I GENERATORS TIG 3000D USE AND MAINTENANCE MANUAL AND INSTALLATION INSTRUCTIONS GB Vers. 001 TIG 3000 D V.
GB This manual has been drawn up by the Manufacturer in order to provide basic information and instructions for performing all generating set operation and service tasks in an adequate and safe manner. It is an integral part of the generating set equipment, must be kept with care throughout the equipment life, and must be protected against any agent that could damage it. It must follow the generating set if installed on a new vehicle, or if its ownership changes hands.
GB In the event of a circuit break, do not replace the fuses with other higher amp ones. Do not insert objects through ventilation holes. Inspections and maintenance must only be carried out with the engine stopped and by skilled staff. In case of fire, never open the generating set casing and use only approved type fire extinguishers. Never use water to put out flames in the generating set.
GB CONTENTS 1 GENERAL INFORMATION ............................................................................................................... 7 2 CHARACTERISTICS ........................................................................................................................ 7 2.1 Technical Specifications............................................................................................................ 7 2.2 Overall dimensions ............................................................
GB 8.10.1 Check engine oil level .................................................................................................... 22 8.10.2 Engine oil replacement ................................................................................................... 22 8.10.3 Low fuel level ................................................................................................................. 23 8.10.4 Stop with D+ signal ............................................................................
GB Via E. Majorana , 49 48022 Lugo (RA) ITALY "CE" COMPLIANCE STATEMENT Under Machine Directive 2006/42/CE, attachment II A We hereby represent that the generator-set, the data concerning which appear 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 not be valid any longer if any changes are made on the machine without our written approval.
GB 1 GENERAL INFORMATION The generating set TIG3000D, shortly referred to as generator here below, is designed to be installed on vehicles, although this does not exclude its use in stationary applications requiring a versatile, stable and reliable power source, applying the latest technology.
GB 2.2 Overall dimensions Figure 1 shows the overall dimensions of the generating set TIG3000D. 7 8 9 10 Fixing brackets Exhaust silencer Electronic control panel Signal cable 2.4 Identification plate 1 2 3 4 5 6 7 8 9 Generating set model Serial number Frequency Power factor Maximum electric power Maximum output current Rated voltage 230V AC Battery charger specifications Weight 2.3 Main components 3 SHIPPING, HANDLING, STORAGE 3.
GB 3.3 Handling Always observe safety and accident prevention rules when lifting and handling. Use lifting and handling equipment with capacity greater than the load to be lifted. The generating sets, complete with their packaging, can be handled using common lifting and handling equipment. The packages have special spacers to allow for transpallet forks insertion. 4 INSTALLATION 4.1 Preliminary information 4.2.
GB 4.2.2 Hanging installation The generator is provided with supporting brackets designed for fixing in a hanging configuration. Figure 6 shows the arrangement of the fixing brackets and vibration damping cylinders. Figure 7 shows the generator with the mounting brackets and damping mounts correctly installed on the generator. Ensure that the ride height of the generator is not such as to risk contact with the ground during travel.
GB For quick preparation of the support surface, the generator is supplied with a drilling template (fig.10). 4.3 Connecting the external exhaust silencer The generator is supplied with an external exhaust silencer kit consisting of the silencer, a flexible steel pipe and accessories for generating set connection and fixing. As a first step the generator internal muffler (fig.12 ref. 1) must be fixed to the supplied coupling (fig.12 ref. 3) by interposing the seal (fig.12 ref. 2).
GB Insert at the other end of the flexible pipe the clamp D.32-35 (Fig.13 ref. 5), insert the silencer in the pipe (fig.13 ref. 4), and tighten the clamp. Fix the silencer to the vehicle underside with the spacer grommets (fig.13 Ref. 6) and secure the flexible pipe, taking care that it does not prevent the generator from sliding out for routine maintenance purposes.
GB quirements it can be connected either to the vehicle battery or to the service battery. The connected battery is charged by the generator itself with a maximum current of about 10 A. For connection purposes, insulated cables of different colours should be used (usually red and black, connected to the positive pole and negative pole - respectively) with sections: 16 mm² for lengths up to 6 metres 25 mm² for longer lengths.
GB Connection of 230 V~ utilities should be carried out by using insulated leads with 2.5mm² section, in compliance with the applicable regulations in force. The output terminals are marked with Ph (Phase), N (Neutral) and GND (metal Ground). In order for the electrical circuit breaker devices to operate correctly, the generator is supplied with an output voltage at 230 V ~ related to its mechanical and electrical mass.
GB • Connect the two wires of the direct line to the utilities to the PINS 7 - 9. • Connect the two wires of the 230 V external line (fig.19 ref.5) to the PINS 6 - 4. • Jumper the PINS 4 – A. • Jumper the PINS 6 – B. Fig.19 also shows the connection of a thermomagnetic + safety cutout switch (fig.19 ref. 3), not supplied with the generator. 5.6 Electronic control panel connection Choose your required position for the control panel inside the vehicle and drill a 35 x 25 mm rectangular hole (fig.20 ref.
GB lock"). This wire is live with +12 V voltage when the vehicle engine is running. The information is used by the generator to stop at each change of state of D+. • REMOTE On-Off connector (fig. 22 ref. 4): this connector can be used to connect the two poles of a galvanically isolated open-closed contact, (for example, the contact of an electromechanical relay), controlled by a remote device. When the contact is closed, the generator will start and it will stop when the contact is opened.
GB - with regard to the size of the cables used, comply with the specifications in the paragraph on electrical connections If these rules are not complied with the overall power output will not equate to the sum of the outputs of the two generators, or worse still, might create a malfunction with damage to the generators. 5.
GB 2 Display: allows generator operation to be monitored. It shows the operation state and any messages related to internal diagnostics 6.2 Fuel Use Diesel oil in compliance with the minimum requirements as provided for by the following standards: EN-590 or BS-2869-A1/A2 or ASTM-D-9751D/2D. At ambient temperatures below 0°C use wintertype diesel fuel.
GB 6 LED Booster, it illuminates when the BOOST function is on (fig.30 ref. 3) 7 MAINTENANCE red LED: the display shows the type of required maintenance (engine lubricating oil level check or replacement). 8 ALARM red LED: indicates a fault. The display provides detailed information on the fault detected by the system. 9 GEN ON LED: it illuminates when the generator is in operation. The display shows the parameters relating to the state of operation of the generator.
GB indicates the generator model and hardware and software versions alternate when the generator makes 230 V~ voltage available indicates the language setting; by pressing BOOST followed by START/STOP or AUTO it is possible to scroll through the available languages output voltage delivered power end of the available list, by pressing BOOST the panel is returned to its standard display mode. 8.
GB The generator will start when the connected battery voltage drops below the set threshold (default is 12.0 volts). Once the generator has started the display shows in sequence the icons . . 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-Off command.
GB 8.9.3 Low output voltage the output voltage has dropped too far below the minimum limit, probably due to poor performance of the internal combustion engine or to a single very high load being applied without the use of the BOOST function, the generator stops, the red alarm LED lights up (Fig. 30 ref. 8). 8.9.
GB Press the MENU button again to confirm zeroing of the hour counter. The following message will appear the red LED switches off (Fig. 30 ref. 7) and the related message disappears from the display. 8.10.3 Low fuel level if the connection described in another part of the manual 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.
GB 9 MAINTENANCE INSTRUCTIONS 9.
GB Remove the engine oil dipstick (fig.35 ref. 1), and wipe it clean if required, reinsert it in its seat and then pull it out again to obtain an accurate reading of the level of lubricant. If the oil level does not reach the top notch on the dipstick (fig.36) restore the level by pouring oil through the special opening after removing the cap (fig.35 ref. 2). (You may want to refer to the engine user and maintenance manual.
GB 9.3.2 Air filter maintenance A clogged air filter will reduce air flow to the engine. To prevent engine malfunction, check the air filter regularly. If the engine is used in a heavily dusty environment, we suggest checking the air filter daily. Never operate the generator without an air filter since the engine would be damaged very quickly. Never use Diesel oil or solvents with a low evaporation point to clean the air filter cartridge.
GB The internal filter is replaced by removing it from the pipes to which it is connected and loosening the metal clamp that retains it. Use original filters. 9.3.4 Oil filter maintenance For cleaning the engine oil filter is necessary to remove it from its housing (fig.42 ref 1), loosening the screw as indicated. Clean the oil filter cartridge by blowing compressed 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.
GB Reassemble the oil filter pushing it all the way in its seat (fig.46 rif.1) and screw back on again. In all cases in which the filter is damaged, replace it with another original. In this case, before installing the new filter, lubricate the sealing rings (Fig. 45 ref 1 and ref 2). 9.3.5 Complex maintenances More complex maintenance operations may require that the generator be either partially or fully removed from the case.
GB 11 GENERAL WARRANTY TERMS TELAIR guarantees its products against any construction material and/or manufacturing faults and defects. The right to warranty cover for new products is valid for a period of 24 months from the time of handing over to the end user, or for maximum 1000 operating hours, whichever limit is reached first. In all cases the warranty period will end no later than 26 months (28 months if delivered outside of Europe) after ex factory delivery.
GB 12 TIG 3000D WIRING DIAGRAM 30 TIG 3000 D Vers.
GB Vers.
GB CAPTION OF THE WIRING DIAGRAM All connectors are seen side wire insertion Corrispondenza colori fili: BK Black BL Blue BR Brown GR Green GY Grey OR Orange PK Pink PU Purple RD Red WH White YE Yellow YE-GR Yellow-Green 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 Auxi
GB 13 TIG 3000D LIST OF SPARE PARTS Vers.
GB 34 TIG 3000 D Vers.
GB Vers.
GB 36 TIG 3000 D Vers.
GB Pos. Code Q.tà 1 06138 N.
GB Pos. Code Q.tà 13 06157 N. 1 14 15 16 17 18 06587 06588 06494 06493 06492 N. 1 N. 1 N. 1 N. 4 20 02117 N. 4 21 06354 N. 2 22 06414 N.
GB Pos. 27 28 29 30 31 Code 06601 06134 06595 06132 06589 Q.tà N. 1 N. 1 N. 1 N. 1 06593 N. 1 33 06133 N.
GB Pos. 39 40 41 42 43 44 45 46 47 48 49 40 Code 06352 06496 06331 01059 06497 06498 06495 06304 06136 06323 06148 Q.tà N. 1 N. 1 Descrizione Dèsignation Beschrijving Description Bezeichnung Descripcion Supporto per pannello superiore Support pour Panneau Supérieur Stijgbeugel voor Boven Paneel Holder for Upper Panel Unterstützung für Obere Panel Soporte para el Panel Superior.
GB Pos. 50 51 52 53 54 58 59 60 61 62 63 64 Vers. 002 Code 06209 06179 06387 06416 06417 06137 06499 06503 06501 06502 06303 05504 Q.tà N.
GB Pos. 65 66 67 68 69 70 71 Code 06504 06411 06283 03157 06632 01197 00810 Q.tà N. 1 N. 1 N. 1 N. 1 73 00478 N.
GB Pos. Code Q.tà 76 06131 N. 1 77 78 79 06130 06590 00632 N. 1 N. 4 06120 N. 2 81 06305 N. 2 82 06121 N. 1 84 85 86 Vers.
GB Pos. 87 88 89 90 Code 02332 01202 03653 04739 Q.tà N. 1 N. 1 N. 1 92 01871 N. 1 96 97 06418 03796 N.
GB Pos. 98 99 100 101 Vers. 002 Code 01761 00705 02440 01655 Q.
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