Telair Generators
Contents
1. 6 DT SOGE A A 6 PA 6 o AA Eo E A 7 A INSTALLA THON WE 7 AA REINA Ee E 7 4 2 Instructions for fastening the generating eet 7 4 3 FASTENING the pressure reducer EN Eai 8 4 4 Wiring connection instructions pp 9 4 5 Battery ee n ee mmm 9 Ao e de e e Keel Ae den DEE 9 4 7 Auxillary electric cable connection pp 10 Ter Le E E 10 4 8 Electronic control panel connection pp 11 e Ce e E 11 4 9 1 Auxiliary Battery Charger pp 11 4 10 Connecting an additional nnne nnn nenas 12 4 11 Connecting an External Network Relay 4 13 5 OPERATING INSTRUCTIONS ascnsii nceciascanaascicasinicicinrc EEN deeg 14 51 E ele EE 14 6 USING THE GENERATING SE WE 15 6 1 Starting up the generating set 15 6 2 Turning the generating sets off nna sre anser sna nns 15 6 3 Information on not recommended USES nennen nnn nna nnne nsn resa nnns 15 04 USCIS 16 6 5 Control and alarm functions Fig 24 16 6 6 Control panel alarm causes and resetting pp 16 7 MAINTENANCE INSTRUCTIONS 17 Ao Eum 17 7 2 Maintenance not requiring specialised poersonnel pp 17 7 3 Checking the engine oil level 4 17 7 4 Maintenance operations to be carried out by qualified 17 7 4 1 Engine oi2. pJeod eje dnes JoOloeuuoo 94045 uoniub uonduosog 9ued 23100J 29 3 T uondiosoeg Energy 2500 G DRAWING FOR SPARE PARTS LIST ENERGY 2500 G GL op 01 62 OPTIONAL Vers 022 Energy 2500 G Vers 022 2500 Tel air Ga 8 7 E Telair sje Inu uJapuos ujezula JUDIU 7 yy un ue SeplpueA sepiun Sezald ue epJepuo BJYDOWIVA JOS uae ui ue epiesjuoulec IN ay nas un ue je ssajguussse seoald d y ejBuis e ui pjos pue Saoald do WY un ul a neuleisse 12294 Vers 022 2500 lt gt Telair i emm Code Descrizione 2 Designation Denomination Description Bezeichnung Descripcion 03895 N 1 Capot sup rieur Bovenste kap Upper hood Obere Haube Cap superior Antivibrante AMV Trillingsdemper 00632 N 7 Vibration e Seelen Anti vibrador penis Anchor clamp serestigungsbpuge Estribo de anclaje D nec Kabelschelle Kraftstoff Taco Portacables Carburante Fuel Cable Holder ven C 3 53 Left hood insulation Isolierung links fur Ha
3. 1999 7 Anchoring bracket LEM 1 8 Electronic control panel MAX OUTPUT 9 Gas pipe and cable outlet block pl o re yp 10 Sliding surface locking screw D C OUTPUT 10a 12 v d c WEIGHT 11 Supply gas arrival pipe 12 Sliding surface all out locking screw 2 3 Overall dimensions Figure 3 shows the dimensions of the generating sets 2 2 Identification plate Fig 2 1 2 3 4 5 6 7 Generating set model Model code number 00 Telair Serial number YAMAHA cas Date of manufacture Power factor Frequency Maximum electric power Vers 022 Energy 2500 G Telair 2 4 Technical specifications ENERGY ENGINE Type Single cylinder 4 stroke LPG overhead valves air cooling Yamaha MZ 175 GAS Displacement cm 171 Bore x Stroke mm 66 x 50 Max Fuel Consumption an D Fuel supply LPG Ignition system opark plug BPR4ES Oil sump capacity litres 0 6 Speed governor Automatic with centrifugal weights ALTERNATOR A ______ Synchronous single phase self adjusting two poles Type brushless 84 T 555 x 385 x 295 58 dBA 7 m Operation Hours 3 SHIPPING HANDLING STORAGE INFORMATION A AAA INFORMATION Do not turn the package upside down The correct position is the one 3 1 Storage GENERATOR A ______ shown by the symbol printed on the package The generating set is protecte
4. aur GENERATORS Tel USE AND MAINTENANCE MANUAL AND INSTRUCTIONS FOR INSTALLATION v 022 December 2008 Telair 1 Telair Via E Majorana 49 48022 Lugo RA ITALY COMPLIANCE STATEMENT Under Machine Directive 89 392 EEC attachment II A We hereby represent that the generating set the data concerning which are specified below has been designed and built to correspond to the essential safety and health requirements laid down by the European Directive on Machine Safety This statement shall no longer be valid if any changes are introduced in the machine without our written approval Machine GENERATOR SET Model ENERGY 2500 G Serial number Reference Directive Machine Directive 89 392 EEC version 91 31 EEC Low Voltage Directive 73 23 EEC Electro magnetic Compatibility 89 336 version 93 31 EEC Harmonised standards applied in particular EN 292 1 EN 292 2 EN 60204 1 DATE 18 12 2008 THE PRESIDENT Energy 2500 G Vers 022 Telair INDEX T FOREWORD WEE 4 1 1 Purpose and scope of this manual pp 4 UC Wun Lee EE ne KEE le e S RR 4 Caedm Umm 4 2 GENERATING SET IDENTIFICATION DATA 5 2 Comnponenls PIO A EE 5 2 2 Identification plate Fig 2 4 5 2 3 Overall dimensions 4 5 24 Tecnica SOC 6 3 SHIPPING HANDLING
5. Energy 2500 G 5 OPERATING INSTRUCTIONS WARNING The generating set is delivered without engine oil Use detergent oil for multigrade 4 stroke petrol engines having SAE viscosity suitable for the operating climate see table and detailed indications user and maintenance manual of the engine ENERGY series generators consist of petrol internal combustion engines connected to an alternator that can produce both alternating and direct electrical current The generating sets are assembled inside a steel plate casing insulated and sound proofed using special sound absorbing materials Fuel is fed to the internal combustion engine via a pump fitted to the generating set as part of the standard supply 5 1 Machine safety The generating sets come with perfectly sealed casings so there is no danger of contact with any moving or high temperature parts or with live cables The doors open with a lock and key The keys must not be left within the reach of children or inexperienced persons The generating sets must only and exclusively be used with their doors shut Remove any flammable substance for example petrol paints solvents etc from near the generating sets Make sure that any hot parts of the generating sets are not in contact with any flammable material Never fill up the fuel tank while the engine is running Never touch the generating sets or the wiring connections with wet hands
6. Thermostat 45 Thermostat 45 Termostato 45 sr cs YAMAHA motor Motor YAMAHA Motor YAMAHA e Bedienpanel ENERGY Panel de control ENERGY ENERGY control panel 5 generatore a C ble 5 m du G n rateur au 5 m kabel van generator naar Pannello di controllo Panneau de Contr le bedieningspaneel o m cable from generating 5 m Kabel von Generator zu Cable 5 m de generador set to control panel Bedienpanel panel de control Cavo 7 m da generatorea 7 m du g n rateur au 7 m kabel van generator naar Pannello di controllo Panneau de Contr le bedieningspaneel 7 m cable from generating 7 m Kabel vom Generator Cable 7 m de generador a set to control panel zum Bedienpanel panel de control 10 m kabel van generator naar bedieningspaneel Cable 10 m de generador a panel de control 15 m kabel van generator naar bedieningspaneel Cable 15 m de generador a panel de control Protezione termica Protection thermique Thermische beveiliging Thermal protection Thermoschutz Protecci n t rmica 37 03796 N 1 037971 N 1 Cavo 10 m generatore Cable 10 m du g n rateur au Pannello di controllo Panneau de Contr le 10 m cable from generating 10 m Kabel vom Generator set to control panel zum Bedienpanel 03798 N 1 Cavo 15 m da generatore a C ble 15 m du g n rateur au Pannello di controllo Panneau de contr le 15 m cable from generating 15 m Kabel vom Generator set to control panel zu
7. attention to a potentially dangerous situation which could cause malfunction or damage the machine The drawings are only provided by way of example Even though the machine you actually have may differ from the illustrations contained in this manual safety and information about the same are guaranteed The manufacturer as part of his policy of constant product development and updating may introduce changes without giving any notice 1 3 General Information The ENERGY generating set has been designed for installation on vehicles lt can deliver power at a voltage of 230 VAC 50 Hz The ENERGY 2500 G model must be fed with LPG In order to achieve a low noise level the ENERGY series generating sets are provided with internally insulated sound proofing cases They can be accessed easily in order to perform maintenance work and are provided with a remote control panel which can be installed inside the vehicle The generating sets can be connected to the tank of the vehicle as long as the fuel type is compatible Otherwise install a special tank which can be supplied as an option Vers 022 Telair 2 GENERATING SET IDENTIFICATION 8 Maximum current DATA 9 Rated voltage 230V AC IUS 10 Current delivered at 12V DC 11 Weight 2 1 Components Fig 1 gt Barcode 1 Sound proofing casing 2 Supporting brackets 3 Access door 4 Access door closure 5 Technical features sticker 6 Anti vibration support YEAR OF MANUF
8. The Manufacturer shall also not be liable for any injury or damage to people or property 4 DANGER Installation must performed by qualified and adequately trained personnel only 4 2 Instructions for fastening the generating set The ENERGY 2500 G generating sets are provided with anchoring brackets with extra vibration dampers Fig 4 Ref 1 and a fuel filter to be fitted along the generator feeding pipe The brackets allow for hanging assembly This kind of assembly provides the following advantages less room taken up quick installation easy access for routine and unscheduled maintenance Make sure that there is enough room around the hood of the generating set to let cooling air through also leave 20 mm free room between the hood and the surrounding parts Should the generating set air intake be behind a wheel of the vehicle care should be taken to prevent water from being sprayed into the generating set by the wheel when raining 7 WARNING Ensure that when the door is open the engine sliding surface can be taken out Fig 9 4 3 FASTENING the pressure The generating set comes standard with the suitable pressure reducer Fig 5 Ref 4 already set and 1 metre long gas hose Fig 5 Ref 2 which is already connected to both the generating set Fig 5 Ref 1 and the pressure reducer The reducer should be fastened using the suitable holes located on the 3 wings Fig 7 Re
9. This way you can operate under safe conditions as the generating set cannot start up 7 1 Service check list See table at the bottom of page 21 7 2 Maintenance not requiring specialised personnel To perform this kind of service it will be necessary to open the generating set door The following precautions must therefore be taken 1 The generating set must not be in operation and all its parts must be cold 2 Let the generating set cool off 7 3 Checking the engine oil level e Unscrew the engine oil filler cap and clean the dipstick Fig 26 Ref 1 Put the dipstick back in without screwing e Take the dipstick out again and make sure that the engine oil level is between the two min and max notches Should the oil level be below the minimum notch restore the oil level using the recommended type of engine oil refer to the engine user and maintenance manual e Put the dipstick and filler cap back on and screw tightly 7 WARNING Do not fill to exceed the maximum level as this could cause malfunctioning of the fuel pump and hence of the generating set Vers 022 For cold climates Energy 2500 G B INFORMATION checking operations must be performed with the generating set in a perfectly horizontal position engine oil level 7 4 Maintenance operations to be carried out by qualified personnel To carry out certain servicing operations it is possible to extract the engine alternator
10. 19 Ref 2 Now insert the hose code 00433 Fig 19 Ref 5 on the coupling Fig 19 Ref 3 Lock the hose with the clamp code 00543 Fig 19 Ref 4 Replace the flame trap parts Fig 21 Ref 2 3 4 5 on the silencer terminal and by using the bracket welded on the silencer fix it at a position where it is not likely to hinder electric cables or fuel pipes IN WARNING po not use silencers not supplied by Telair Silencers that have not been specially sized may damage the motor 4 11 Connecting an External Network Relay An optional relay or change over switch code 05423 Fig 22 should be fitted to the vehicle wiring system lts purpose is to insulate the generating set when the vehicle is connected to an external electric input network Connect the relay Fig 23 according to the following instructions Fix the flexible hose Fig 20 Ref 2 to the Connect the two wires of the 230 V line of the generating set to the PINS 1 3 Connect the user line to the PINS 7 9 Connect the outside line to the PINS 6 4 Jumper the PINS 4 A Jumper the PINS 6 B Connect all the grounding cables together silencer terminal on the inlet side Fig 20 Ref 1 by using the other supplied clamp Fig 20 Ref 3 Vers 022 Energy 2500 G Electric connections to the generating set should be carried out by skilled electricians only SALVAVITA DISJONCTEUR CIRCUIT BREAKER SICHERUNGSAUTOMAT
11. N 1 tronica kaart Wiring with electronic board Verkabelung mit elektronis Cableado con tarjeta elec cher Platine tr nica 12V 70 A Relay Relais 12 V 70 A Rele 12 V 70 A 53 00478 N2 Raccordo 90 1 8 MF Raccord 90 1 8 MF Koppeling 90 1 8 MF 1 8 MF union elbow Anschlussstuck 90 1 8 Empalme 90 1 8 Aluminium washer Alu Scheibe Arandela aluminio pos E Extension Verlangerung Extension Tappo p Dop MK MN Vis de mei A l alternateur Vite fissagio alternatore Bevestigingsschroef 5931 screw Schraube 5931 Tornillo UNI 5931 CASTING 2501 2 GUSSTEIL 2501 2 FUNDICION 2501 2 Alternator washer Scheibe der Lichtmaschine Arandela alternador Alternator bearing Lager der Lichtmaschine Cojinete alternador DIU Mr A m Alternator stator Stator der Lichtmaschine Estator alternador El Motor 12 V 0 30 kW Elektromotor 12 V 0 30 kW Motor el 12 V 0 30 kW Alternator rotor Rotor der Lichtmaschine Rotor alternador DIN s t Ze _ Machined flange Bearbeiteter Flansch Brida trabajada Si dentata Couronne dent e Conisch tandwiel Ss Mozzo flangiato brid e Geflensde Ventilateur Ventilator 01023 g _ 5 022 2500 G f Telair D Code Descrizione J L Designation Denomination NENNEN Description 2386 Bezeichnung Descripcion e 01431 Fusione 2503 C1 Moula
12. Protection en caoutchouc du Beschermrubbertje Diodi 02046 N 1 Diode bridge protection grommet pont de diodes gelijkrichterbrug Gummiteil zum Schutz der Proteccion de caucho puente Diodenbrucke de diodos 01251 N 1 Diodo ponte raddrizzatore Diode redresseur en pont Diode gelijkrichterbrug Bridge rectifier diode Gleichrichterbr ckendiode Diodo puente rectificador Vers 022 Energy 2500 G Telair D A i Pos Code Descrizione E Designation Denomination NENNEN Description lli Bezeichnung Descripcion Tappo olio Bouchon de l huile Oliedop 25 01432 opua Raccordo Ger motors V s Raccord huile moteur Oliekoppeling YAMAHA 00980 N 1 MAHA motor YAMAHA motor oil fittin Olanschluss f r YAMAHA Empalme aceite motor 9 Motor Guarnizione 14x29x15 AL Joint 14x20x1 5 ALUMINIUM Afdichting 14x20x1 5 27 02115 N 1 Dichtung 14x20x1 5 ALUMINIUM Gasket 14x20x1 5 ALUMI ALUMINIUM Junta 14x20x1 5 ALUMINIO NUM a aena a P box Luftfiltergehause Caja filtro aire DCN s _ Filter holding Filtertragnetz Red porta filtro Filtro aria Filtre air Luchtfilter 30 102060 1 Aen _ ale re ment Be _ Air cleaner lid Luftfilterdeckel Tapa filtro aire Candela Bougie Bougie sonn Bua _ meme emm e _ Thermostat 90 Thermostat 90 Termostato 90
13. assembly from the front See paragraph 4 4 This will make it easier to obtain access to all the inside parts of the generating set for unscheduled maintenance or repair operations 7 4 1 Engine oil replacement Use multigrade detergent oil for four stroke petrol engines having a SAE viscosity degree suited to the climate the generating set is working in see table and detailed instructions in the engine use and maintenance manual MULTIGRADE SE SF SAE 154 50 KN KE SAE 101 30 For hot climates 10 0 10 30 20 30 40 To make it easier to drain the spent engine oil it is advisable to let the engine run for 3 5 minutes in this way the oil will be more fluid and emptying will be quicker and more thorough Undo the special cap on the soil sump Fig 27 Ref 1 which can be reached through a special hole under the sound proofing case Fig 28 Ref 2 and allow all the contained oil to be drained to a collecting tank After doing this screw the cap back on and restore the oil level inside the oil sump using the filler hole Fig 26 Ref 2 Check the following table for the right amount of oil to pour in the sump Table 2 Table 2 MODEL Oil quantity litres ____ 06 O 4 DANGER e Hot oil can scald e Causing the engine to run when the oil level 15 too low can seriously damage it Check the oil level when the engine has been turned off Energy 2500 G 8 Spent oil should no
14. generating set is provided with two special terminals Fig 10 Ref 2 3 used to connect the positive and negative poles of the battery Connect the cable of the positive pole red cable to the terminal already having a red cable and the cable of the negative pole black pole to the terminal already having a black cable The cable of the negative pole must be of the same cross section as the positive cable and must be Vers 022 Energy 2500 G Telair connected both to the negative pole of the battery and to the vehicle chassis Make sure there is good contact remove any paint or rust from the contact surface and protect the connection by applying grease The capacity of the battery to be used for starting up must not be less than 80 A h The soundproofing box is equipped with two cable outlets used to let through the battery connection cables Fig 8 Ref 1 The cable presser block is used to prevent water seeping into the power generating set 8 Always fit a 70 fuse onto the positive cable connecting the generating set to the positive pole of the battery 4 6 Electric Load connection To connect loads to the power generating set use a three pole cable up to the applicable standards in force The correct cross section 15 shown in Table 1 Table 1 Sect mm Cable leng Cable leng line 230 V Lgth lt Lgth gt 6m MEC CONNECTION 230 V CONNECTION For connection to the 230V input l
15. right corner Fig 24 Ref 10 and release it immediately thereafter Wait a couple of minutes before turning the generating set off In certain situations the data contained in the microprocessor inside the panel may be altered This may be because the battery is very low or because the cables used to connect the battery to the set have too small cross sections Altered processor data may prevent the generating set from running In order to restore the generating set operating efficiency proceed as follows Alarm the shows random characters Cause malfunctioning due to low voltage during start up low battery cable cross section too small Reinitialise the panel How to reset the control panel press the button Fig 24 Ref 10 and while holding it down turn on the control panel Only release the push button when 4 zeros 0000 are displayed The panel has been reinitialised display unit Vers 022 7 MAINTENANCE INSTRUCTIONS l INFORMATION Only use original spare parts Using poorer quality spare parts may damage your generating set Routine checks and adjustments are of the essence in preserving a high level of performance Routine maintenance also ensures long generating set life A DANGER Before performing any check or maintenance operation on the generating set turn the ON OFF switch of the control panel to the OFF position Then disconnect the red 12 Vdc cable from the terminal Fig 10 Ref 2
16. to signify that the generating set has failed to start up If the startup failed indicator Fig 24 Ref 5 light only stays lit you can repeat the procedure several times Vers 022 Energy 2500 G Telair If the generating set has not started up after several attempts contact the manufacturer s After sales service The start up battery should never be disconnected as there would be no input to the electronic control panel which would prevent the generating set from working 6 2 Turning the generating sets off To stop the generating set set the switch 1 to its OFF position Fig 24 Ref 1 Ah DANGER The generating set 15 provided with an internal combustion engine therefore the fuel used is highly flammable The exhaust gases are conveyed under the casing their temperature inevitably is quite high even though they are mixed with cooling air Do not touch the casing areas near the exhaust and do not put your hands or any objects inside the casing 6 3 Information on not recommended uses A DANGER These generating sets must be installed and used by qualified and authorised personnel only according to the manufacturer s instructions These generating sets must only and exclusively be used to produce electrical power on vehicles provided with an electrical system built to standards and according to the quantity of power delivered Telair 6 4 Useful tips To make the best use of the generating s
17. 02 48583585 e mail teleco telair bleysetd com Service Technique France 06 83 31 44 05 ESPANA NAUCCA CARAVANING S A Poligono Industrial ROQUETA 2 Calle Can Lletget 2 08202 Sabadell Barcelona Espana Tel 00 34 937 457 054 Fax 00 34 937 254 484 e mail comercial naucca com OSTERREICH TELECO GmbH 82041 Deisenhofen Deutshland Tel 0049 8031 98939 Fax 0049 8031 98949 e mail telecogmbh telecogroup com www telecogroup com IN DEUTSHLAND TELECO TELECO GmbH 82041 Deisenhofen Tel 0049 8031 98939 Fax 0049 8031 98949 e mail telecogmbh telecogroup com www telecogroup com Service f r Teleco Anlagen in Deutschland 09001000690 Service f r Teleco Anlagen in Osterreich 0900949470 Les photos et les dessins ne sont donn s qu titre indicatif We reserve the right to make technical changes without prior notice Fotos und Zeichnungen nicht vertraglich Foto s en tekeningen niet contractueel Fotos y planos no indicados en contrato
18. 18 ER 4221 Cavo raccordo GAS C ble raccord GAS Verbindingskabel GAS GAS fitting cable Verbindungskabel GAS Cable de empalme GAS Pezziassiemati e venduti in ununicokt _____ GB Pieces assembled and sold in a single kit Pi ces assembl es et vendues en un seul kit 0 1 1 0 Piezas unidas y vendidas en un kit nico o D Zusammengesetzte Teile die nicht einzeln sondern nur als Kit erh ltlich sind Energy 2500 G Vers 022 Vers 022 2500 k x Telair AIR CONDITIONER ITALY Via E Majorana 49 48022 LUGO Tel 39 0545 25037 Fax 39 0545 32064 E mail info telecogroup com www telecogroup com ZIMMER TECHNIK F R MOBILE FREIZEIT Haiffeisenstr 6 64347 Griesheim Tel 06155 797873 Fax 06155 797871 info zimmer mobiltechnik de KUNDENDIENST AUSGEWAHLTEN BOSCH SERVICE Foto e disegni non contrattuali IN EUROPE GREAT BRITAIN SCAN TERIEUR LTD 30 The Metro Centre Tolpits Lane Watford Herts England WD18 9XG Tel 01923 800353 Fax 01923 220358 HOLLAND BELGIUM KARMAN TRADING Lagewed 54 3849 PE Hierden the Netherlands Tel 0341 722450 Fax 0341 722451 e mail info karmantrading nl web site www karmantrading nl FRANCE BLEYS JEAN PHILIPPE 19 Rue de la Parcheminerie 18700 Aubigny sur Nere France Tel 02 48580367 Fax
19. Never replace the fuses or the cut out switches with others having higher amperage Should any electrical part need checking this must only be done with the engine turned off and by specialised personnel The generating sets have been built in compliance with the safety standards listed in the CE statement of compliance Vers 022 6 USING THE GENERATING SET 6 1 Starting up the generating set The generating sets are provided with an electronic remote control panel which allows you to perform starting up turning off operations and to check their running conditions The panel controls are 1 ON OFF switch 2 Display unit 3 High temperature indicator 4 Engine minimum oil level indicator 5 Startup failed 6 Generator running indicator flashing 7 Engine oil change indicator 8 Gas reserve indicator 9 Display time changeover switch 10 Reset Set the startup switch Fig 24 Ref 1 to its ON position The message WAIT will be displayed for 8 seconds After this time the electronic control panel will start the first automatic procedure for starting up the generating set If the engine starts up at the end of this phase the generator running indicator light Fig 24 Ref 6 will start to flash Should the engine not start up this automatic procedure will be repeated up to 4 times If at the end of a complete cycle the engine has not yet started up the startup failed indicator Fig 24 Ref 5 will light up
20. d during transport by suitable carton packaging and a wooden base It must be stored horizontally a covered 3 2 Weight dry and ventilated area EM Total weight including packing ENERGY 2500 G 60 kg 6 2500 Vers 022 3 3 Handling The generating sets complete with their packaging can be handled using common lifting and transport vehicles The boxes are provided with spacers in order to allow for the introduction of pallet truck forks y DANGER During lifting transport comply with accident prevention and safety regulations Use lifting and transport equipment with a capacity greater than the load to be lifted 4 INSTALLATION 4 1 Preliminary information LIN MANUAL Before installing generator set it is absolutely necessary to read these instructions prevent any installation errors 7 NWARNING The generator must be installed so as to prevent water seeping directly into the alternator through the air inlets it must therefore be protected Vers 022 Energy 2500 G Telair Incorrect installation of generating sets can cause irreparable damage to the equipment and endanger the safety of users Should the generating sets be installed not in compliance with the instructions in this manual the Manufacturer shall not be held responsible for malfunctioning or for the safety of the generating set by the terms of the Italian Law Decree D M 89 392 EEC
21. e never open the generating set casing and use only approved type fire extinguishers A DANGER Never use water to put out flames in the generating set Vers 022 GENERAL WARRANTY TERMS Telair TEL AIR guarantees its products against any construction material and or manufacturing faults and defects The right to warranty cover for new engines is valid for a period of 24 months from the time of handing over to the end user or for a maximum of 2000 operating hours whichever limit is reached first In all cases the warranty period shall end no later than 26 months 28 months if delivered outside of Europe after ex factory delivery For electric and hydraulic components pipes belts sealing elements injection nozzles clutches drives the warranty term is 12 months from the time of handing over to the end user or a maximum of 2000 operating hours whichever limit is reached first In all cases the warranty period shall end no later than 14 months 16 months if delivered outside of Europe after ex factory delivery In any case the costs of lubricants and consumables shall be charged Any transport expenses shall have to be covered by the purchaser the same applies 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 has carried out all routine maintenance according to the recommended schedule and has promptly
22. erent temperature degree from those listed above e Take the cap off the spark plug Fig 29 Ref 2 and using the special wrench take out the plug e Perform a visual inspection Replace in case of obvious wear or if the insulator is broken or cracked e Use a steel brush to clean the spark plug if it can be used again e Use a thickness gauge to measure the distance between the electrodes The right distance should be between 0 7 and 0 8 mm Fig 30 Correct the distance if necessary bending the side electrode e Make sure that the spark plug washer is in good condition and then screw back on by hand to make sure that it is correctly put back in place Finally tighten to the right torque using the special wrench see instructions in the engine user and maintenance manual INFORMATION When assembling a new spark plug tighten by 1 2 turn after the spark plug has compressed the sealing washer If you put back the old plug after having removed it tighten it by 1 4 turn after it has compressed the sealing washer Vers 022 Energy 2500 G tightened firmly A badly positioned spark plug may become very hot and damage the engine 7 4 4 Voltage adjustment Adjust the voltage when the engine is hot without any applied load and the generating set is running Check the voltage of the generating set using a voltmeter via a 230 V vehicle socket The voltage must be between 230 V and 245 V without any connected
23. eserve detector is provided in the gas tank it is possible to connect the suitable cable located inside the generating set Fig 10 Ref 8 This way the pilot lamp will light up when the gas level has gone below its reserve level 9 Display time changeover switch press this switch to display the running hours since the latest engine oil change 10 Reset When the display shows characters without any apparent logic the panel needs to be reinitialised Press the Reset key Fig 24 Ref 10 and holding it down switch on the panel When 4 zeroes 0000 are displayed the panel has been reinitialised Energy 2500 G 6 6 Control panel alarm causes and resetting During generating set use alarm signals may be displayed referring to engine oil checks After checking the engine oil the control panel must be reset in the following way Alarm the red service light is flashing Cause 50 hours have elapsed since the latest engine oil change and oil level should be checked How to reset the alarm press the counter key Fig 24 9 and while holding it down turn the panel on and release the push button when the unit has started up Alarm the red service light is lit Cause 100 hours have elapsed since the latest engine oil change and engine oil should be changed How to reset the alarm turn on the panel and wait for the generating set to start Now press the button hidden under the small hole in the bottom
24. ets remember that even minor overloads if they last long enough will operate the thermal cut out switches Fig 10 Ref 5 During the running in period do not subject the new engine to loads exceeding 70 of the rated load at least for the first 50 running hours 6 5 Control and alarm functions Fig 24 2 Display when the generating set has started up the total running hours will be displayed Press the key provided below the control panel display unit Fig 24 Ref 9 to display the number of generating set operation hours since the latest engine oil change 3 High temperature indicator this warning light will light up when the temperature of the generating set goes over its safety value the engine will stop at the same time 4 Engine oil minimum level indicator this warning light will light up to indicate that oil in the engine has gone below the minimum level A safety system will kill the engine automatically to prevent failures 5 Engine startup failed this warning light will light up to indicate that the generating set has not started up after all four start up attempts 6 Generator running indicator this indicator flashes during proper operation of the generating set 7 Change oil this warning light will light up when the engine has reached 100 running hours since the latest oil change Every time the oil is changed the After sales service staff must reset the timer to zero 8 Gas reserve indicator if a r
25. ets out the purpose the machine was designed for and contains all the information required to guarantee that it is used in a safe and proper manner Constant compliance with the instructions laid down here will guarantee the safety of the user operating economy and longer life of the machine To facilitate reference this manual has been subdivided into chapters specifying the main notions contained therein for quick consultation refer to the table of contents The most important parts of the text are in bold letters and preceded by symbols described here below It is strongly recommended that you read the contents of this manual and the reference documents carefully doing so is essential to the correct long term performance and reliability of the generator set and the prevention of injury and or damage Note The information contained in this publication was correct at the time it went to print but may be modified without advance notice Energy 2500 G 1 2 Symbols and Definitions Graphic safety symbols have been employed in this booklet to identify different levels of danger or important information 4 DANGER This means that you must pay attention to avoid serious consequences which might lead to serious accidents or damage the health of the operators 7 WARNING This means potentially hazardous situation which could lead to accidents or damage to property INFORMATION This calls the
26. f 1 Energy 2500 G A DANGER Remember that the pressure reducer must NOT be installed in the body interior Moreover it should be located in a well ventilated area No pressure reducing device should be placed between the Telair reducer Fig 5 Ref 4 and the gas bottle The gas hose Fig 5 Ref 5 which directly connects the pressure reducer and the gas bottle Fig 5 Ref 3 is not supplied For this connection the installer will use a suitable type approved hose which is equipped with the suitable fittings A DANGER Connections as shown in Fig 6 are FORBIDDEN on both the reducer and the gas bottle Fig 7 shows proper connection with a suitable hose on which the fitting 6 is tightened Fit the ogive 7 hold the fixed hexagon ring 8 by means of a wrench and tighten the ring nut 9 Vers 022 4 4 Wiring connection instructions By using the special key to open the lock remove the front door Then remove the bottom surface locking screws Fig 8 Ref 2 on both sides Take out the bottom surface with the engine all the way to the mechanical stop Fig 9 If you wish to completely remove the engine surface screw out the locking screws Fig 8 Ref 3 too 4 5 Battery connection To start up the generating set connection to the battery of the vehicle must be provided using a sheathed power cable up to current standards with the cross section shown in Table 1 To this end the
27. ge ATR 2503 C1 Gietwerk ATR 2503 C1 Casting ATR 2503 C1 Gussteil ATR 2503 C1 Fusi n ATR 2503 C1 01 351 Miscelatore Gigleur 2 7 M langeur Gigleur 2 7 Menger Gigleur 2 7 Gicleur 2 7 mixer Mischer Gigleur 2 7 Mezclador Gigleur 2 7 71 03834 N 4 Raccordo GAS a 90 Raccord GAZ a 90 GAS aansluiting 90 GAS union elbow GAS Anschluss 90 Conexion GAS 90 72 03855 Tubo GAS Tuyau de raccord GAZ GAS aansluitpijp GAS GAS Anschlussleitung Tubo conexion GAS Anello di serraggio Bague de serrage Klemring 03422 Anilo de apretado Ghiera di serraggio Douille de serrage 03423 Locking ring nut Befestigungsschraube Virola de apretado 04042 Raccordo uscita GAS Raccordo uscita GAS GAS uitlaatkoppeling GAS output fitting GAS output fitting Conexi n salida GAS 76 1009311 1 Rondella alluminio Rondelle en aluminium Onderlegring van aluminium Aluminium washer Alu Scheibe Arandela aluminio Bobina di starter d allumage Starterspoel 77 02292 01 349 Riduttore Manod tendeur GAZ GAS drukregelaar GAS pressure GAS Druckreduzierer Reductor Presi n GAS Bobina GAS 12 V Bobine GAZ 12 V Gasspoel 12 V 01 344 un GAS 12 V coil Spule GAS 12 V Capuchon GAS 12 V E 05570 Raccordo ingresso GAS Raccord d admission GAZ GAS inlaatkoppeling GAS input fitting Anschlusss Eingang GAS Conexi n entrada GAS Bouchon Dop 9 042
28. ine the generating set is equipped with a special terminal strip Fig 10 Ref 1 to which the cables must be connected Use the special cable outlet Fig 8 Ref 1 to prevent water seeping into the generating set Although the generating set is equipped with a special internal thermal cut out to cut power delivery in the event of overload or short circuits Fig 10 Ref 5 it is advisable to install in the vehicle control panel a thermomagnetic cut out switch suitably set to stop power delivery to the various users when current absorption exceeds 9 5 Amp for ENERGY 2500 G If the generating set thermal cut out switch has been operated press the button Fig 10 Ref 5 to restore closed circuit and power delivery conditions 00 Telair DANGER Carefully check the position of the line connection for picking up 230 Volt current Wrong connection could damage the generating set irreparably or create dangerous short circuits 4 7 Auxiliary electric cable connection All 3 auxiliary cables to connect are equipped with a polarized connector One cable is necessary for generator operation while the other 2 are optional cables e Cable from the generating set to the control panel mandatory It is included in the standard supply and is 5 metres long Check that its length is sufficient to cover the chosen rout between the generating set and the control panel Optional cables in longer sizes are also available Al
29. ing to an optional RCB regulator code 05424 as shown in Fig 14 The generating set will not autonomously recharge the battery used for starting up unless this is connected to a battery charger OFF Contatta non utilizzato Contact nat used Koontakt nicht verwendet Contact inutilis Contacto sin utilizar Ongebruikt contaci Contacto de activaci n del cargabaterias Inschakelcontact van de acculader Vers 022 Energy 2500 G Telair 4 10 Connecting an additional silencer To further reduce the generating set operating noise an optional additional silencer can be installed externally The additional silencer kit code 02482 consists of e A silencer code 02019 Fig 15 Ref 1 e A one metre long section of flexible steel tubing code 00433 Fig 15 Ref 2 e Two connection fastening clamps code 00543 Fig 15 Ref 3 e One hose coupling code 03645 Fig 15 Ref To connect the silencer to the generating set first of all remove the door Fig 16 Ref 2 by using the special key Fig 16 Ref 1 and the muffler guard Fig 16 Ref 3 Energy 2500 G Now remove all the flame trap parts Fig 17 Ref 2 3 4 5 from the muffler Fig 17 Ref 1 Vers 022 After introducing the coupling code 03645 Fig 18 Ref 2 into the muffler terminal Fig 18 Ref 1 drill a small hole in the muffler terminal large enough to accept a self tapping screw to lock the muffler terminal Fig
30. l Fix the electronic control panel Fig 11 by using 3 x 20 mm self tapping screws making sure that the rear part does not interfere with other surfaces Apply light pressure to fix the plastic frame until the anchoring tabs click in 4 9 Battery charger ENERGY 2500 G generating sets are equipped with a battery charger which can deliver current of approximately 10 Amp at 12 V lt can be used to recharge the generating set start up battery To obtain this function use a 2 5 cross Morsetti dai generatore Termina from generator Lelstungs Klemmielste des generators Bornier du g n rateur Tablero de bornes del generador Vermogensklemmenstrook van de generator CH SS 12 V 6 Batteria Battery Batterie Batterie Bateria Accu Contatto di attivazione del Battery charger activation contact Akiivierungskonlakl des batterie Jadegerats Contact d activation du chargeur de batteries Telair section cable to connect the terminal identified by CHARG Fig 13 Ref 1 to the positive pole red cable of the generating set Fig 13 Ref 2 4 9 1 Auxiliary Battery Charger If you wish to recharge a different battery or do not wish to use the CHARG terminal it is possible to use the 12 Volt alternating current output provided on the bipolar connector shown in Fig 10 Ref 6 To these two Faston terminals 2 4 sq mm cross section cables should be connected to obtain interfac
31. l replacement 17 TAZ Alter malena E m 18 4 3 Spark pl g aia 19 LA aan 19 8 ROUTINE MAINTENANCE SCHEDULE 20 DISMANTLING 20 10 RECOMMENDED FIRE FIGHTING EQUIPMENT ee 20 GENERAL WARRANTY Eege 21 WIRING DIAGRAM ENERGY 2500 G coocnccocccconccconccccnncccnnncconnnccnnnccnnncrnnnnrrnnnnrnnnnrnnnnrnnanrrnnnnrnnnnrenanrenanas 22 DRAWING FOR SPARE PARTS LIST ENERGY 2500 G ee 24 Vers 022 Energy 2500 G Telair 1 FOREWORD MANUAL Refer carefully to this manual before performing any operation on the power generator set 1 1 Purpose and scope of this manual This manual has been drawn up by the Manufacturer in order to provide basic information and instructions for performing every operation for servicing and using the generating set in a proper and safe manner It is an integral part of the generating set equipment must be kept with care throughout the life of the same and must be protected against any agent which could damage it It must follow the generating set if this is installed on a new vehicle or if its ownership changes hands The information in this manual is addressed to the personnel in charge of installing the generating set and to all those involved in its maintenance and use This manual s
32. m Bedienpanel 03799 N 1 O 1 4 A fuse 4 A Sicherung Fusible 4 A 15 A fuse 15 A Sicherung Fusible 15 A 1 Potafusibile Tableau des fusibles Zekeringhouder Fuse carrier Sicherungshalter Portafusible N 584 N 1 688 N 1 O7 N 1 05 N 1 O O B Energy 2500 G Vers 022 E 00 2 Ka Tel i Descrizione D signation Denomination Code Nr Description 2486 Bezeichnung Descripcion rum Piastra fissaggio Potafusibile Plaque fixation tableau Bevestigingsplaat 01603 N 1 Fastening plate for fuse car Befesti MA zekeringhouder rier gungsp Placa fijaci n Portafusible gshalter 46 03854 N 1 Scatola di Comando Boitier de Commande Besturingskast Control box Steuerbox Caja de Mando Morsetto Legrand 25 mm Borne LEGRAND 25 mm ES n e 47 03779 N 2 Terminal Legrand 25 mm Klemme LEGRAND 25 mm nm Borne LEGRAND 25 mm 01139 N 1 Morsetto Muller 3 12 Borne Muller 3 12 Aansluitklem Muller 3 12 Terminal Muller 3 12 Klemme Muller 3 12 Mordaza Muller 3 12 Distanziale Esaaonale M3x8 Entretoise Hexagonale M3x8 Zeskantafstandshouder 03440 N 9 Distanzst ck Sechskant M3x8 Hexagonal M3x8 spacer M3x8 Separador Hexagonal M3x8 03853 N 1 Fondo Scatola di Comando Base Boitier de Commande Bodem besturingskast Control box bottom Boden der Steuerbox Fondo escala de Mando C C blage avec carte lectro Bedrading met elektronische ablaggio con scheda elet 04220
33. so see paragraph 4 8 After leading the cable through the cable outlet block Fig 8 Ref 1 connect the white connector to the fixed connector Fig 10 Ref 9 provided inside the generating set checking that the plugging direction is correct e cable is delivered standard together with the generating set for connection from the generating set to the pressure reducer It is already connected to the pressure reducer Let the cable through the cable holder Fig 8 Ref 1 and connect the 3 pole white connector to the fixed connector Fig 10 Ref Energy 2500 G 8 which is located inside the generating set near the 12 Vdc terminals e Cable from the generating set to the auxiliary battery charger optional From the bipolar connector Fig 10 Ref 6 it is possible to derive supply for an RCB battery charge regulator via two 4 mm cables also see paragraph 4 9 1 4 7 1 Electric System fuses The unit is provided with two protection fuses A 15 Ampere fuse Fig 10 Ref 7 protects the auxiliary battery charger output A 4 Ampere fuse Fig 10 Ref 4 protects the pressure reducer output Vers 022 4 8 Electronic control panel connection Choose your required position for the control panel inside the vehicle and drill a 30 x 32 mm rectangular hole After letting out of the hole the connecting cable coming from the generating set paragraph 4 7 connect the cable black connector on the back of the electronic control pane
34. t be disposed freely in the environment but taken to special disposal centres carrying out disposal and or recycling in compliance with the applicable law provisions in force in the country of use 7 4 2 filter maintenance clogged air filter will reduce air flow to the carburettor To prevent carburettor malfunction check the air filter regularly If the engine is used in a heavily dusty environment we suggest checking the air filter every time before starting up the engine 4 DANGER Never use Diesel oil solvents with a low evaporation point for cleaning the air filter cartridge as this could cause fires or explosions Never operate the engine without an air filter the engine would wear down quickly due to air borne dust To access the filter cartridge remove the air filter closing lid Fig 29 Ref 3 after having unscrewed both screws that fix it to the air filter box Take out the cartridge Fig 29 Ref 1 and wash it in mild detergent and water then rinse thoroughly Let the filter cartridge dry out completely then dip it in clean engine oll Squeeze out carefully any excess oil Replace the cartridge only if visibly worn out Vers 022 7 4 3 Spark plug maintenance For both models of generating sets use spark plug models BP6ES BPR6ES W20EP U W20EPR U ND or else spark plugs made by other manufacturers but compatible with the above Never use spark plugs with diff
35. ube Aislante Izquierdo Cap Rear hood insulation Isolierung hinten fur Haube Aislante Trasero Cap Right hood insulation Isolierung rechts fur Haube Aislante Derecho Cap Upper hood insulation Isolierung fur Haube Aislante Superior Capo Base Insulation Isolierung f r Grundrahmen Aislante Base Case base Kasten Grundrahmen Base caja DIN p 4 Condenser 13 uF 450 V Kondensator 13 450 V Condensador 13 uF 450 V Collar 25 60 Schelle fur 25 60 Collar tubo 25 60 Serratura Serrure Slot forzada ee er LII ub EK Door closing plate Turblech Chapa cierre puerta Exhaust plate Auslassplatte Chapa de descarga Chi Fermeture du convoyeur pot Afdekking geleider iusura convogliamento WE 01827 N 1 maria d chappement knaldemper Verschluss des Auspufftopf Cierre transportador Leitblechs silenciador escape Marmitta Pot d chappement Knaldemper Fascetta Collier Bandje s pure IL G regadera _ _ Plain washer Flachscheibe e Arandela plana Rete metallica Grille m tallique Metalen rooster 2057 H _ Redde alamme terminale pot eer uffler end pipe Auspuff Endrohr ubo de descarga OSI Convoyeur pot Geleider knaldemper 01830 N 1 M d chappement Transportador silenciador uffler conveyor A Uspufftopf Leitblech Gommino protezione ponte di
36. user If different values are measured will be necessary to set the right values by working on the engine rpm adjustment screw Fig 31 Ref 1 Turn the screw clockwise to increase the engine rem and consequently the voltage Turn the screw counter clockwise to decrease the engine rpm and consequently the voltage Telair lt gt 8 ROUTINE MAINTENANCE SCHEDULE ROUTINE MAINTENANCE SCHEDULE To be performed after the period of time or the number of running hours listed here whichever the earlier Level check Engine Oil Replacement Air Filter Clean and replace if necessary Fuel Clean and replace if necessary Spark plug Clean and replace if necessary Valve Adjustment Check Adjust Fuel Pipe Check for leaks or cracks Check for leaks or cracks Filter and Muffler Clean and replace screen if necessary Air Choke Valve Check correct operation Engine rpm or Check Adjust Frequency Vibration Damper Suspension Points Check Replace if necessary i N N gt gt AS N gt i N 7 N gt NOTES 1 Clean more frequently if you use it in a very dusty environment 2 These operations must be performed by specialised personnel only 9 DISMANTLING Should you have to dismantle the generating set contact specialised companies Energy 2500 G 10 RECOMMENDED FIRE FIGHTING EQUIPMENT In case of fir
37. visited the nearest after sale centre if required the customer can produce a document showing the date of sale invoice or receipt Such document will have to be kept with care and be intact when produced to the TELAIR After Sales centre on requesting service In any case the purchaser shall not be entitled to terminate the contract claim damages to persons or property e ask that the warranty be extended in the event of product defects or malfunctioning Vers 022 Energy 2500 G G agy mm Se 22 HH NI mH JONVHO i IN sueooy 97049 22919 NI349 E 24 ams pe 3LIHM ED 001 N33M9 MOTIBA N3389 MOTI3A ARS E Telair f N 8 el1e Vers 022 J0 299UUO J0 EUJ9 V uonooejoJg DUUIM SYS 5 SYH epoiq Y9JIMS pJeoq uonoeuuoo JeNod JeonpeJ 59 asnj uonoejoJd apolg DUU Sec s euiuJe uonoeuuoo dnyejs 1949 10 MO 9n y
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