Teleco Telair ENERGY 2510D User guide

Energy 2510 D Vers. 002
GB
1
INDICE
USE AND MAINTENANCE MANUAL AND
INSTRUCTIONS FOR INSTALLATION
GB
ENERGY 2510D
V. 00
4
–
April
201
8
GENERATORS

Energy 2510 D Rev. 004
2
GB
INDEX
1 FOREWORD ...................................................................................................................................4
2 GENERATING SET IDENTIFICATION DATA.................................................................................5
2.1 Components (Fig. 1) .................................................................................................................5
2.2 Identification plate (Fig. 2).........................................................................................................5
2.3 Overall dimensions ...................................................................................................................5
2.4 Technical specifications ............................................................................................................6
3 SHIPPING, HANDLING, STORAGE ...............................................................................................6
3.1 Storage.....................................................................................................................................6
3.2 Weight ......................................................................................................................................6
3.3 Handling ...................................................................................................................................7
4 INSTALLATION ..............................................................................................................................7
4.1 Preliminary information .............................................................................................................7
4.2 Instructions for fastening the generating set..............................................................................7
4.2.1 Hanging assembly..............................................................................................................7
4.2.2 Floor fastening ....................................................................................................................8
4.3 Connecting the mufflers ............................................................................................................9
4.4 Connecting the fuel pipes........................................................................................................10
4.5 Connecting the Fuel Reserve..................................................................................................10
4.6 Auxiliary battery charger connection .......................................................................................10
5 ELECTRIC CONNECTIONS .........................................................................................................10
5.1 Preparing the Wiring connection .............................................................................................10
5.2 Battery Connection .................................................................................................................11
5.3 230 VAC wiring connection.....................................................................................................11
5.4 Connecting an External Network Relay...................................................................................12
5.5 Electronic Control Panel Connection.......................................................................................13
6 OPERATING INSTRUCTIONS......................................................................................................13
6.1 Fuel.........................................................................................................................................13
6.2 Machine safety........................................................................................................................13
6.3 Information on not recommended uses....................................................................................14
6.4 Useful tips...............................................................................................................................14
7 USING THE GENERATING SET....................................................................................................14
7.1 Starting up the generating set .................................................................................................15
7.2 Turning the generating set off .................................................................................................15
7.3 Control and alarm functions (Fig. 24) ......................................................................................15
7.3.1 Control panel alarm causes and resetting .........................................................................15
7.3.2 Automatic Version (optional) ............................................................................................16
7.4 MANUAL operation.................................................................................................................16
7.4.1 AUTOMATIC operation ....................................................................................................16
8 MAINTENANCE INSTRUCTIONS.................................................................................................17
8.1 Service check list ....................................................................................................................17
8.2 Maintenance not requiring skilled personnel ...........................................................................17
8.2.1 Checking the engine oil level............................................................................................17
8.3 Maintenance operations to be carried out by skilled personnel ...............................................18
8.3.1 Engine oil replacement.....................................................................................................18
8.3.2 Air filter maintenance .......................................................................................................19
8.3.3 Oil filter maintenance .......................................................................................................19
8.3.4 Checking the Alternator Belt.............................................................................................21
8.3.5 Adjusting the Alternator Belt.............................................................................................21
9 DECOMMISSIONING AND DISMANTLING INSTRUCTIONS ......................................................21
10 RECOMMENDED FIRE-FIGHTING EQUIPMENT.......................................................................21
11 GENERAL WARRANTY TERMS ................................................................................................22
12 ENERGY 2510 D WIRING DIAGRAM .........................................................................................23
13 ENERGY 2510 D LIST OF SPARE PARTS ................................................................................24

Rev. 004
Energy 2510 D
GB
3
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.
Machine: GENERATING SET
Model: ENERGY 2510 D
Maximum power: 2,2 KW @ 3000 r.p.m
Serial number: ………………………...
Directive of reference:
Machine Directive 2006/42/UE.
Low Voltage Directive 2014/35/UE.
Electro-magnetic Compatibility 2014/30/UE.
Harmonised standards applied: EN 60204-1.
Directives noise emission in the environment 2005/88/CE, 2000/14/CE (Attachment VI, procedure 1),
DLGS 262/2002.
Measured noise power LWA : 88 dB
Guaranteed noise power level LWA: 90 dB
Certificate issued by: ECO Certificazioni S.p.a.
via Mengolina 33; 48018 Faenza (RA) Italy
Organismo notificato n° 0714
Technical documentation manager: Raul Fabbri, engineer
Lugo, 01/03/2017 THE PRESIDENT
Raul Fabbri

Energy 2510 D Rev. 004
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GB
1 FOREWORD
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 sets 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 sections 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.
Please read the contents of this manual and of
the reference documents carefully. This is the
only way to ensure that the generating set will
work smoothly and reliably over time, while
protecting people and property from damages.
Note: The information contained in this
publication was correct at the time it went to print,
but may be modified without advance notice.
1.2 Symbols and Definitions
"Graphic safety symbols” have been employed in
this booklet to identify different levels of danger or
important information.
This means that you must
pay attention to avoid serious consequences
which might lead to serious accidents or damage
the health of the operators.
This means a potentially
hazardous situation which could lead to accidents
or damage to property.
This calls the user’s
attention to a potentially dangerous situation
which could cause malfunction to 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. It can deliver power at
a voltage of 230 VAC 50 Hz.
The ENERGY 2510D model must be fed with
Diesel oil.
In order to achieve a low noise level, the
ENERGY 2510D generating set is provided with
an internally insulated sound-proofing case.
It can be accessed easily in order to perform
maintenance work, and is provided with a remote
control panel which can be installed inside the
vehicle.
The generating set can be connected to the tank
of the vehicle as long as the fuel type is
compatible. Otherwise, it is possible to install a
special tank which can be supplied as an option.

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2 GENERATING SET IDENTIFICATION DATA
2.1 Components (Fig. 1)
1 Sound-proofing casing
2 Supporting brackets
3 Access door closure
4 Access door
5 Electronic control panel
6 Vibration mount
7 Anchoring bracket
8 Technical specifications sticker
2.2 Identification plate (Fig. 2)
1 Generating set model
2 Serial number
3 Frequency
4 Power factor
5 Maximum electric power
6 Maximum current
7 Rated voltage 230V AC
8 Current delivered at 12V DC
9 Weight
2.3 Overall dimensions
Figure 3 shows the overall dimensions of the
Energy 2510D generating sets.
A B C D E
mm 295 415 660 710 377

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2.4 Technical specifications
ENERGY
ENGINE
2510 D
Type Diesel single cylinder air cooling
Engine Hatz 1B20V
Displacement cm
3
232
Bore x Stroke mm
69 x 62
Consumption gkW / h
260
Fuel supply
Diesel fuel
Oil sump capacity litres
0,950
Speed governor
Masse centrifughe
ALTERNATOR
2510 D
Type
Synchronous, single phase, self-adjusting, two poles,
brushless
Max power kW
2,2
Continuous power kW
2
Voltage/ Frequency V / Hz
230 / 50
Continuous current output A / Vdc
5,0 / 12
Rotor insulation class
H
Stator insulation class
F
Cooling
Centrifugal fan
GENERATOR
2510 D
Overall weight kg
98
Dimensions (L x W x H) mm 660 x 415 x 377
Starting
Electrical
Fuel supply
Electrical
Noise level 65 dBA @ 7 m
Operation Hours h 7
3 SHIPPING, HANDLING, STORAGE
3.1 Storage
The generating set is protected during transport
by suitable carton packaging and a wooden
base. It must be stored horizontally, in a covered,
dry and ventilated area.
Do not turn the package
upside down. The correct position is the one
shown by the symbol printed on the package
(  )
3.2 Weight
Total weight including ENERGY 2510D packing:
110 kg

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Energy 2510 D
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3.3 Handling
The generating sets, complete with their
packaging, can be handled using common lifting
and transport equipment.
The boxes are provided with spacers in order to
allow for the introduction of transpallet forks.
During lifting and
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
Before installing the
generating set, it is absolutely necessary to
read these instructions to prevent any
installation errors.
The generator must be
installed so as to prevent water seeping
directly into the alternator through the air
inlets; it must therefore be protected.
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 Law Decree
2006/42/EC. The Manufacturer shall also not be
liable for any injury or damage to people or
property.
Installation must be
performed by skilled and adequately trained
personnel only.
4.2 Instructions for fastening the generating
set
The ENERGY 2510D generating sets are
provided with anchoring brackets with extra
vibration dampers (fig. 4, ref. 1) and a fuel filter
(fig. 4 ref. 2) to be fitted along the generator
feeding pipe. The brackets allow for hanging
assembly and floor 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 10 cm 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.
4.2.1 Hanging assembly
The generator, when sticking out of the package,
is preset for hanging assembly, as shown in fig.
5.

Energy 2510 D Rev. 004
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The package also contains 4 vibration-damping
cylinders (fig. 6 ref.1) and 2 brackets for hanging
assembly (fig. 6 ref. 2).
The vibration-damping
cylinders must imperatively be fitted as
shown in fig. 6. They must be pressed, and
NOT extended (as shown in fig. 7) by the
generator weight.
4.2.2 Floor fastening
The package contains a drilling jig, which allows
the generator bearing surface to be prepared
quickly, fig. 8.
Place a spongy, heat-
resistant gasket around the outlet opening of
the exhaust pipe. The gasket height must
reach the bottom of the generator and has the
purpose of preventing hot air from spreading
inside the generator compartment.
The brackets of the generator must be moved in
order to fasten the Energy 2510D on the bearing
surface.
On both sides, remove the hole plugs (fig. 9 ref.
1) and screw out the screws (fig. 9 ref. 2) in order
to remove the bracket (fig. 9 ref. 3).

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Energy 2510 D
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Place the bracket (fig. 10 ref. 3) on the 4 holes
which were previously covered by the plugs
using the same screws (fig. 10 ref. 2) and apply
the hole plugs (fig. 10 ref. 1) in the seats which
previously housed the screws.
The generator can now be located on the
previously drilled surface (fig. 8) using the
suitable vibration-damping cylinders (fig. 11 ref.
1)
4.3 Connecting the mufflers
The Energy 2510 D generating set comes with a
suitable exhaust pipe kit which consists of 2
mufflers, 2 exhaust pipes and their connections
Insert first the U-shaped fastening clamp code
00828 on a terminal of the 2m pipe code 00705,
let the pipe terminal through the suitable slot by a
section of at least 3 cm (fig. 12 ref. 3) into the
exhaust manifold of the generator (fig. 12 ref. 1),
then tighten the U-shaped clamp (fig. 12 ref. 2)
on the pipe-manifold connection.
Connect the 2-terminal muffler code 01760 (fig.
13 ref. 3) on the other end of the 2m pipe (fig. 13
ref. 1) observing the arrow showing the gas flow.
Tighten with a clamp D.32-35 code 01655 (fig. 13
ref. 2). Place the muffler (fig. 13 ref. 3) under the
floor of the vehicle via a suspending rubber
stopper code 02440 (fig. 13 ref. 4) and fasten the
2 mt pipe in several spots (fig. 13 ref. 1), taking
care that such fastening does not prevent the
generator from being drawn out for maintenance
purpose.
Now insert the 40 cm pipe code 03161 (fig. 13
ref. 6) in the other end of the muffler (fig. 13 ref.
3) and tighten by means of a clamp D.32-35 code
01655 (fig. 13 ref. 5).
Then insert the other end of the 40 cm pipe (fig.
14 ref. 6) in the 1-terminal muffler (fig. 14 ref. 8)
and tighten by means of a clamp D.32-35 code
01655 (fig. 14 ref. 7).

Energy 2510 D Rev. 004
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Place the muffler (fig. 14 ref. 8) under the floor of
the vehicle via 2 suspending rubber stoppers
code 02440 (fig. 14 ref. 9 and 10)
4.4 Connecting the fuel pipes
No. 2 pipes come out of the generator. The pipe
with a larger inside diameter (7mm), on which the
fuel oil filter is located, is the fuel inlet one. The
pipe with a smaller inside diameter (5mm) is the
fuel return one.
If an independent tank is fitted, the installation
position must be chosen so as ensure that the
fuel pipe length is reduced to a minimum. Also
ensure that the hose cross-section is not reduced
due to choking, bending or crushing.
We advise to install the tank at the same height
as the generating set. If it is fitted in a lower
position, the installation height difference should
never exceed 20 cm.
Do not install the fuel tank next to sources of
heat; the tank should be protected from the risk
of outside water seeping.
Carry out the fuel tank-to-generating set
connection by using rubber hoses suitable for
Diesel oil, with an ID of 7 mm (code 00536) for
the fuel delivery pipe and an ID of 5 mm (code
01548) for the return pipe.
Both fuel pick-up and
return must take place in the tank and NOT
through branch pipes.
Should the fuel flow rate to the generator be
insufficient owing to a long route covered by the
feeding pipe, it is advisable to install an additional
fuel pump code 00507. This pump, which is
equal to the one fitted inside the generating set,
is electrically operated. The electric control which
drives the additional pump is located in a 3 pin
connector (fig. 15 ref. 1) in the generating set
near the 12 Vdc terminals.
4.5 Connecting the Fuel Reserve
If the tank is provided with a fuel reserve
indicator. To electrically connect this component,
the reserve wire on the fuel tank must be
connected, via an electric lead, to the 3-pin
connector terminal (fig. 15 ref. 2) inside the
generating set, close to the 12 Vdc terminals. If
the tank reserve indicator has 2 leads, connect
the other lead to the ground.
A special fuel warning light located on the control
panel (fig. 24. ref. 8) will light up to show that the
fuel level inside the tank has gone below the safe
reserve level.
4.6 Auxiliary battery charger connection
It is possible to connect a battery other than the
one connected to the generator through the 2-pin
connector (fig. 15 ref. 3), on which there is an
alternated voltage of 12 V 50 Hz, max current 5
A; this can be done by installing a charge
regulator RCB (optional, item code 05424)
between this connector and the battery.
Do not directly connect
any battery to this connector!
5 Electric connections
5.1 Preparing the Wiring connection
By using the special key to open the lock,
remove the front door (fig. 16 ref. 3).
Then remove the bottom surface locking screw
(fig. 16 ref. 1) on both sides.