manual can be found on our website
www.endressparts.com
2.1 Constituent parts of the documentation

Apart from these operating instructions, the following documents are needed to
ensure that you have the all of the documentation for your device:
• Operating and maintenance instructions for the engine
• Electric generator's documentation
• Starter battery handling instructions (electric start)
• EU Declaration of Conformity
• Generator's test report
NOTICE!
The complete documentation is an integral part of the device and you must
adhere to it.
► All of the integral parts of the documentation must always be accessible to
the operating personnel and they should be kept with the device.
6
About this manual
2.2 Using this operating manual

In order to increase the legibility, comprehensibility and transparency of
the document, certain information is highlighted or identified according a
uniform system. The following particularly belong in this category:
signs warning about dangers to life and limb

Safety and warning notices are necessary at all locations where there is potential
danger from the device which cannot be eliminated by design or operational
measures. We restricted ourselves to the permitted minimum in order to place
the required distinctive warning notices at the correct point in time without impair-
ing the legibility and comprehensibility of the operating manual. This is according
to the regulations contained in the international standard DIN ISO 3864 de-
scribes a fixed rule for all safety and warning notices, as shown in the following
example.
Examples:
DANGER!
Electrical voltage
Risk of suffering potentially deadly electrocution by touching live parts
► Only use undamaged connecting lines
► Avoid all damp / wetness when connecting consumers
► Never operate the power generator with an opened control panel
The standard mentioned classifies the safety risks according to different risk po-
tentials. To understand and avoid dangers to one’s health and even life, please
be sure to read the explanations given in Chapter 4.1 .
Safety symbols
These warning notices are usually used in a safety symbol which also emphasis-
es the type of danger; see next example. A list of the safety symbols used in this
operating manual can be found in Chapter 3.3 . The safety symbols never stand
alone.
Notices on avoidance of damage to the device

According to DIN ISO 3864, notices which warn against false operation and pos-
sible damage to the device or to the equipment used should be clearly distin-
guishable from previously named warning notices in as far there is no danger to
health. An example of such a notice can be seen here:
NOTICE!
Use of wrong or outdated fuel damages or destroys the engine.
► Only use released diesel fuel.
► Observe the shelf life of the fuel according to the supplier.
► Observe the Operating manual from the engine manufacturer
7
About this manual
Symbols and formattings in the text

In order to increase the legibility, comprehensibility and transparency of the doc-
ument, various information and activities are awarded uniformly repeating bullets
or formattings. The following example shows presentation of a sequence of ac-
tions with established work steps:
Example:  Prerequisites which must be fulfilled before starting any sequence of actions
1. Action steps according to a fixed sequence.
2. The action steps must be fully completed.
3. The sequence must be observed.
Results of the action which should be achieved after performing the sequence of
action.
Additional notices for operation or for function of a unit are marked with the
adjacent symbol.
NOTICE!
The adjacent symbol is situated anywhere where the supplier documenta-
tion must be read and observed and refers to,
► appropriate information,
► tasks or
► action steps.
References to details and components in figures are made with blue bordered
position numbers in the text such as the example of CE signs on the type plate
demonstrates, see Fig. 3-3 .
8
Product identification
3 Product identification
3.1 Welcome to ENDRESS!
We are pleased that you have made the decision to purchase a ENDRESS
power generator. You have purchased a high-performance product into
which we have embodied decades of our experience and have integrated
many functions oriented on daily use. Through careful selection of high
quality components and materials in combination with the proverbial Swa-
bian engineering performance you have in your possession a device which
will operate reliably for many years, also under the hardest of operating
conditions.
3.2 Your product

Customer service In order to precisely identify your device there is a type plate attached to the Gen-
erators (see Fig. 3-3 ), which includes details about the device designation and
"S/N" serial number. If you have any questions about device details, functions or
notices concerning operation, please contact our
Customer service: Tel. +52 (442)192.9100
You will find competent contact persons there, also concerning original spare
parts and wear parts. (see also Chapter 13 )
Type plate The type plate shown below is a representation of the adhesive label placed on
the device. Please be prepared, when contacting our service team, to assist us
in exactly identifying your device. Refer to your generator's operating instructions
for further information about finding the type plate.
Fig. 3-1 Example of a type plate
3.2.1 A device description and intended use

Your power generator generates electrical energy for the "direct supply" mode as
part of a mains backup operation for supplying electricity to a mobile distribution
system. This enables mobile use of commercially available electrical devices
with single-phase 127V AC / 60Hz or three-phase 220V AC / 60Hz (depending
on the equipment being used).
Your power generator has been designed for manual or automatic operation (re-
mote start) with one or more electrical consumers. To protect against electric
shock (i.e. current flowing through your body), automatic switching off according
9
to DIN VDE 0100-551: 2017-02 is used as the protective separation measure.

The protective conductor system from the attached consumers will take over the
earthing function. The terminal strip (Fig. 6-4 ) is used for connecting up a suit-
able earth (e.g. an earthing stake). Proper is needed and it must be implemented
by a qualified electrician.
Your generator consists of an AC generator that is driven by a combustion engine
that is bolted onto it. This unit is mounted elastically inside a closed and sound-
insulated housing and vibration dampers are used to ensure low vibrations. The
current is taken from the terminal strips through measures implemented by an
electrician.
The unit generates three-phase AC (three-phase current) with a nominal voltage
of 220V at 60Hz. More detailed technical data can be found in Chapter 12 . An
integrated voltage regulator ensures that the stability of the generated voltage is
within the nominal rotational speed range. The current is drawn off through the
connection terminal.
The generator is only to be used outdoors within the indicated voltage, output,
and nominal rpm ranges (see type plate).
The power generator must never be used for direct feeding into other power dis-
tribution systems (e.g. public power supply) or be used with other power gener-
ation systems (e.g. other power generators).
The generator is not to be used in explosion-prone environments.
The generator is not to be used in environments where there is a risk of fire.
The generator must be operated according to the specifications in the technical
documentation.
Every inappropriate use or all activities on the generator which are not described
in these instructions is forbidden misuse outside the legally defined limits of lia-
bility of the manufacturer.
3.2.2 Foreseeable misuse

Apart from the description of appropriate use, the lawmaker also requires
concrete references to the results of “reasonably foreseeable misuse“. In
a case of incorrect use or inappropriate handling of the generator the man-
ufacturer's EC Declaration of Conformity, and automatically thereby also
the operating licence, are nullified. For products with a manufacturer’s war-
ranty the manufacturer will reject any claims made under warranty for dam-
ages which were caused by misuse and its direct as well as indirect
consequences.
As not authorised Misuse is particularly the case when:
• operation of the generator takes place without valid checks for
– electrical safety
– checking that the prescribed servicing and maintenance work has been
done
• operation of the generator takes place without the protective equipment in-
stalled by the manufacturer
• constructional or electrical modifications of the generator were undertaken
• use of the generator by inadequately instructed operating personnel
Furthermore at all costs avoid the following Misuses:
• Never refuel the generator’s own tank when the engine is running. The vibra-
tions and strong exhaust streams during operation can lead to fuel spillage.
This leads to an increased risk of explosion and fire and therefore danger to
operating personnel, the environment and the device.
10
• Never refuel the generator’s own tank when it is hot. Overflowing fuel and
outflowing fuel vapours can ignite on hot parts of the device.
• The generator is never to be connected up to other energy distribution sys-
tems (e.g. public power supply) or to other energy generation systems (e.g.
other generators, solar plant, etc.). To start with this is usually not permitted
by the energy supply company. In both cases this will inevitably lead to se-
vere damage and possibly also severe injury.
• Never place the generator in explosion-prone environments. The individual
components of the generator are not designed EX-protected.
• Never operate the generator in rooms, narrow pits or vehicles. The combus-
tion exhaust gases contain poisonous substances including the odourless
but deadly gas carbon monoxide (CO) which, when breathed in, can accu-
mulate in cases of poor air circulation to reach deadly concentrations. Also a
lack of fresh air circulation leads to overheating and possible damage to the
generator right through to destruction.
• For the same reasons of risk, never divert exhaust gases for the purposes of
heating rooms or vehicles.
• Never clean the generator with the aid of a high pressure cleaner or a strong
jet of water.
• Never allow water to find its way inside the generator. Never pour water over
the generator and never clean it using a water hose or a high pressure clean-
er.
• Never operate the generator in any area where it could be flooded by high
water or any other events. The Protection Class of the device (see Chapter
12 ) allows operation for spray water, however not in the case of floods.
11
3.3 included in delivery

Apart from the technical documentation mentioned in Chapter 2.1 the following
articles are Scope of delivery of your generator:
Fig. 3-2 included in delivery
Item Name
Supplier documentation
Tool kit
Coolant overflow tank
(no image operating manual

shown)
12
3.4 Labels on the generator

An important part of the operating manual is in the form of labelling and notices
on your generator. These labels must not be removed and they must always be
maintained in a legible condition. New labels can be ordered from our customer
service team if the originals become damaged. The following figures and tables
show the stipulated attachment point and a short explanation about labels.
Fig. 3-3 Labels on the device
13
Item Label Significance
Warning
Mortal danger from toxic
combustion gases when the
engine is running
Risk of burns
Hot surfaces
Note
Lift the unit only from here
(crane loading eyes)
Prohibition signs
Smoking and open flames
are prohibited
Note
Fuel quality
Read the operating manual

before starting up
Smoking and open flames
are prohibited
Do not operate the power
generator if a risk of fire ex-
ists
You are forbidden to make
any changes to the power
generator
Warning
Warning about a general
hazard
Note
Forklift loading pockets
(forklift pockets)
14
Item Label Significance
Warning signs
Dangerous voltage
For electricians only
Type plate
Prohibition signs
No naked flames
Tab. 3-1 Labels on the device
15
For your safety
4 For your safety

The following chapter describes basic Safety instructions for safe operation of
your generator. Your device is a very high-performance electrical machine which
is potentially dangerous when operated if it has not been installed, commis-
sioned, used, serviced and repaired according to the operating manual. If neces-
sary, the operating manual will also include different supplements that depend on
the country of use, in addition to the present one.
Operation, use, servicing as well as any work with or on the generator is therefore
only permitted by such persons who have read this chapter and have put its pro-
visions into practice!
Concrete warning notices can also be found regarding basic safety instructions
further on in this operating manual. These are always placed in an explanatory
text immediately before the description of work steps which can be dangerous if
the warning notice is not observed. Read the following sections for correct and
rapid understanding of these safety and warning notices. They describe their
systematic structure as well as the meaning of markings and symbols.
4.1 Safety symbols

The safety symbol indicates graphically that a source of danger exists. We
use the internationally valid safety symbols from ISO 7010 for rapid and
unique classification of the respective dangerous situation. In the follow-
ing there is a description of the warning symbols used in this operating
manual with an explanation about the respective dangerous situations.
Warning of a general hazard

This warning symbol indicates activities where several causes can lead to risks.
The concrete danger must be respectively more clearly specified by further no-
tices.
Warning of a dangerous electrical voltage

This warning symbol is indicates activities where the danger of electric shock ex-
ists, possibly with lethal consequences.
Warning of potentially explosive materials

This warning symbol indicates activities where the danger of an explosion exists,
possibly with lethal consequences.
Warning of toxic substances

This warning symbol indicates activities where a risk of poisoning exists, possibly
with lethal consequences.
16
For your safety
Warning of corrosive substances

This warning symbol indicates activities where a risk of chemical burns to the en-
vironment as well as people exists, possibly with lethal consequences.
Warning of environmentally damaging substances

This warning symbol indicates activities where a risk of contaminating the envi-
ronment exists, possibly with catastrophic consequences.
Warning of hot surfaces

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

This warning symbol indicates activities where the danger of falling loads exists,
possibly with lethal consequences.
Warning of automatically starting machines

This warning symbol indicates activities where a danger of being injured by self-
starting machines exists, possibly with lethal consequences.
17
For your safety
4.2 General safety instructions

ENDRESS generators are designed to operate electrical equipment with
appropriate power output requirements. Other uses can lead to severe in-
juries to operating personnel as well as persons nearby. There is also in-
creased risk of damaging the generator as well as further damage to
equipment.
DANGER!
Mortal danger due to an electric shock if live parts are touched.
► Never operate the device if it is in a damaged condition.
► Never operate the electrical consumers and connecting cable (power con-
suming equipment) in a damaged condition.
► Never feed directly into existing networks that are already connected to a
power source (e.g. power supplier, solar plant, etc.).
► Never operate the device with wet hands.
The majority of injuries and damage to equipment can be avoided if all instruc-
tions given in this manual and all instructions attached to the device are followed.
The generator must not be modified in any way, also not temporarily. This can
lead to a mortal risk to operating and deployed personnel and damage to the gen-
erator as well as the consumers being used.
Operating company and Operating personnel may only use the generator ac-
cording to regulations contained in the whole technical documentation (hereinaf-
ter referred to as appropriate use).
Every instance of inappropriate use as well as 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. In return all claims for dam-
ages and claims made under warranty to ENDRESS-Elektrogerätebau GmbH
which are associated with misuse are null and void.
4.3 Residual risks

As a manufacturer of EU-compliant machines, ENDRESS make great ef-
forts to create designs which already eliminate possible risk potentials at
the design stage. If this is not possible without significantly impairing the
functions of a device, we implement suitable protective measures protect
the user from injury.
If there are still some residual risks associated with working with the de-
vice, we clearly advise the user about these sources of danger, possible
consequences as well as measures to avoid such dangers.
The residual dangers were analyzed and Residual dangers identified during the
development and design of your Generators by means of a danger analysis ac-
cording to DIN EN 60204, DIN EN ISO 12100 and DIN EN ISO 8528-13.
References to general sources of danger can be found in chapters 4 and 5 .
From Chapter 6 one can find concrete warning notices placed before every ac-
tion step which represents a residual risk.
The exact structure and contents of warning notices are defined in the
ISO 3864 series of standards and follow an established identification mark-
ing required to immediately be able to estimate the degree of the respective
18
For your safety
danger. Exactly impress upon yourself the identification marking of the

four different danger levels in order to be able to reliably assess the dan-
gers associated with the individual operating states and action steps when
reading the operating manual.
DANGER!
DANGER describes a danger which represents a high level of risk,which
can lead to death or severe injuries,when not avoided.
► The individual points provide instructions and
► notices as aids to avoid the danger
► or to reduce the risk to an acceptable level.
WARNING!
WARNING describes a danger which represents a medium level of
risk,which can lead to death or severe injuries,when not avoided.
CAUTION!
CAUTION describes a danger which represents a low level of risk,which
can lead to minor or medium level injurieswhen not avoided.
NOTICE!
ATTENTION! describes a situation or action that might result in damage to
equipment and/or malfunctions if it is not prevented.
► The individual points provide instructions and notices
► as an aid to avoid or prevent damage to equipment.
19
For your safety
DANGER!
DANGER!
Engine exhaust gases contain poisonous and partially invisible gases such
as carbon monoxide (CO) and carbon dioxide (CO2).
Risk of death due to poisoning or asphyxiation.
► Ensure that there is good ventilation during the whole period of operation.
► Only operate the generator in the open.
► Never direct the exhaust gases into rooms or pits.
DANGER!
Danger of severe or mortal injuries being incurred from falling loads.
► Never stand under or close to a suspended load, also not to provide assis-
tance.
► Ensure that there is no person in the area of swivel of the lifting device.
► Use all suitable measures to prevent the suspended load from swaying.
DANGER!
Leaking engine oil and fuel can burn or explode.
A risk of suffering severe even deadly burns.
► Prevent engine oil or fuel from leaking out.
► Remove leaked operating fluids immediately and appropriately.
► Never use an additional start aid.
► Smoking, naked flames and sparks are forbidden.
DANGER!
Hot parts can ignite flammable and explosive materials.
► Never operate the generator in the vicinity of combustible or flammable ma-
terials.
► Never operate the generator in an environment prone to an explosion.
20
For your safety
WARNING!
There is a risk of explosion and fire in the case of inappropriate handling
and spark development when working with the battery.
Danger from spraying sulphuric acid. Danger of suffering severe even deadly
burns and chemical burns. Danger of being blinded.
► Never lay electrically conductive parts on the starter battery.
► Flames, sparks, an open light and smoking are prohibited.
► Avoid sparks when handling cables and electrical devices, as well as electro-
static discharge.
► Avoid short-circuits.
► Wear acid-resistant protective clothing.
WARNING!
Escaping corrosive acid fumes or sulphuric acid during and after the
charging process. A risk of suffering severe or even deadly burns.
► Only work with acid-resistant protective equipment.
► Clean surfaces covered in acid immediately using adequate amounts of wa-
ter.
► Only charge the starter battery in a well ventilated environment.
CAUTION!
Certain surfaces on the device can get very hot whilst it is running.
Risk of burns
► Never touch any engine parts (in particular the exhaust system) for a few min-
utes after ceasing operation.
► Always leave hot engine parts to cool down before touching them.
CAUTION!
A high device weight. Risk of crushing from improper handling during op-
eration or transport.
► Only lift the generator with the aid of all handles provided or by using a suit-
able hoist.
► During transport on vehicles, ensure that there is the prescribed load secur-
ing in place.
► With it in a raised condition, never come close to or stand under the genera-
tor.
21
For your safety
NOTICE!
Leaking engine oil and operating fluids can contaminate the soil and
groundwater.
► Ensure that the generator is transported horizontally and mounted.
► Make all efforts, at all costs, to prevent escaping of operating fluids.
► Dispose of contaminated soil immediately and according to regulations.
NOTICE!
► Only use the fuel displayed on the sign (Fig. 3-3 ).
► Observe the possibly enclosed documentation for the fuel release of the en-
gine manufacturer
► Observe the engine operating manual.
NOTICE!
Excessive heat or moisture can destroy the device.
► Always ensure that there is a good supply of air and heat removal.
► Never operate the generator in rooms or narrow pits.
► Never clean the device with the aid of a strong jet of water or high pressure
cleaner.
► Never allow water to find its way inside the generator.
22
For your safety
4.4 Authorised operating personnel – qualifications

and obligations
Your Generators is a complex machine, the operation and maintenance of
which requires exact knowledge of its functions and danger potentials.
Therefore any work with or on the device, of any kind, may only be per-
formed by authorised and instructed operating personnel.
Quite apart from the authorisation which the operating company of the de-
vice must issue, only such persons may operate or service the device who
fulfil the following criteria. They are designated in this operating manual as
operating personnel.
The authorised operating personnel must:
• be of age.
• be trained in First Aid and be able to provide it.
• be familiar with the accident prevention regulations and safety instructions
relevant to the Generators and be able to apply them.
• have read Chapter 4 , have understood the contents and are able to use and
implement them in practice.
• be trained and instructed according to the rules of conduct in the case of mal-
functions.
• have the physical and mental abilities to carry out their responsibilities, tasks,
and activities on the Generators.
• be trained and instructed in their responsibilities, tasks and activities on the
Generators.
• have understood the entire technical documentation concerning their respon-
sibilities, tasks and activities on the Generators and be able to implement
these in practice.
23
For your safety
4.5 Danger zones and work areas

In order to be able to consider all of a machine's safety aspects and to com-
ply with the safety and health protection requirements of the applicable
standards and EU directives, we have assessed the use of your Generators
in all of the phases that it will go through during its product service life
(product life cycle). The following zones were defined on the Generators for
this purpose: The danger zones and work places (work areas) around the
generator are determined by the activities to be undertaken within the var-
ious phases in individual life cycles:
• Working zone: In this zone on and around the Generators (approx. 1 metre
radius) the trained operating personnel (see Chapter 4.4 ) may operate and
inspect the device in compliance with all of the safety and operating instruc-
tions given in the technical documentation. All other people (especially mi-
nors and people with disabilities) must remain outside this working zone.
• Danger zone: This zone must be kept free of all personnel during all phases
of use and service life of the device. Any work in this zone is only to be un-
dertaken by specially trained specialists if it is essential for the fulfilling of the
task and if all of the protective equipment (PPE) needed is used. You must
always comply with the following limits:
Product's service life phase Danger zone
Transport and installation within a radius of 1m around or below the de-

vice
Operation within the outer limits of the device
Service and maintenance Within the outer limits of the device when
switched on Generators
Tab. 4-1 Danger zone on Generators
24
Checking the electrical safety
5 Checking the electrical safety

Checking of electrical safety requires different measures to be taken which
may only be undertaken by respectively authorised personnel. The respec-
tive valid versions of the appropriate and relevant standards must be ad-
hered to.
In particular you must never use defective or damaged consumers, cable con-
nections or plug connectors, etc., (power consuming equipment). Their correct
conditions must be checked at regular intervals (see Tab. 5-1 )
Earthing Your power generator has been designed for manual or automatic operation (re-
mote start) with one or more electrical consumers. To protect against electric
shock (i.e. current flowing through your body), automatic switching off according
to DIN VDE 0100-551: 2017-02 is used as the protective separation measure.
The protective conductor system from the attached consumers will take over the
earthing function. The terminal strip (Fig. 6-4 ) is used for connecting up a suit-
able earth (e.g. an earthing stake). Proper is needed and it must be implemented
by a qualified electrician.
We strongly recommend that you also comply with the legal requirements for oth-
er applications.
DANGER!
There will be no RCD personal protection during operation if the earthing
of the Generators is faulty.
Mortal danger from electrocution
► The use of an RCD (FI circuit breaker) for personal protection requires proper
earthing of the Generators and this must be undertaken by a qualified elec-
trician before the initial commissioning.
► The effectiveness of this protective measure should be regularly checked by
an electrician.
► Check the personal protection according to the check intervals given in Tab.
5-1 .
In addition to the details given above, the electrical safety of the generator is to
be checked by a qualified electrician at regular intervals. The periods between
testing must be established in such a way that the generator and all work equip-
ment to be connected can, according to the general status of knowledge, opera-
tional experiences or on the basis of specific evidence, be safe to use in the
period between the two inspections.
NOTICE!
The operator is responsible for defining and adhering to the test intervals
. Above all one must ensure observance of the respectively valid national
regulations.
This responsibility also extends to any additional equipment installed in
conjunction with the device.
We recommend the following checks and deadlines as general guideline values:
25
Checking the electrical safety
When What / how Who
First start-up at the op- • See Chapter 7 and also abide by the operating manual Operating
erating location provided by the engine manufacturer personnel
• Visual inspection for externally visible defects such as
transport damage.
Start-up on a daily basis • See Chapter 7.3 and also abide by the operating man- Operating
ual provided by the engine manufacturer personnel
• Visual inspection for externally visible defects (such as
damaged insulation, connectors, cable; leaks, noise)
• If the power generator is fitted with insulation monitoring
and/or an RCD, then the operating personnel must run
protective device function tests every working day. The
operating personnel must be trained to do this.
Retest at the latest once • According to BGI/GUV-I 5090 “Repeated testing of mo- Qualified
every six months bile electrical equipment“) electrician
• Sample test report according to
DGUV information 203-032 *)
*) Download as a text file under → www.dguv.de Webcode:

d138299
Tab. 5-1 Recommended test intervals
26
Description of the device
6 Description of the device

6.1 Power generator view
The following section provides an overview of the name and location of the
most important components in your Generatorss. It is important that you
become familiar with them in order to understand the functions and oper-
ating steps explained below and to be able to implement them safely. Se-
vere or deadly personal injuries can result and/or damage to the generator
as well the attached power consuming equipment if these instructions are
ignored.
In order to be in a position to clearly re-find named operating controls and com-
ponents in the following descriptions and instructions, the individual views of the
generator are designated throughout in a way which can be taken from the fol-
lowing figure.
Fig. 6-1 Views of the generator
Maintenance page Exhaust side
Control side Engine side
27
6.2 Components on the connecting side
Fig. 6-2 Components on the exhaust and operating side
Generator’s maintenance flap Crane loading lug
Control panel Engine’s maintenance access point
Oil drain pump Oil filter
Fuel tank’s filling opening Forklift pockets
28
6.3 Components on the maintenance side
Fig. 6-3 Components on the exhaust and maintenance side
Engine’s maintenance doors Fuel filter
Oil filling cap Oil dipstick
Air filter
29
6.4 Control panel components
Fig. 6-4 Components on the control panel
EMERGENCY-STOP smash button Control module E-MCS 6.0
Main switch Control module’s ON / OFF switch
Terminal strip cover (only to be ac-

Terminal strip
cessed by electricians!)
30
Commissioning
7 Commissioning
The following chapter explains the basic procedure for initial or repeated
generator start-ups in "Manual" mode. Follow the working steps described
below when you put your generator into operation for the first time or re-
start it again after transporting it.
7.1 Transporting and preparing your generator

Choose the transporting vehicle and lifting gear so that the generator can be
moved safely at all times according to its total mass (see Chapter 12 ). The unit's
solid base frame allows it to be lifted and transported by a forklift. Alternatively,
loading by crane is also possible after the crane eyes have been fitted correctly.
Ensure that all of the power generator’s maintenance flaps and covers are se-
curely closed.
Requirements:  The ground at the installation site must be even and be capable of bearing
the load.
 The generator is turned off.
 The generator has cooled down
DANGER!
Danger of severe or mortal injuries being incurred from falling loads.
► Never stand under or close to a suspended load, also not to provide assis-
tance.
► Ensure that there is no person in the area of swivel of the lifting device.
► Use all suitable measures to prevent the suspended load from swaying.
NOTICE!
Leaking engine oil and operating fluids can contaminate the soil and
groundwater.
► Ensure that the generator is transported horizontally and mounted.
► Make all efforts, at all costs, to prevent escaping of operating fluids.
► Dispose of contaminated soil immediately and according to regulations.
31
Commissioning
Fig. 7-1 Transporting with a forklift

Transporting with a 1. Move the lifting forks into the pockets in the base frame.
lifting device
2. Insert the lifting forks as far as possible because of the machine’s heavy
weight.
3. Raise the power generator slowly and evenly.
4. Move the power generator slowly into its place of use.
5. Lower the device slowly and evenly.
6. Remove the forklift.
The generator has been transported to its place of use and positioned.
32
Commissioning
Fig. 7-2 Top
Transporting by 1. Connect up to the crane eyes to the lifting device approved for use with
crane the unit’s heavy weight and secure it against falling off.
2. Raise the power generator slowly and evenly.
3. Move the power generator slowly into its place of use.
4. Lower the device slowly and evenly.
5. Unhook the lifting device.
The generator has been transported to its place of use and installed.
7.2 Refuelling your generator

Proceed as follows to refill the generator's own tank: the generator.
Requirements:  The power generator is switched off
 the generator has cooled down
 there must be an adequate air supply and air removal
 all power consuming equipment must be disconnected or switched off
DANGER!
33
Commissioning
NOTICE!
Leaking fuel can contaminate soil and groundwater.
► Take note of the residual quantity in the tank and its maximum filling capacity.
► Always bear in mind that the fuel gauge reacts only after a time delay.
► Fill the tank to a maximum of 95%.
► Always use a filling aid (e.g. funnel).
NOTICE!
► Only use the fuel displayed on the sign (Fig. 3-3 ).
► Observe the possibly enclosed documentation for the fuel release of the en-
gine manufacturer
► Observe the engine operating manual.
NOTICE!
When selecting the fuel, please note that if you use bio-diesel, then the war-
ranty is no longer fully guaranteed.
► Only the fuel recommended by the engine manufacturer is to be used.
► Abide by the fuel notes given in the engine manufacturer’s operating instruc-
tions.
Refuelling the gen- 1. Unscrew the tank cover Fig. 6-2 .

erator
2. Insert the filler nozzle into the filling opening.
3. Fill with fuel slowly and evenly.
4. Take note of the tank's fuel level indicator Fig. 6-2 as well as the fuel level at
the filling opening to ensure that you do not overfill the tank.
5. Remove the filler nozzle.
6. Refit the tank cover.
The generator is now refuelled.
34
Commissioning
7.3 Starting the generator

Starting the power generator in manual control mode (see Chapter 7.4 ) is
described here.
Proceed as follows to start the power generator directly from the E-MCS 5.0 con-
trol module’s control panel.
Fig. 7-3 Manually starting and stopping the power generator

Requirements:  electrical safety has been checked (see Chapter 5 ).
 the fuel tank is sufficiently full.
 sufficient coolant (fill with coolant before initial use, see the engine operating
and maintenance instructions for this).
 sufficient oil level (fill with engine oil before initial use, see the engine operat-
ing and maintenance instructions).
 there is an adequate air supply and air removal.
 The main battery switch must be in the “ON” position.
35
Commissioning
DANGER!
DANGER!
Engine exhaust gases contain poisonous and partially invisible gases such
as carbon monoxide (CO) and carbon dioxide (CO2).
Risk of death due to poisoning or asphyxiation.
► Ensure that there is good ventilation during the whole period of operation.
► Only operate the generator in the open.
► Never direct the exhaust gases into rooms or pits.
Starting the motor 1. Turn the main switch into the "ON" position.
2. Turn the controller’s switch into the "ON" position.
The control module's display will come on and the controller will run up.
3. Wait until the start screen is displayed (see Fig. 7-7 ).
4. Set up "Manual" mode on the display by pressing the mode button (right ar-
row) once.
5. Press the “Start“ button once.
The engine will start up after the preheating phase.
The engine has started.
The green control LED shows you the readiness state of the Generators.
Familiarise yourself with the complete operating procedure for the E-MCS 6.0
control module before the initial commissioning of the power generator, see
Chapter 7.4 .
NOTICE!
Do not apply load to the generator immediately after a cold start.
► Allow the generator engine to warm up for a few minutes before switching on
a load when the generator has not been operating for more than eight hours
(or for very low external temperatures).
36
Commissioning
7.4 Operating the E-MCS 6.0 control module

We will explain in detail how to operate the power generator via the control
module in the following chapter, (see Fig. 6-4 ), and under various operating
conditions. You will also learn how to display and edit various operating
parameters and error messages.
The uses different control modes. The control mode that is currently being used
is shown in the top line of the display, see Fig. 7-4 . Change modes by pressing
the buttons on the control panel Fig. 7-5 on the control module.
Fig. 7-4 Control module’s display
Control mode - Controller off

The “ “ displayed in the top line of the display indicates that the Generators
can neither be started manually from the control module nor automatically due to
a problem caused by the power supply company. This mode is reserved for main-
tenance and configuration work or if starting the Generators must be prevented
under all circumstances.
NOTICE!
Automatic mains switching is deactivated in the “ “ control mode.
The power generator will not start if the power supply has failed.
► Only use the “ “ control mode for temporary purposes and only if starting
the Generators must be prevented.
► After you have finished accessing the unit, you must ensure that the control
module is back in the “ “ mode.
Control mode - Manual

The manual is indicated by “ “ being displayed in the top line of the display,
see Fig. 7-4 . The power generator can be switched on and off manually and oth-
er functions can also be controlled in this mode.
37
Commissioning
NOTICE!
Automatic mains switching is deactivated in the “ “ control mode.
The power generator will not start if the power supply has failed.
► Only use the manual control mode for temporary purposes or if automatic
mains switching is not needed.
► After you have finished accessing the unit, you must ensure that the control
module is back in the “ “ mode.
Control mode - Automatic

The Automatic control mode is indicated by “ “ being displayed in the top
line of the display. The generator will start automatically in this mode as soon as
the integrated mains monitoring system detects a power company fault. Howev-
er, some functions such as resetting the warning tone can still be used.
Controller switched off

If the 7.3 -switch is in the “0“ position, then the controller is completely
switched off. The power generator cannot be started neither automatically nor
manually in this mode. However, certain optionally installed functions for ensur-
ing operational readiness (e.g. tank heating, coolant preheating, battery charge
retention) remain available.
DANGER!
Dangerous electrical voltage is still present even when the power genera-
tor is switched off
Mortal danger from electric shock if live parts are touched.
► Access only for electricians in areas marked with an adjacent warning sign.
► Maintenance work on the generator is only to be undertaken after an electri-
cian has switched off the power generator and it is completely voltage-free.
38
Commissioning
7.4.1 Descriptions of the operating and display buttons
Fig. 7-5 Control module’s control panel
Item Button Description
START ENGINE Press this button to start the power generator if the
control mode has been selected, see
SWITCH OFF ENGINE as well Press this button oncein control

mode and the control module will start the power generator’s cooling-
down phase and it will be switched off afterwards. If this button is pressed
for a 2nd time, then the control module will skip the cooling down phase
and the power generator will be switched off immediately (NOT RECOM-
MENDED!).
RESETTING A FAULT Press the button to acknowledge an alarm mes-

sage displayed on the screen and to turn off the horn. Inactive alarms are
immediately faded out on the display and the status of the active alarms
changes to “acknowledged" so that this will be faded out immediately af-
ter the cause is eliminated.
RESETTING THE WARNING HORN Not installed (function is run by

pressing the button)
SELECTING A CONTROL MODE Pressthis button to switch between

the or ) control modes. The buttons will only be functional if
Fig. 7-7 is displayed in the main window on the controller’s screen. If nec-
essary, you should press the button repeatedly until the main window
is displayed.
39
Commissioning
Item Button Description
CHANGE GENERATOR MODE (only with an external changeover

contactor).
Press this button to go to the control mode for supplying the con-
nected distribution network from the power generator.
CHANGING THE MAINS OPERATION (only with an external change-

over contactor)
Press this button to enter the control mode for supplying the con-
nected distribution network from the public mains supply.
SELECTION MENU
This function can only be enabled by service personnel.
ENTER BUTTON
Press this button and hold it down. Press one of the buttons simulta-
neously to set the screen's contrast.
MOVING BETWEEN THE SCREEN PAGES

Press these buttons to move between the different windows displayed on
the screen.
Tab. 7-1 Control buttons on the control module
Fig. 7-6 Operating display on the control module
Item Description
MAINS FAULT The red LED will flash if the power supply from the mains is faulty. It will be
continuously lit after the power generator has been started and remain so until the mains fault
has been eliminated.
MAINS VOLTAGE OK The green LED diode lights up of there is a voltage present from the
generator and the measured parameters lie within the limit values.
MAINS CHANGEOVER CONTACTOR ON This LED lights up green if the connected distri-
bution network is being supplied from the public mains system (only with an external change-
over contactor).
GENERATOR CHANGEOVER CONTACTOR ON This LED lights up green if the connected

distribution network is being supplied from a generator (only with an external changeover
contactor).
GENERATOR VOLTAGE OK The green LED lights up if voltage from the generator is pres-
ent and the measured parameters lie within the limit values.
40
Commissioning
Item Description
GENERATOR FAULT The red LED will flash if the power supply from the power generator
is faulty. It will go out if the button is pressed after the problem has been eliminated. The
fault is still present if it remains permanently lit.
Tab. 7-2 Operating display on the control module
7.4.2 Display window on the control module’s screen

The control module screen shows you different Information about operating
states, measured values, error messages and statistical data is shown in a struc-
tured form in the display windows. Press the arrow buttons Fig. 7-5 to move
around the different display windows.
You will find a detailed list with all event and error messages in the appen-
dix.
Alarm list If an alarm is triggered, the alarm list will be displayed on the screen and you
should select the entry that is preceded by an *. Proceed as follows to acknowl-
edge the alarms:
1. If there are several entries present should use the arrow keys to select the
entry that you want.
2. Press the button to acknowledge the alarm.
The * character will disappear.
The entry will only disappear after the error has been eliminated.
Fig. 7-7 Control module’s display screen
41
Commissioning
7.5 Low load diesel engine operation

Internal combustion engines normally run most economically and environmental-
ly friendly when they have reached their optimum operating temperature (with a
coolant temperature from approx. 80°C). Prolonged operation well below the op-
erating temperature or without a specific minimum load will have a negative effect
on the service life. Incomplete combustion processes inside the engine will cause
more and more deposits to form within the engine. If this operating state contin-
ues for too long or it is not compensated for by regular phases running at full load,
this might result in a total engine failure and high repair costs in the worst case.
NOTICE!
Damage to the drive motor or other Generators components that was
caused by low load operation that is contrary to our recommendations (see
below) and/or those of the engine manufacturer will void any warranty or
liability claims.
NOTICE!
Avoid, as far as possible, short-term operation or operation without a load
or with a basic load that is too low. Follow these recommendations if the
engine manufacturer does not provide detailed information or he provides
different information:
► Run your Generators at a minimum of 30% - 40% of the rated nominal output
(see nominal output in Chapter 12 Technical data).
► Avoid short-term operations where the engine does not reach its operating
temperature.
► Run the engine at regular intervals for at least one hour at maximum load
(see Chapter 8.1 Maintenance plan as well).
► Take note of the instructions provided by the engine manufacturer
7.6 Turning off your power generator

Proceed as follows to switch off your generator:
Requirements:  Any dangers that might be caused by interrupting the power supply have
been eliminated.
 Anyone who might be affected by shutting down the power supply have been
informed.
 The power generator is in the manual control mode (see Chapters 7.3 and
7.4 .
Switching the gen- 1. Press the Fig. 7-5 -button once .
erator off The green control LED will start to flash.
The engine will go into the cooling-down phase and it will switch off auto-
matically after a few minutes.
The red control LED will light up.
2. Use the Fig. 7-3 - switches to switch the controller “OFF”
3. Turn the main switch into the “OFF” position.
All of the displays have gone out.
The generator is switched off and secured.
42
Commissioning
7.7 Turn off your generator in the event of an EMER-

GENCY
Your Generators is fitted with an EMERGENCY-STOP smash button . It
enables you to immediately switch off the device in an EMERGENCY in or-
der to prevent other dangerous situations from occurring.
CAUTION!
The EMERGENCY-STOP smash button is only to be used in the event of a
dangerous situation arising in an emergency.
Risk of injuries if consumers are suddenly switch off.
► Always switch off the generator normally as described in Chapter 7.6 .
Requirements: Actuating the EMERGENCY-STOP smash button must always be possible with-
out any preconditions. Ensure that the EMERGENCY-STOP smash button is
easily accessible at all times.
Fig. 7-8 EMERGENCY-STOP smash button

EMERGENCY- 1. Push down or hit the EMERGENCY-STOP red smash button .
STOP The engine is stopped.
The EMERGENCY-STOP smash button's latching function is blocking the Gen-
erators against renewed operation.
The EMERGENCY-STOP smash button is locked in place in its actuated state.
The generator can only be switched back on again after the danger has been
eliminated if the EMERGENCY-STOP smash button is unlocked manually. How
to unlock the EMERGENCY-STOP smash button:
Requirements:  The danger or cause of the EMERGENCY-STOP process has been eliminat-
ed.
 All of the connected consumers are disconnected or switched off
Unlocking the 1. Turn the red smash button on the EMERGENCY-STOP slightly to the left
EMERGENCY- or to the right.
STOP This will unlock the red smash button and it will spring back up into its normal po-
sition.
The Generators is now ready for operation again and it can be restarted, see
Chapter 7.3 .
43
Commissioning
7.8 Connection of power consuming equipment
DANGER!
DANGER!
There will be no RCD personal protection during operation if the earthing
of the Generators is faulty.
Mortal danger from electrocution
► The use of an RCD (FI circuit breaker) for personal protection requires proper
earthing of the Generators and this must be undertaken by a qualified elec-
trician before the initial commissioning.
► The effectiveness of this protective measure should be regularly checked by
an electrician.
► Check the personal protection according to the check intervals given in Tab.
5-1 .
Consumables are connected up through measures implemented by an

electrician and they are connected to the terminal strip.
44
Maintenance
8 Maintenance
Generators maintenance is described in this section. It may only be per-
formed by qualified specialist personnel.
Maintenance and repair which is neither described in this operating manual
nor in the possibly also delivered operating and maintenance instructions
may only be undertaken by authorized service personnel from the manu-
facturer.
8.1 Maintenance plan

Maintenance work on your generator must be performed periodically in or-
der to secure its readiness to use and reliability over a long period. This
work is only to be undertaken by trained specialist personnel. Contact your
dealer or our
Service hotline +52 (442) 192.9100
[email protected]
NOTICE!
Please note that, in the case of a concluded warranty agreement, you will
lose all rights to make claims if your generator is not serviced according to
manufacturer regulations.
Maintenance work on the power generator mainly concerns working on the

drive motor as well as some work on the remaining equipment.
NOTICE!
Always abide by the accompanying operating and maintenance instruc-
tions provided by the engine manufacturer when carrying out maintenance
work on the drive motor.
The most important maintenance tasks are described in the following overview
of the schedule and scope of the necessary maintenance work. Always abide by
the maintenance schedule given in the accompanying operating and mainte-
nance instructions provided by the engine manufacturer:
45
Maintenance
daily / after 8 hours (during operating times)
 Check the engine oil level

 Check the coolant level
 Check the cleanliness of the heat exchanger
 Check the cleanliness of the air filter
 Drain off the water from the fuel pre-filter
 Check / refill the battery acid level and clean the terminals
after 300 hours
 Check the tensioning and state of the v-belts
after 600 hours
 Lubricating oil change

 Oil filter change
 Fuel filter change
 Fuel pre-filter change
after 900 hours
 Change the oil vapour filter (electric motors)
after 1,200 hours
 Change the v-belts for the auxiliary equipment

 Change the air filter
 Change the coolant
Tab. 8-1 FPT engine maintenance schedule, source FPT engine operating and mainte-
nance instructions
8.2 Maintenance work

Only authorised personnel are allowed to carry out maintenance tasks.
Carry out all of the maintenance work listed in the maintenance plan ac-
cording to the instructions given in the accompanying operating and main-
tenance instructions provided by the engine manufacturer. This operating
manual merely describes the instructions that differ from or go beyond
those instructions.
DANGER!
Mortal danger from unintentional generator start up.
Danger of burns and being caught by rotating parts.
► Before accessing the generator you must switch it off and secure it so that
unintentional starting of the machine is prevented under all circumstances.
(see Chapter 7.2 as well).
46
Maintenance
CAUTION!
Certain surfaces on the device can get very hot whilst it is running.
Risk of burns
► Always leave hot engine parts to cool down before touching them.
NOTICE!
Also always read about the checking and maintenance work which con-
cerns the electrical safety of the generators in the chapter “Checking the
electrical safety“.
8.3 Starter battery

Your Generators has a 12V for supplying power to the starter motor and the en-
gine control unit of the drive engine.
NOTICE!
Your Generators was fitted with a maintenance-free starter battery in the
factory.
► It is imperative that you abide by the accompanying battery handling instruc-
tions.
8.3.1 Charging the battery

The battery can discharge after a longer immobilisation period or exces-
sive power consumption in the control circuit of the generator.
Always remove the starter battery before charging (see Chapter 8.3.2 ). Exactly
observe the handling instructions provided by the battery manufacturer. Wrong
charging destroys the battery!
WARNING!
static discharge.
 The starter battery is removed.

 For charging the starter battery is located at a well ventilated location.
47
Maintenance
1. Attach the starter battery according to the regulations from the battery and
charger manufacturers.
2. Set a suitable charge current for the charger if necessary.
3. Switch off the charger of expiry of the charging time.
4. Disconnect the starter battery from the charger.
5. Allow the starter battery to rest for about thirty minutes.
6. Install the starter battery again in the generator (see Chapter 8.3.2 ).
The starter battery is charged.
If the generator cannot be started after fully charging the battery, there is a defect
in the starter power circuit of the generator. Contact your service partner.
NOTICE!
The starter battery from the factory is maintenance-free throughout its en-
tire service life.
► Never try to open the battery - risk of destruction.
8.3.2 Replacing the battery
WARNING!
static discharge.
48
Maintenance
Fig. 8-1 Starter battery

requirements:
Proceed as follows to change the starter battery:
 Power generator is switched off (switch 7.3 - is in the “OFF” position)
 Battery disconnecting switch is in the “OFF” position.
 You are wearing personal protective equipment
1. Pull off pole protection cap (if fitted) from the battery’s negative pole and the
negative cable Fig. 8-1 -must always be the FIRST cable to be disconnect-
ed from the battery.
2. Pull off pole protection cap (if fitted) from the battery’s positive pole and the
positive cable Fig. 8-1 -must always be the LAST cable to be disconnected
from the battery.
3. Undo the two fixing nuts and then remove the retaining bracket Fig. 8-1
from the battery.
4. Remove the battery from the power generator.
The starter battery is now removed.
5. Prepare a new starter battery (abide by the battery manufacturer’s instruc-
tions).
6. Place the starter battery in the battery compartment.
7. Use the retaining bracket Fig. 8-1 to secure the starter battery in place .
8. FIRST attach the plus cable Fig. 8-1 to the positive pole of the battery and
then pull the red pole protection cap over the pole if necessary.
9. Fasten the negative cable Fig. 8-1 LAST to the minus pole of the battery
and then pull the pole protection cap over the pole if necessary.
10. Turn the battery disconnector switch into the ON position (image )
The starter battery has been replaced. The generator can now be started.
49
Maintenance
8.4 Engine oil

The drive motor for your generator, like every internal combustion engine,
requires the required engine oil for cooling and inner cooling. It is also very
important to use the correct engine oil, both for refilling and when chang-
ing the oil, and to adhere the stipulated maintenance intervals. Refer to the
accompanying operating and maintenance instructions provided by the
engine manufacturer for all necessary information.
Fig. 8-2 Viscosity grade engine oil
8.4.1 Checking the oil level

Your generator is fitted with a low oil automatic switching off system to prevent
the engine from being damaged due to a low oil level. It has two functions:
1) It prevents the engine from starting with an insufficient engine oil level
2) It switches off the drive motor whenever the engine oil level drops below the
minimum value during operation.
The engine oil level must be checked regularly despite the fitted protective devic-
es described here (see maintenance schedule 8.1 ).
50
Maintenance
Fig. 8-3 Oil level checking and oil changing
Oil drainage screw
Pump lever
and old oil suction pump
Oil filling inlet
Oil dipstick
CAUTION!
The engine and operating equipment on the generator can get very hot
while running.
Risk of burns
► Allow the engine to cool off for at least five minutes before changing or check-
ing the engine oil.
NOTICE!
Follow the instructions given in the accompanying operating and mainte-
nance instructions provided by the engine manufacturer to ensure that the
precise procedure is used.
51
Maintenance
8.4.2 Changing the engine oil

Your generator's drive motor needs the engine oil and the oil filter to be
changed at regular intervals. The first oil change is due after 50 hours and
then every 600 hours under normal operating conditions (see Chapter 8.1
). The maintenance intervals must be shortened accordingly if used in dif-
ficult operating conditions (e.g. dusty environment, extreme ambient con-
ditions, etc.). All of the necessary information and the handling steps are
described in detail in the maintenance and operating instructions supplied
by the engine manufacturer.
In contrast to the operating and maintenance instructions for the engine Gener-
ators you also have a special oil suction device (see Fig. 8-3 ). All of the engine
components that are important when changing the engine oil and the oil filter can
be accessed via the maintenance flaps on the tank and battery side.
NOTICE!
Leaking engine oil contaminates the soil and groundwater.
► Use a suitable oil catching receptacle.
► Old oil is a special waste and may only be disposed of over suitably qualified
collection points.
CAUTION!
The engine and operating equipment on the generator can get very hot
while running.
Risk of burns
► Allow the engine to cool off for at least five minutes before changing or check-
ing the engine oil.
Draining the engine Proceed as follows to pump out the old oil after implementing the preced-
oil ing handling steps in accordance with the engine manufacturer's mainte-
nance instructions:
Requirements:  The power generator is switched off
 When it is still hot: Wait until the engine oil has cooled down to approx. 30°C
– 50°C.
 When it is cold: Run the engine until it has heated up accordingly.
1. Unwind the oil drainage hose and guide its end into a suitable oil collecting
tank (take note of the oil filling quantity).
2. Open the oil filling opening for better venting .
3. Open the shut-off valve.
4. Operate the pump lever on the old oil suction pump .
The old oil will pass through the drainage hose and run into the collecting tray.
5. Clean and stow away the oil drainage hose again when no more old oil
comes out.
6. Close the shut-off valve.
The engine's old oil has now been pumped out.
52
Maintenance
NOTICE!
The other procedures for changing the engine oil correspond with the de-
tails given in the engine's operating and maintenance instructions. Take
note of the other maintenance and disposal of operating equipment in-
structions that can be found there.
53
Storage
9 Storage
It is important to store the device at a suitable storage location as soon as your
generator is no longer being used.
• The storage location must be roofed and must not be subjected to standing
water, aggressive vapours or soiling as well as major accumulation of dust.
• Protect your device with a cover made out of breathable material.
• Ensure that the storage temperature and air humidity lie within the specified
limits (see Technical data).
NOTICE!
Due to the limited shelf life of the different operating fluids, it is important
for decommissioning for more than one month that additional measures
for storage are taken. While doing this observe the instructions given in the
attached operating and maintenance instructions from the engine manu-
facturer.
54
Disposal
10 Disposal
Your device, which is an electrical or electronic device, is subject to European Di-
rective 2012/19/EU (“WEEE directive“) which is implemented in Germany in na-
tional law through the decree regulating the use of dangerous substances in
electrical and electronic equipment (ElektroStoffV). This regulates disposal and
use of recycling waste electrical equipment. The adjacent icon with a crossed-out
wastebasket on your device states that it must not be disposed of in the house-
hold waste at the end of its service life.
As a private end-user (a so-called b2c customer) there are free collecting points
(recycling centre) near you for electrical equipment as well as possible also other
collection points available for reuse of devices. The addresses can be obtained
from your city or communal authority. In as far as the old electrical and electronic
equipment contains personal data, you are responsible yourself for its deletion
before giving it back.
Pure b2b devices (devices which, for appropriate use, or exclusively are only
used the commercial area) must not be disposed of over public collecting points
in Germany and further EU countries. Speak to your authorised ENDRESS gen-
erator dealer about handing back your recycling waste electrical equipment. The
dealer is also your point of contact for any differing regulations on the respective
country of deployment. There are also possible agreements in the purchase con-
tract to observe.
Please observe the pertinent environmental protection regulations when dispos-
ing of the old oil. We recommend bringing the oil in a closed container to an old
oil collection centre for disposal. Never put used engine oil in the domestic waste.
Storage or introduction of old oil into nature is associated with very high fines.
An inappropriately disposed of battery can greatly damage the environment.
Give back your old battery directly free of charge to your dealer when purchasing
a new one.
Always observe the valid local regulations and laws concerning correct disposal
of all old parts and operating materials. Please contact your ENDRESS service
partner for a replacement.
55
Troubleshooting
11 Troubleshooting
The following table is an aid for you to use in a case where faults arise
during use. Based on experience a number of malfunctions can already be
removed by operating personnel or the possible causes limited. In all other
cases contact your service partner as described in the table. The same ap-
plies for faults which are not listed in the table.
If a fault cannot be removed using the remedies described, shut down your gen-
erator and secure it against further use. Contact your service partner and give
him an explanation, not only of the symptoms but also the possible causes which
you can already exclude based upon the table. In this way you are supporting the
diagnostic process so that the fault can often already be identified over the tele-
phone or through written exchange with our specialists.
NOTICE!
The following table does not make any claims to completeness and does
not mention any faults which can be caused by operating error.
► In order to avoid operating errors, please exactly follow the instructions in the
existing and delivered documentation.
Malfunction possible cause Correction
Fuel level too low Top up with fuel
The fuel filter is clogged. Replace the fuel filter.
The fuel is unusable due to overaged Carburettor cleaning,

clean the fuel tank and replace
the fuel
The engine turns but does not Spark plug connector detached Firmly put the spark plug con-
start. nector in place again
The spark plug is very dirty or defec- Clean the spark plug and ad-
tive just or replace it
Engine oil level too low (oil lack auto- Bring the engine oil level up to
matic switch-off) the maximum
Insufficient compression Contact your service partner
The starter battery is discharged or Clean a corroded battery pole

defective (only for electrical starting) Check the starter battery and
charge it or replace it
The engine does not rotate
Starter defective Replace the starter
Engine mechanically blocked (also Contact your service partner

for starting by hand)
56
Troubleshooting
Malfunction possible cause Correction
Fuel level too low Top up with fuel
The fuel filter is clogged. Replace the fuel filter.
Engine oil level too low (oil lack auto- Bring the engine oil level up to
The engine starts but stops
matic switch-off) the maximum
again shortly afterwards
Spark plug connector detached Firmly put the spark plug con-
nector in place again
Tank ventilation (tank cover) blocked Clean ventilation holes
Overload protection triggered (oper- Connect up a piece of power

The generator is running but ating status display lights up red) consuming equipment with a
there is no (output) voltage at low output
the socket
The alternator or cabling is defective Contact your service partner
The engine speed regulator is wrong- Contact your service partner

ly adjusted or defective
The generator is running but The electronic voltage regulator is Contact your service partner
the output voltage is outside of wrongly adjusted or defective
tolerance
The load of the attached power con- Connect up a piece of power
suming equipment is too high consuming equipment with a
low output
Operation under extreme climatic Adapt to the climatic condi-

conditions tions or stop the generator
The power output remains sig-
The generator has been poorly ser- Perform maintenance work
nificantly below the nominal
viced
output
The generator has reached its wear Contact your service partner
limit
The engine oil level is too high Draining off excess engine oil
The air filter insert (paper) is dirty or Clean the air filter insert or re-
The engine smokes contaminated with oil place it
The air filter insert (foam) is dirty Clean the air filter insert and
re-oil it
The engine is still in the warm up Wait until the engine has
phase reached its operating tem-
perature
The generator is running at a
high speed and with strong The carburettor is wrongly adjusted Contact your service partner
voltage fluctuations or defective
The engine speed regulator is defec- Contact your service partner

tive
Tab. 11-1 Troubleshooting
57
Troubleshooting
Please contact our customer service for further fault diagnosis as well as pro-
curement of original spare parts and wear parts at
Service hotline +52 (442) 192.9100

[email protected] or
www.endressparts.com (see Chapter 13 )
58
Technical data
12 Technical data
The following table contains the technical data for your generator.
Name Value Unit
ESE 67 IW/AS ESE 125 IW/AS ESE 220 IW/AS
Max. output [LTP] 75/60 125/100 226/180.8 [kVA/kW]
Continuous output [PRP] 68/54.4 114/91.2 205/164 [kVA/kW]
Nominal output factor ~3 0.8 [cosφ]
Nominal frequency 60 [Hz]
Nominal speed 1,800 [min-1]
Nominal voltage ~3 / 1~ 220 / 127 [V]
Nominal current [PRP] ~3 98.2 164.5 295.9 [A]
Empty weight (approx.) 1,360 1,580 2,050 [kg]
Tank capacity 170 290 [l]
Fuel consumption (at 75%

9.6 18.3 34.8 [l/h]
load) 1)
Running time (at 75% load) [h]

about 1)
Length 2,650 3,190 [mm]
Width 1,080 1,125 [mm]
Height 1,786 1,905 [mm]
Sound power level LWA 3) [db (A)]
Noise pressure level

[db (A)]
in the workplace LpA2)
Noise pressure level

[db (A)]
at a distance of 7m LpA3)
Switch cabinet protection

IP 23 IP
class
1)
Average value; deviations might occur in specific cases, therefore they are non-binding
2) Measured at a distance of 1 m and a height of 1.6 m in accordance with ISO 3744 (Part 10)
3)
Measured in accordance with ISO 3744 (Part 10)
Tab. 12-1 Power generator technical data
59
Replacement parts
13 Replacement parts
Maintenance and replacement parts can be obtained quickly and easily
from your responsible ENDRESS service partner or ENDRESS dealer. You
can alternatively obtain support from our central customer service
by telephone: +52 (442) 192.9100
by email: [email protected]
Have the item and serial number of your device ready for identification.
As a registered user you can obtain rapid and uncomplicated access to a range
of services over our home page to obtain suitable original spare parts for main-
tenance and repair work. Using your internet browser please go to
https://endressparts.com
and click on the area “Documentation and replacement parts“.
Fig. 13-1 Spare parts over endressparts.com
60
Replacement parts
NOTES
61
Replacement parts
NOTES
62
Replacement parts
Keyword index
A Starting 35
alarm list 41 T
C Turning off 42
Control mode U
AUTO 38 under the operator's obligations 25
MANUAL 37
OFF 37 W
switching 39 Warning notices 18
control mode 37 WEEE directive 55
control module 37
Control panel 28 30
Crane loading lug 28
Customer service 60
D
DIN ISO 3864 7
display windows 41
E
Earthing 25
earthing 10
Electrical safety 25
EMERGENCY-STOP smash button 30 43
energy supply company 11
evaluated 18
Exhaust gases 20 36
H
Home page 60
I
Imprint 2
included in delivery 12
M
misuses 10
O
operating manual 7
Operating personnel 18 23
Own tank 33
R
refuel 33
Resetting an error message 39
S
safety instructions 16
Safety symbols 16
Standards
DIN EN ISO 12100 18
DIN EN ISO 8528-13 18
DIN VDE 82079-1 6
ISO 3864 18
ISO 7010 16
standards
DIN EN 60204 18
starter battery 47
63
Elektrogerätebau GmbH
Neckartenzlinger Str. 39
D-72658 Bempflingen, Germany
Tel: +49 (0) 7123 /9737-0

Fax: +49 (0) 7123 /9737-50
www: www.endress-stromerzeuger.de
© 2020, ENDRESS Elektrogerätebau GmbH

ESE Power Generator: Translation of The Original Oper-Ating Manual

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ESE Power Generator: Translation of The Original Oper-Ating Manual

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ESE Power Generator

TRANSLATION OF THE ORIGINAL OPER-

ESE 75-250 IW/AS

Tel: + 49 (0) 71 23 / 9737 - 0

Document number / E136679 / i01

Copyright   2020 ENDRESS Elektrogerätebau GmbH

2 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

4 For your safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

5 Checking the electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

6 Description of the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

12 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

13 Replacement parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Keyword index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Fig. 3-1 Example of a type plate .9

1.2 List of tables

Tab. 3-1 Labels on the device .15

2 About this manual

2.1 Constituent parts of the documentation

2.2 Using this operating manual

signs warning about dangers to life and limb

Notices on avoidance of damage to the device

Symbols and formattings in the text

3.2 Your product

Fig. 3-1 Example of a type plate

3.2.1 A device description and intended use

to DIN VDE 0100-551: 2017-02 is used as the protective separation measure.

3.2.2 Foreseeable misuse

3.3 included in delivery

Fig. 3-2 included in delivery

Coolant overflow tank

(no image operating manual

3.4 Labels on the generator

Fig. 3-3 Labels on the device

Item Label Significance

Read the operating manual

Item Label Significance

Tab. 3-1 Labels on the device

4 For your safety

4.1 Safety symbols

Warning of a general hazard

Warning of a dangerous electrical voltage

Warning of potentially explosive materials

Warning of toxic substances

Warning of corrosive substances

Warning of environmentally damaging substances

Warning of hot surfaces

Warning of a suspended load

Warning of automatically starting machines

4.2 General safety instructions

4.3 Residual risks

danger. Exactly impress upon yourself the identification marking of the

4.4 Authorised operating personnel – qualifications

4.5 Danger zones and work areas

Product's service life phase Danger zone

Transport and installation within a radius of 1m around or below the de-

Operation within the outer limits of the device

Tab. 4-1 Danger zone on Generators

5 Checking the electrical safety

We recommend the following checks and deadlines as general guideline values:

When What / how Who

*) Download as a text file under → www.dguv.de Webcode:

Tab. 5-1 Recommended test intervals

6 Description of the device