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Telair TIG 3000D, Use And Maintenance Manual And Instructions For Installation

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Telair TIG 3000D Use And Maintenance Manual And Instructions For Installation Download Page 4

 

 

TIG 3000 D

 

Vers. 002

 

4 

 

GB 

 
 

CONTENTS 

 
1 GENERAL INFORMATION ............................................................................................................... 7

 

2 CHARACTERISTICS ........................................................................................................................ 7

 

2.1   Technical Specifications ............................................................................................................ 7

 

2.2   Overall dimensions ................................................................................................................... 8

 

2.3   Main components ...................................................................................................................... 8

 

2.4   Identification plate ..................................................................................................................... 8

 

3 SHIPPING, HANDLING, STORAGE ................................................................................................. 8

 

3.1   Storage ..................................................................................................................................... 8

 

3.2   Weight ...................................................................................................................................... 8

 

3.3   Handling ................................................................................................................................... 9

 

4   INSTALLATION .............................................................................................................................. 9

 

4.1   Preliminary information ............................................................................................................. 9

 

4.2   Instructions for generating set fixing .......................................................................................... 9

 

4.2.1 Ventilation and protection ..................................................................................................... 9

 

4.2.2   Hanging installation .......................................................................................................... 10

 

4.2.3  Floor mounting .................................................................................................................. 10

 

4.3   Connecting the external exhaust silencer ................................................................................ 11

 

4.4   Connecting the fuel pipes ........................................................................................................ 12

 

5   ELECTRIC WIRING CONNECTIONS ........................................................................................... 12

 

5.1   Access to internal electrical connections ................................................................................. 12

 

5.2   Safety Switch .......................................................................................................................... 13

 

5.3   Battery connection .................................................................................................................. 13

 

5.4   Connection to a 230 V~ utility ................................................................................................. 13

 

5.5   Cut-off Relay connection ......................................................................................................... 14

 

5.6   Electronic control panel connection ......................................................................................... 15

 

5.7   Auxiliary connections .............................................................................................................. 15

 

5.8   Connection to the fuel tank ..................................................................................................... 16

 

5.9   Connecting two TIG3000D units in parallel ............................................................................. 16

 

5.10   Isolating the internal battery charger ..................................................................................... 17

 

6   OPERATING INSTRUCTIONS ...................................................................................................... 17

 

6.1   Machine safety ........................................................................................................................ 17

 

6.2   Fuel......................................................................................................................................... 18

 

6.3   Useful tips ............................................................................................................................... 18

 

7 CONTROL PANEL .......................................................................................................................... 18

 

8 GENERATING SET USE ................................................................................................................. 19

 

8.1   First starting ............................................................................................................................ 19

 

8.2   Information menu .................................................................................................................... 19

 

8.3   Language Setting .................................................................................................................... 20

 

8.4   Starting the generator in manual mode ................................................................................... 20

 

8.5   Generating set stop ................................................................................................................. 20

 

8.6   Starting the generating set in automatic mode ........................................................................ 20

 

8.7   Remote starting ...................................................................................................................... 21

 

8.8   BOOST Function..................................................................................................................... 21

 

8.9   Alarm messages and causes .................................................................................................. 21

 

8.9.1   Over load ......................................................................................................................... 21

 

8.9.2   Short circuit ...................................................................................................................... 21

 

8.9.3   Low output voltage ........................................................................................................... 22

 

8.9.4   Oil pressure ...................................................................................................................... 22

 

8.9.5   Engine temperature too high ............................................................................................ 22

 

8.9.6   Data communications error .............................................................................................. 22

 

8.9.7   Error codes ...................................................................................................................... 22

 

8.10   Warning messages and causes ............................................................................................ 22

 

Summary of Contents for TIG 3000D

Page 1: ...Vers 001 TIG 3000 D I 1 USE AND MAINTENANCE MANUAL AND INSTALLATION INSTRUCTIONS TIG 3000D V 002 January 2017 GENERATORS GB ...

Page 2: ...c safety symbols have been employed in this booklet to identify different levels of dan ger or important information Information to avoid potentially danger ous situations that could result in serious injury or possible harm to one s health Information to avoid situations that could potentially result in damage to property Important information for correctly carry ing out the operations described ...

Page 3: ... ating set casing and use only approved type fire extinguishers Never use water to put out flames in the generating set This equipment is not intended for use by people including children with physical sensory or mental limitations or lacking experience or knowledge unless they have been instructed in the use of the equipment by a person responsible for their safety The information contained in th...

Page 4: ...30 V utility 13 5 5 Cut off Relay connection 14 5 6 Electronic control panel connection 15 5 7 Auxiliary connections 15 5 8 Connection to the fuel tank 16 5 9 Connecting two TIG3000D units in parallel 16 5 10 Isolating the internal battery charger 17 6 OPERATING INSTRUCTIONS 17 6 1 Machine safety 17 6 2 Fuel 18 6 3 Useful tips 18 7 CONTROL PANEL 18 8 GENERATING SET USE 19 8 1 First starting 19 8 2...

Page 5: ...d personnel 24 9 2 1 Checking the engine oil level 24 9 3 Maintenance operations to be carried out by skilled personnel 25 9 3 1 Engine oil replacement 25 9 3 2 Air filter maintenance 26 9 3 3 Diesel fuel filters replacement 26 9 3 4 Oil filter maintenance 27 9 3 5 Complex maintenances 28 10 DECOMMISSIONING AND DISMANTLING INSTRUCTIONS 28 11 GENERAL WARRANTY TERMS 29 12 TIG 3000D WIRING DIAGRAM 30...

Page 6: ...written ap proval Machine GENERATING SET Model TIG 3000 D Maximum power 2 5 KW 3200 r p m Serial number Directive of reference Machine Directive 2006 42 CE Low Voltage Directive 2014 35 UE Electro magnetic Compatibility 2014 30 UE Regulation 10 UN ECE rev 4 amendment 1 and 2 Directives noise emission in the environment 2005 88 CE 2000 14 CE Attachment VI procedure 1 DLGS 262 2002 Measured noise po...

Page 7: ...r via the supplied remote control panel which can be in stalled on the inside of the vehicle or from an optional domotics control unit As part of its product development and upgrade policy the manufacturer reserves the right to in troduce modifications without prior notice 2 CHARACTERISTICS 2 1 Technical Specifications Output voltage V ac 230 2 Output frequency Hz 50 1 Maximum continuous power kW ...

Page 8: ...ating set model 2 Serial number 3 Frequency 4 Power factor 5 Maximum electric power 6 Maximum output current 7 Rated voltage 230V AC 8 Battery charger specifications 9 Weight 3 SHIPPING HANDLING STORAGE 3 1 Storage During transport and storage the generator is protected by suitable cardboard packaging and placed on a wooden support base It must be stored horizontally in a covered dry and well vent...

Page 9: ...E Moreover the manufacturer will not be liable for any resulting injury or damage 4 2 Instructions for generating set fixing The generator is equipped with 4 support brack ets fig 4 ref 2 fixed on the sides that allow for both wall mounting and floor mounting 4 cylindri cal vibration damping mounts fig 4 ref 1 and 2 omega shaped mounting brackets fig 4 ref 3 are supplied particularly useful for eq...

Page 10: ... in a pulling configuration as shown in fig 8 is strictly not permitted Ensure that the ride height of the gen erator is not such as to risk contact with the ground during travel A good rule is to ensure that the ride height of the lowest point of the generator is not less than that of the other components of the vehicle on which it is in stalled 4 2 3 Floor mounting Is it possible to install TIG3...

Page 11: ...hot air is recycled by the generator in addition to a system shutdown occurring when the safety temperature threshold is reached irreparable damage may occur to the internal combustion engine and the electronic boards 4 3 Connecting the external exhaust silencer The generator is supplied with an external ex haust silencer kit consisting of the silencer a flexible steel pipe and accessories for gen...

Page 12: ...ator in any case the height gap should never exceed 50 cm The fuel tank should be installed at a location protected from external water infiltrations and away from sources of heat In case of connection to the vehicle tank ensure direct fuel inlet and outlet from and to the tank and NOT through bypass hoses supplying fuel to the vehicle engine or other utilities To facilitate the first generator st...

Page 13: ...tery for the required specifications see the table with generator data Depending on the re quirements it can be connected either to the ve hicle battery or to the service battery The connected battery is charged by the genera tor itself with a maximum current of about 10 A For connection purposes insulated cables of dif ferent colours should be used usually red and black connected to the positive ...

Page 14: ...c cutout switch for single phase network in the utility distribution control panel with maximum capacity 12 A It is good practice to close the switch after starting the generator and re open it before switching it off Once the connections have been made replace the terminal block cover Fig 17 ref 3 5 5 Cut off Relay connection If a 230 V voltage is applied to the generating set output even for a s...

Page 15: ...wall using the 4 self tapping screws then apply the frame fig 20 ref 3 by exerting a slight pressure until you hear the anchor tabs click in The supplied standard cable is 5 m long Also available are optional 7 m long 10 m long and 15 m long cables Connect the other end of the connection cable to the corresponding white connector on the gen erator fig 22 ref 3 5 7 Auxiliary connections The termina...

Page 16: ...ly fitted with a tap with a reserve indicator When choosing the position in which to install the fuel tank ensure that the fuel line length is as short as possible Position the fuel tank away from sources of heat and in a location protected from external water The level of the tank must differ by no more than 20 cm from that of the generator If the fuel tank is installed at a level much lower than...

Page 17: ...ts own The first generator to be started automatically becomes the master 5 10 Isolating the internal battery charger In the event that it is decided to isolate the inter nal battery charger from the generator a fuse must be removed from the motor control circuit board In this instance the battery will not be recharged and an external device will have to be used To isolate the internal battery cha...

Page 18: ...ONTROL PANEL The generator is equipped with an original re mote control panel from which it is possible to control its operation fig 30 The panel has a access port for connection to an domotics control unit and a USB port for connec tion to a PC Controls and signals on the panel Fig 30 1 ON OFF switch allows control panel activation The display 2 and the LED 11 are switched on 2 Display allows gen...

Page 19: ... First starting If the fuel supply circuit is empty the first start up can be difficult because the elec tric pump will take several seconds to fill it You may want to perform a number of at tempts Before the first starting check the oil level in the engine see the chapter concerning mainte nance Turn the safety switch fig 16 ref 1 on the gen erator to I Set to ON the switch fig 30 ref 1 on the co...

Page 20: ...ator stand by state icons sequence 8 4 Starting the generator in manual mode Press the START STOP button the corre sponding LED lights up fig 30 ref 9 and the generator controls the starting procedure the display shows the icon Once the equipment has started the display re peatedly shows the sequence of icons related to the generator state of operation alternate when the generator makes 230 V volt...

Page 21: ...rting the generator At this point the generator is ready to receive a command on the REMOTE connector when the contact is closed the generator will start and it will stop when the contact is opened Should any high level alarms come from the generator such as oil or temperature the signal from the D input or pressing the START STOP button on the control panel will take priority over the REMOTE On O...

Page 22: ...is is the list of the main alarm codes 1 Start up failed 2 Battery voltage too low 3 Motor over revving 4 Oil level or pressure 5 Motor over heating 9 Data connection to inverter lost 50 Short circuit on inverter output 51 Overload on inverter output 52 Inverter voltage too low 53 Inverter over heating 57 An inverter input phase is missing 59 Inverter continuous voltage too high 8 10 Warning messa...

Page 23: ...al has been performed this message indicates that the fuel has reached the minimum reserve level and the maintenance LED lights up Fig 30 ref 7 The generator will continue to operate until the fuel runs out 8 10 4 Stop with D signal if the connection described in another part of the manual has been performed this message indicates that the generator has stopped due to a change in status of the D s...

Page 24: ...ease refer to the tech nical manual of the engine manufacturer supplied together with the generator 9 2 Checks not requiring skilled personnel To perform this kind of inspections it will be nec essary to open the door of the generating set The following precautions must therefore be taken 1 The generator must not be running 2 All its parts must be cold 9 2 1 Checking the engine oil level Engine oi...

Page 25: ...make it easier to drain the spent engine oil it is advisable to let the engine run for approxi mately 3 minutes in this way the oil will be more fluid and emptying will be quicker and more thor ough The drain plug for emptying the oil sump is lo cated on the generator underside fig 37 ref 1 Remove the oil filler cap fig 35 ref 2 Remove the rubber guard fig 37 ref 2 on the generator bottom Then rem...

Page 26: ...emoving the lid screw out the filter knob fig 39 ref 2 and take out the air filter fig 39 ref 1 Lightly tap the cartridge on a hard surface to re move any excess dust or blow the filter clean in side out with compressed air fig 41 Never brush the filter cartridge as this would push dust in between the fibres If excessively dirty replace the filter cartridge 9 3 3 Diesel fuel filters replacement Th...

Page 27: ...ilter maintenance For cleaning the engine oil filter is necessary to remove it from its housing fig 42 ref 1 loosen ing the screw as indicated Take the filter out of its seat fig 43 ref 1 Clean the oil filter cartridge by blowing com pressed air inside out fig 44 Check the sealing rings fig 45 ref 1 and ref 2 for damage and make sure they are properly fixed in its seat Replace if necessary ...

Page 28: ... through the cable grommet Fig 16 ref 2 disconnect the electrical output and control cables Disconnect the external fuel filter and the fuel return line Fig 14 Disconnect the exhaust pipe from the internal muffler Fig 12 ref 3 Remove the 7 screws indicated in Fig 49 At this point the generator can be removed from the case running the two fuel lines coming from within the generator through their re...

Page 29: ...no later than 14 months 16 months if delivered outside of Europe after ex fac tory delivery In any case the costs of lubricants and consumables will be charged Any transport expenses will have to be covered by the purchaser the same ap plies to any expenses connected with inspections requested by the customer and accepted by TELAIR The manufacturer s warranty shall only be valid if the customer ha...

Page 30: ...TIG 3000 D Vers 002 30 GB 12 TIG 3000D WIRING DIAGRAM ...

Page 31: ...Vers 002 TIG 3000 D 31 GB ...

Page 32: ...en Identifying parts 1 Engine 2 Electric start motor 3 Oil pressure probe 4 Engine temperature probe 6 Elettrostop valve 7 Stepper motor 8 Internal electrical fuel pump 9 Stator 10 Battery charger 11 Inverter 12 Engine control board 13 Safety breaker 14 230 V out power terminal strip 15 Auxiliary terminal strip 16 Control panel cable connector 17 REMOTE On Off connector 18 E P O connector 19 Signa...

Page 33: ...Vers 002 TIG 3000 D 33 GB 13 TIG 3000D LIST OF SPARE PARTS ...

Page 34: ...TIG 3000 D Vers 002 34 GB ...

Page 35: ...Vers 002 TIG 3000 D 35 GB ...

Page 36: ...TIG 3000 D Vers 002 36 GB ...

Page 37: ...ere Isolierung Haube Aislante Superior Capò 6 06598 N 1 Isolante protezione mar mitta Isolation protecteur d échappement Isolatie van de Geluid demper Muffler protector insulation Schutzisolierung aus dem Schalldämpfer Aislante del silenciador 7 06585 N 1 Isolante 1 Sinistra Cofano Isolation 1 Gauche Capot Isolatie 1 links voor kap Left hood insulation 1 Isolierung 1 links für Haube Aislante 1 Izq...

Page 38: ... Inferior de la Puerta 18 06492 N 1 Guarnizione superiore Sportello Joint Supérieur de la Porte Boven Afdichting van der Deurtje Door upper seal Obertürdichtung Sello Superior de la Puer ta 19 06208 N 4 Staffa di sostegno Bride de Support Steunbeugel Support bracket Haltebügeln Estribo de Soporte 20 02117 N 4 Antivibrante Anti vibration Trillingsdempers Vibration damper Schwingungsdämpfer Antivibr...

Page 39: ... 32 06593 N 1 Isolante 2 per panello in terno Isolant 2 pour Panneau Intérieur Isolatie 2 voor Interne Paneel Internal Panel Insulation 2 Isolier 2 für Internen Pa nel Aislante 2 para Panel In terior 33 06133 N 1 Pannello Superiore Panneau Supérieure Boven Paneel Upper Panel Höher Panel Panel Superior 34 06599 N 1 Isolante 1 pannello supe riore Isolant 1 pour Panneau Supérieur Isolatie 1 voor Bove...

Page 40: ...g naar de motor Engine Fuel inlet Hose Kraftstoffzuleitungsrohr zu dem Motor Tubo Entrada Combusti ble al Motor 44 06498 N 1 Tubo ingresso carburante Tuyau d admission de carburant Inlaat Slang Brandstof Fuel inlet Hose Kraftstoffzuleitungsrohr Tubo Entrada Combustible 45 06495 N 1 Tubo ritorno carburante Tuyau pour Retour Car burant Brandstof Retourslang Fuel Return Hose Kraftstoff Rücklaufschlau...

Page 41: ...ut Terminal block 3 pole 4 mm Ausgangs klemmblock 3 polig 4 mm Bornes de salida de 3 po los 2 5 mm 58 06137 N 1 Convogliatore scarico aria Déflecteur d air sortant Luchtgeleider Afvoerlucht Air exit duct Ausgegeben Luftleitblech Deflector para aire en sa lida 59 06499 N 1 Ventilatore superiore Ventilateur supérieur Opper Ventilator Upper Fan Obere Lüfterrad Ventilador Superior 60 06503 N 1 Convogl...

Page 42: ...o filtro aria Virole de fixation du filtre à air Luchtfilter bevestigingsring moer Air filter fixing ring nut Luftfilter Befestigungs ring Anillo por fijación del filtro de aire 70 01197 N 1 Filtro aria Filtre à air Luchtfilter Air cleaner Luftfilter Filtro aire 71 00810 N 1 Tappo scarico olio Bouchon de vidange d huile Olieaftapschroef Lubricant Discharge Stopper Ölablassschraube Tapón de vaciado...

Page 43: ...steuerung Zwischenhebel Palanca Intermedia Control del Acelerador 81 06305 N 2 Vite speciale in bronzo Vis Spécial de bronze Speciaal Schroef van Brons Special bronze screw Spezialschraube aus Bronze Tornillo especial de Bronce 82 06121 N 1 Staffa comando accelera tore Bride Commande de l ac célérateur Beugel Gashendel Con trole Throttle lever Control Bracket Drosselklappensteuerung Estribo para C...

Page 44: ...d stof ElettroStop for Fuel ElettroStop für Kraftstoff ElettroStop para el com bustible 93 06578 N 1 Cablaggio elettrico com pleto Câblage électrique com plet Volledige elektrische bedrading complete electrical wiring Komplette elektrische Verdrahtung Cableado eléctrico com pleto 96 06418 N 1 Pannello di controllo Tableau de contrôle Schakelpaneel Control Panel Bedienpanel Panel de control 97 0379...

Page 45: ... L 2 mt Slang ø30 L 2 mt Flexible Hose ø30 L 2 mt Schlauch ø30 L 2 mt Tubo flexible ø30 L 2 mt 100 02440 N 2 Supporto in gomma per Silenziatore Appui en caoutchouc pour silencieux Rubberen Steun voor Ex terne Uitlaatdemper Rubber support for Si lencer Gummi Unterstützung für Schalldämpfer Soporte de Goma para Silenciador 101 01655 N 2 Fascetta acc speciale 32 35 Collier acier spécial 32 35 Bandje ...

Page 46: ...TIG 3000 D Vers 002 46 GB Notes ...

Page 47: ...Vers 002 TIG 3000 D 47 GB ...

Page 48: ......

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