Home

Baldor GLC105 Portable Generator User Manual

1. 3NI9N3 OL 3NION3 OL sadoud 40 48 Bho NOSE u aaien ut Paida Fk i ETT 5 e DM Mod Hane h k YOLOANNOD 1 di m i 1902 Asx 44 AA E 4 88 FEEF SEES i om TARRAA 8 3 5 8 o 8 8 5 a 18 8 8 8 8 5 lt 18 18 S E 5 8 Bye Na 8 Fl uj 3254 ono ond 8 38 e sus icu zi Jaroor Bei Bi Fl 3ndino 403009u99 ono BEE BELLE t BEEEE 2 41113 4433 96100060 14001921906 555 EN eS 55 ug E wc 9Adsisel 0 8 9DAQPZ VO S 51901000 y 1 711777 2 Ll GERE do1s3 Ww NT sur 10 uedo s yun pasn Jeduunf jpuondo uo si gzsooma dos 3 azsooma 87100010M I 9 100010M S I
2. NOILdO LNA 310Nn8 WOILN3OI 3TdlL1nN Sv dnONO Q3sn 34v SIYM 31d 1n 3l 7M3H13901 SIYM UNOY du yunys pedinbe s qun eui jo Ul 94D 0 SHIM du punys JBuondo m sjexbauq dui junus uwous Sy suonpouddo Jedosd LOON 2009 1009 LOOS 71002 LOOL 5 Joy jjou uuei WOH 285 v uogooo porsKud ay you saop uonpuuoju uonoeuuoo umous Suon3euuoa eBbyoA 101DJ0u65 aes jeunjoojnupu jojbuaus uo 77 pejou sse un 5 50 94M IV L 3AV3J SISS HO OVN 21 4 4 s 225 7 9 92 ___ 2 alqo moj g 24M allouDd 40 euo Bunuoys 21q01 434X Eu 69 88S 002 2 40 e 2 xLOON N Qa Qv 1001 FA 100
3. 12 L3 N a 2 a Remote a USI E 7771 RPM EMERGENCY STOP BATTERY REMOTE SSTART STOP FUELLEVEL WATER TEMP OIL PRESSURE STARTER T Zee 221019 d ease EE 5 N gos gaaa CO GENERATOR GENER ATOR BINARY INPUTS CURRENT VOLTAGE 3 x 230 400 CAN b S D II BOOT JUMPER X ARALOGIMPUTS BINARY POWER FE Zz _ a5 5 8 36VDC DA FES 888 SIS SIS SINS FUEL SOLENOII BINARY OUTPUTS TO BATTERY MN2408 Operation 4 11 Digital Engine Controller Description 046 21 MRS17 Continued DIESEL GAS ENGINE FUEL SOLENOID START ER TO BATTERY Figure 4 12 Controller Connection Diagram GENERATOR Remote JDIC Start T A REMOTE SSTART STOP ji EMERGENCY STOP foe
4. v posi veo 10018 99199 5 10A 092 021 NAA n 4 n 2 e SA IA 4 9 OM Qv31 ON Qv31 ON vil ON 24 loo olvanogs P 99 1110209 170A ovz ect uonaeuuo2 20 Jo dous J8j8j v v0000M9 MN2408 B 12 Series GLC Figure B 22 Three Phase Connection Diagram Wire 1 0 and larger 6W0000A42 TURN XOLYXINJ 3SVHd 6 279 2 0000 9 33 6 0000 94 Jld 002 90 20 20 09 91 035 38 414 B HUI 2 OJELLOWTSH JOT IVa VL 919 MON 60 31 LNNHS J33V3H8 2530 3H our 8 6 WOLIOG 11 55303 LON 4 31 OL 193NNOO lt lt 0 foun 5 YSHLASOL S3MIM 31704 Jayoa4q di unus pedinbe jou s pun p 291 jo Ul 240 20 SEOs S94 du junus Ibuondo dui unus 0194 UMOYS Sy S4012npuoo eumbe4
5. 59 o3 Sle Ji 8 lt 24221 5 2 5 2 EX gt et amp 26 5 Em e o os 5 9 5 i 9 42 8 5 g 8 o o 8 P 6 5 37856 F Er Er E ose 2104 T gy lt 59858 law 2050417 8 8 am a28 485 lt es OCOL LI 5 58 82 25204 Coox2 E35 EP SS X pao 9 29 D pu sor Bose 39857 S 96607 5 S 5 07902 5 ae 20902 y o E 21902 5 g 30902 9 os m e 25500 33 s2 98501 21504 Ss 5 S 28604 NE 25502 gt 28 28 o 5 x 90404 CO 8 2707 85 CN E ue 36007 3 3800 ipu 21004 cols eg 29002 5 r 2500 97007 LI 5 9 Qr E3171 HER 22007 z gt i E ne 290 rps e I i310N38 1e onor 290 6 EST tros 51003002 8 pow d g 8 S R RI RJ T sem ANE oro rant oe pes i eja 31909 pepierus 24 nU ees ENS g ST oro 8 ez 20204 ono Senor 56207 52207 a 8 86 8 92 ER SF Jazo ET xl ISOL g B g 2 59007 S ica 8 d de a 8 z 9 21002 122902 29202 g oam 5 2 un 30007 20006 gt ET lt 9 gt a2 25 04 26900 a 2 jjs 8 3 OL 2 22773 5 Ea ui 29v0L Ed voL aro 2270
6. om y uo pesoq Koa ssejun 2 20 M IV 310 Figure B 18 Single Phase Connection Diagram Wire 1 0 and Smaller w o Breaker SISSVHO YOLVYANSS QV31 v g 192 Piaty 61 71510111016 8 9 6 Z xog 91 ti 74 WL 992 21 ZH OG ZH 09 Joyoinbay 6 0000 9 Series GLC B 9 MN2408 Figure 19 Single Phase Connection Diagram Wire Larger than 1 0 w o Breaker CW0000A77 319815 82 D M 89 10 1123 2 SDLVH3N39 379 NONI SES Q 005629 0 8 v 03S3H 8 1811 38 o 21449414 SOGIVG PUN EN SISSVHO icm YOLVYANSD QV3l v 2009 9 3 9 1005 pL 9 7 2 2 R ZH OS 2H 09 JoyojnBay abpyo N S3 IINn amp xL OON JVOIIN3GI 3 Sv dnus5 aasn 1001 Jew SJAA 3 dIL IW 3I gt 3501 S38IA A 31708 S ele y dij junus BAN
7. INCREMENT ENTER lt A GENERATORS Q EMERGENCY STOP VOLTAGE ADJUST LCD Display Alarm LED Shutdown LED Ready LED Speed Signal LED Emergency Stop LED Vavg average voltage display 0 999 volts Aavg average amperage display 0 999 amperes Freq frequency display 0 999 hertz Flashes when a fault is detected Flashes when a fault is detected On when the generator set is ready for automatic operation and no Shutdown or Alarm faults are detected On when the engine speed signal is detected i e the engine is cranking On when the Emergency Stop Switch is used to stop the engine Emergency Stop Switch When pushed the engine is stopped immediately The engine cannot be restarted until the controller is reset Programming Keys Run Switch Run LED OFF Switch OFF LED MN2408 lt Exit pushbutton used to scroll backward through the status menus or programming prompts to the previous item Note The longer the push button is held down the faster the menu prompts appear Decrement pushbutton used to reduce a programming value while in the programming mode Note The longer the push button is held down the faster the value will be decremented Increase pushbutton used to increase a programming value while in the programming mode Note The longer the push button is held down the faster the value will be
8. Engine 4 Control Control 5 ds i TES Alternator L i t Bracket BTCGR6 Frame ELT a BTCGR10A Battery BTCGR10A Battery Tray BTCGRe Tray Installation Considerations Shore power must be available 120VAC or 240VAC to power the battery charger and other components that may be installed Shore power outlets or wiring must be located close to Battery Charger BTCGR6 Charger refer to charger manual for specific details 1 Mount charger refer to Figure A 1 to determine suggested location 2 Connect charger negative wire to battery negative terminal 3 Connect charger positive wire with fuse to battery positive terminal 4 Connect charger AC power cord to shore power outlet BTCGR10A Charger refer to charger manual for specific details 1 Mount charger refer to Figure 1 to determine suggested location 2 Connect charger negative wire Black to battery negative terminal 3 Connect charger positive wire Red to battery positive terminal 4 Connect charger AC power cord to shore power outlet MN2408 Options amp Accessories A 1 Battery Heaters Battery Heater 81 120 Volt 80 Watt Includes 6 ft power cord Installation Considerations Shore power must be available 120VAC or 240VAC to power the battery heater and other components that may be installed Shore power outlets or wiring mus
9. 3009 21812314 WNOILYN 7 201 3ZIS ALIOV dWv N QVOT UN9 QvoT 3LON S3MIM 3SVHd NOLLVOIJILN3GI N 9 9 GONT z diMIS VNIW33L LINIYA IVNWH3L SNOLLO3NNOO YSWOLSND 2408 GWOO000A31 TUN 1 O M 3SVHd HOLVH3N39 AVNOVIC 1 V0000M9 334 29820000199 313 Z9vvi HOL 00 18 01 8221291 03SIA3H 8 YLT A38 9 4714 4 9804 ONY SEOL 534 Q3Q0V 2530 SOIVJ3N39 v Figure B 13 Single Phase w o Breaker Connection Diagram MN2408 d 4 lt 3 ad y 9 z i P 2 ZH OS du 09 uon2euuo2 Yo O gt M NIN NIN S 701 SOL a e gt lt e Y LZEXS LZvXS 5 20 S 9 uid 2802 y uo zou Kou 10 9 ZZOZ 2154 4 291 jduu jou seop j uonouuojur uongoeuuoo api oud 5 suono uuoo
10. 4 23 Engine Parameter Display 4 24 Program Menus zoe RE ERE Seeks RAE E rs 4 24 Main Menu Loop icem meme m ence ee edo tev niet E bee 4 25 Analog Faut Menu Loop Eu TEE Rente UR Ee RUE EUR E eg 4 26 Digital Fault Menu Loop 2 4 27 Calibration Ment LOOP 2 he Aka tM Lu ee EVER en de Oe RM RN RO dat pie fps 4 27 Voltage Sensing Calibration 4 4 27 Voltage Calibration Procedure 4 27 Current Sensing Calibration 4 28 Battery Voltage 4 28 Engine Temperature amp Pressure Calibration 4 29 Section 5 Troubleshooting and Maintenance 5 1 m 5 1 Problems and Solutions jos es m duy e M ER ERU e bald 5 2 Appendix A Options amp Accessories ce beet
11. Fuel Stub Up Electrical Stub Up A3 Table 3 2 Mounting Dimensions enerator A A A 1 2 B1 F1 F2 Open Weather Sound GLC10 25 60 25 72 0 72 0 4 06 26 1 11 75 31 5 30 5 17 60 34 20 GLC30 45 78 0 78 0 108 0 6 0 33 0 30 0 44 0 42 5 21 58 GLC60 65 88 0 88 0 118 0 6 0 38 0 30 0 44 0 42 5 23 63 GLC80 105 88 0 88 0 118 0 6 0 38 0 30 0 44 0 42 5 27 68 Generator 11 Add 11 75 in for Weather amp Sound Attenuated enclosures Table 3 3 Stub Up Detail tub Up Area Electrical Fuel Fuel Connection NG or LP Vapor GLC10 25 6 25 x 5 5 x 18 3 is 3 above base bottom GLC30 45 15 x 6 18 6 37 NPT C Lis 12 above base bottom GLC60 65 21 x 6 20 x 6 1 1 4 NPT is 12 above base bottom GLC80 105 16 x 6 21 x 6 1 1 4 NPT is 12 above base bottom 3 2 Receiving amp Installation MN2408 Secure the Generator Six eight for the GLC125 mounting bolts in the base frame secure the generator to the shipping pallet Remove these bolts lift the generator and remove the shipping pallet Secure the generator to the concrete pad using 3 5 anchor hardware not provided in the base frame mounting holes See Figure 3 2 Anchor bolts must be long enough to extend th
12. 4edoid LOON 2009 1009 LOOS 1000 71001 Seu 20 ees uonpoo jporsKud jonyoo y you uonnuioju 5 Suono uuoo jeypjboJ pub siqb ses 1eimjoojnubu uo pesoq AIDA sbububu 403040U99 ssejun dTX 0 501 9X lv 310N SISSWHO dQL 11 55303 LON 0 31 80102 MOTI3A OL 123 02 1 NOIVH3N3O9 0731 ZL a 4 Te 4 3 eqo GL 9 uouo 902 _ BINN UA aiqo a o9 99 9 1 LOON s 09 Qa Qv 1001 pe G D 1002 ORTA e SL IL 1009 Eu 7267 EZOZ E IM 2807 3 e I 770 NS 7207 lt 02 807 7202 A MOLO 9 Z2 9 S GC xog o4u92 pm SM 91 L IM uL 9 91 z m sn vl zn In N N n n Poa vooon S upuow 100009 79179020 LZEXS ZPXS 540 0 20
13. o 1002 g gt lt 1002 e ig 7202 ECOL Im pedibe jou s qun D oui 10 IN y ur paunoas 0 5 014 JUNYS 2807 O sjexDaJq dui junus 5 Sy G IS ga N e103onpuoo ej dnjnui anb s 6604 4adasd 20 LOON 2009 1009 0 006 1002 1001 eu 40 poyo wie 995 7 lt lt 0 boiS ud y dw you sad 4 fu 807 Suonosuuoo pup 4010J9u99 IZOZ uo m pesog sBurjiow poe 4010J9U99 pejou ssejun dX 2521 SUM b SivicLzLliLOLG 8 Z 9 5 EZ xog 031002 LZ XS puo SM 91 ZM l LM m 9 BL SA 91 ZA a 1A OLL an sn zn A in N N l M n n JOUW 101029490 127 5 sJojojnDau s 9 1 1 IN 40 S uonoeuuo9 siu p eq jou 9 1 0 025 110 9iv OvZ 10 087 222 IAS NAA zm 2 SA ZA 8 sn zn o u
14. OCOL 9 ZH 9 94 SA d sg sn tn 3 SA a 3 5 8 105 a e o in Y 170 08 242 170 086 412 PORT poan PRO 02A NTA u IA NA 24 h 891395 CON N N ei zu ju ACA g M TATUR on 3 a OCOL 9 SA 2 0 2 en eg 11 SM Y vuv Eng DMPC sues Gs sin PE AM 4 GA IN E e S ww 0504 9 SW a ZN ON SA 3 TA OM Qv31 ON 2 ON 110 0F2 6E1 LOA OON Y JAM AR mem pog serus em 19110404 vooon abonan 2204 7204 3AVv34 SISSVHO 7 MOIVS3N39 Qvi 21 2 H Q 3 e pa 9 g z ___ OG 1991 de 09 HON lt 04 21901 oy ay Os N M n Qa qs 1001 gt LOOZ 1 S 1002 F 7201 4 201 IMIS pd 807 9 e B 2001 m P M 7204 0Z 802 1204 SL vLELZLILOL 8 49 Gv Z 310N xog 0 492 uonoeuuoo 9ejp d Jo dous oj SOVOO00M9 Series GL
15. 3HILN3 A U 8 3nouol TWNIWH3L 300812313 ouf zett 8O193NNOO 3HMM Z MXS 0123 02 SLINN 3SVHd 319NIS NO 357 LON 1 TVNIWSL SYOLONGNOD 26 3SIM dW3l 3009 9l319313 1VNOLLVN 2 1 201 3ZIS ALIOV AV TWANVN 23W NMOHS SY NOILVOIJILN3OI SIVNIWH3L 11 diMIS lVNIWiH3L 3YNSOTINA I3NVd 1031NO2 SNOILO3NNOO YJWOLSNI 19 1 00 LYVLS 31032 LNV1009 AWo2 8 vec veovvevsc vat vv 2 2 2 2 2 84 64 06 1 2 VZU V9 VEL VEG yzg VLS lt D 8 2 Z 001 VNIWN3L NOILJ3NNOO 3 015090 19V1NOO Nn 19715 310W38 1NY 1002 M01 UN WNOD Figure 12 Customer Interface w o Breaker Power Connection Diagram 2 2 2 2 82 2 8 2 2 2 2 2 2 2 voz 2 82 vez vos vie ves VES vra vos voc vz vivon ooo S S V8 VZ V9 VS V vi vz vou vzg via lt
16. Series GLC B 3 ALON N311041NOO OZ 23 4 2018 TWNINYSL 2 YIWOLSNO z 310N 5310 SNOILO3NNO2 YIWOLSNI G Sze 41 lt 2 41 G Z 4 sie SOOO TRIS 008 IA Ose IRD 0S 005 NNOO IS ZIMY 91 9f vil o 3 OV3H 130205 OLO3NNO3 no no no SWoionaNoo SNOLLO3NNOO lt NOLO INNO 281 ISL 25 25 Nod dal WNOUWN 1 901 3ZIS ALOVdIV d 6l El OO N OVO1 v 3LON S3HM ereere o N N 3 auone zin 90 E Qvd ONnOND M3Wv3NH LINON si VNIWH31 SNOLO3NNOO YSWOLSNI SNIQNOB qi u 05 1 4 Sv v 9 q u Op OMY qu ec OMY 21 6 YOLONGNOD 30010314 300312313 9NIONnONO S 30123NNOO 3NIM INO Z SLINN 3SVHd 319NIS 0357 LON 1 TWNINYSL 71 SALON S S S 5 3n0301 074 OMY 071 O T 39NVN NNOD 310N zif My zIf OMV 218 zd SNOLL23NNO3 MAYOS MIYOS M3YOS MOLO3NNOO YINOLSNO no no no SesoionaNoo 292 244 24 292 3914 ISI
17. 0502 9 M 1 QA ZA H E 3 sn zn 3 a 2 8 v in 0 nis pos sales Ova ON ava ON ZA on zn ZM 0202 9 1 9 8 3 4 o of of w ujoj z BUS poe usg pO v You Saas 5 8 L SATA coz 9 UM zn ZA ZM avi ON w o af w ofz Ova ON 55 P9 Eod 19110204 20 10 21014 20 dous 08V0000M9 Series GLC B 17 MN2408 Figure 27 Control Box Connections with MEC20 Controller
18. 4edoid JO LOON 2009 1009 604 LOOF 71006 LOOL 049 w WOE 99S y uenooo iporsKud pnjoo y jou O 5 2 SUONDSUUOS 3l S uo 6804 N pesoq 5 poe 0 9 77 COL peyou 0 641 310N 7205 807 1004 7 61 0111016 8 96 lt 201 xog zu 9M 61 91 1 m 9 31 SA 81 ZA 21 1A OW on sn zn in N N n DUN EXT VODW PUS 791029099 IZEXS PUD 2 5 ss0yInBas s 9 uid UO 1 1 20 s sig UO ou ADW 9 0202 9 1 SA ZA 8 zn 9A on w in pas pos LWA 919 094 TOA 084 222 HAS NAA lt o o 8 seues ava ON N ON en zn 0202 9 9 1 1 en a in 9M pea nos ueg 8 gn in SM IM zn on ZA OM WH an V3 ON QV31 ON 1704 aan oN 130A 802 021 n 0997
19. 7 24504 20604 20 0 E g EOL A 2j 5 20907 Ea CSI N 8 a VWVVVVV2 8 55 c Q ee 1502 PPI a Nun o z ira 265 5 ee a go K N N E ox A i 58g e 2479 3 5 aot a zm e NS 8 828 a 99 zac 9 9 85 oe EE EA Men TN 23 lt lt ons BWO099D BALDOR ELECTRIC Co CONTROL BOX CONNECTION DIAGRAM GLC MEC 20 WOODWARD COV PORANBO VERSION 11 REVISED 15 44 04 05 15 2007 DESC REMVD CONNECTION DIAGRAM FROM OWGIS ON CONTROLLER FILE PCA O0003 264 Customer 1 0 Connect TO ENGINE TO ENGINE B 18 Series GLC MN2408 2408 Figure B 28 Control Box Connections with MEC20 Controller amp Governor E Stop Pins 7001 7001 Block WD1000L28 aseooma R
20. VOLTAGE NUM UNDERVOLTAGE SHUTDOWN AC VOLT FREQ DISPLAY UNDERFREQUENCY SHUTDOWN PHASE CURRENT AC CURRENT DISPLAY PORE DIGITAL INPUTS N O or N C LOW OIL PRESSURE SHUTDOWN HIGH ENGINE TEMP SHUTDOWN LOW COOLANT LEVEL SHUTDOWN LOW FUEL LEVEL ALARM EMERGENCY STOP 4 18 Operation RUN 10A 240Vac BA 24Vdc RESISTIVE CRANK 10A 240Vac 8A 24Vdc RESISTIVE PROGRAMMABLE CONTACT 1 10A 240Vac BA 24Vdc RESISTIVE PROGRAMMABLE CONTACT 2 10A 240Vac 8A 24Vdc RESISTIVE PROGRAMMABLE CONTACT 3 240Vac 8A 24Vdc RESISTIVE PROGRAMMABLE CONTACT 4 10A 240Vac BA 24Vdc RESISTIVE NOTES N DIGITAL FAULT LABEL LIST EACH POINT PROGRAMMABLE PROGRAMMABLE FUNCTION LIST VW MN2408 Analog Faults Low Engine Temperature High Engine Temperature 1 High Engine Temperature 2 Low Oil Pressure 1 Low Oil Pressure 2 Low Battery Voltage High Battery Voltage Weak Battery Undervoltage Under frequency Engine Speed Analog Input MN2408 Eight analog fault inputs are user programmable for 12 fault conditions Each analog fault input requires a specific analog signal type Fault Name Low Engine Temperature High Engine Temperature 1 High Engine Temperature 2 Low Oil Pressure 1 Fault Action Alarm Alarm Shutdown Alarm Shutdown Alarm Alarm Alarm Shutdown Shutdown Inputs Signal Engine Temp
21. dous 0 2408 B 14 Series GLC Figure B 24 Three Phase Connection Diagram Wire 1 0 and Smaller w Breaker GWO000A76 ONIN 3SVHd 019 SIVOUDONSCUEN O 005626 XOL 0 8 035 34 478 8 Hb 38 OYLATHY SOQGTVd 20530 Nd 3Wvu4 SISSWHO WHOIVH3N39 031 Zl g 4 8 3 d 901 ses e 9 uoun POMON T aiqo 20 240 FIPA 5 91 JAH NI H 09 9 ON 99S 140 didi 5 020 91991 o9 OH LOON N WA cK A ig Qa Qo Qa 13H13901 100 4 SIYM 31003 5 1expeiq duy unus 100 pedinbe jou s yun D j y JO f 991 Ul 0 PUD CEOs du punys auo suexbe4q junus uwous SY 100 2 4 vcOL
22. x 30022 Busnoujeg 38004 2 gs 30202 um 5 N mom m 1 t em xal PADMPOOM AMO NS 192 3 JS q 9 X A 8 EE 5 1 m H les 32201 Sod Paplalus AR uw m 32202 32204 ovd 491JD S 4 50 LON jo avan HOWL 201914510 e eu z L m E 5 Rv C e rus gn dod oneubb pepieus m 5 n 38207 MN2408 B 22 Series GLC Figure B 32 Engine Wiring Woodward 8 1L GM 00420 WO QuvMQOOM LN Q v003M 43 0 520000 94 3114 OIMLOWIM HOTIVd 16Z12 lt 002 1 L1 12 22 60 Q3SIA3J did AG 3 HL1 A38 d OIld OVW 103 2530 AJY ISd 48 punosg auu t LN zn CES mu aly f dn yoid oS papiaus 3 Popiolus ipuon dg ub ww 38204 S 318 NIHM 3SN eE neon A09 ew poppei 2 Iouondo 32002 F
23. when no E Stop is installed The E Stop cable 4 lt nue lo connects in the connector when BW0052D is 5 Le 5 not installed EIS fa 9 olo oto pl mc mc 3 7034c 7045 Installation Locate and drill 4 holes shown in Figure A 6 Mount the E Stop Switch box to the enclosure Install the E Stop assembly into the E Stop Switch box enclosure Connect the E Stop Switch cable into the connections for BWOO52D Boom A 6 Series GLC MN2408 Remote Annuciators Remote Annunciator For use with MEC2 Controller Provides remote anunciation of faults and generator status Up to 20 individual fault conditions are remotely monitored utilizing both visual LED lights amp audible alarm annunciation Lamp test and alarm horn silence pushbuttons are provided Each fault is individually programmable for audible horn operation and alarm labels are field configurable Requires 12VDC 100mA power supply to operate engine starting battery can be power supply Figure A 7 MEC2 Remote Annunciator MCO 5 110 J1 p COMMUNICATION CABLE J6 MEL 9 r N ANNUNCIATOR uU La b ENGINE eRT o CONTRULCER conection MJ 7 EXT EXT EXT3 EXT4 Be B 1000 MAXIM COMMUNICATION B 8 s a 9 919 CABLE LEN Gm _ 9 EXTERNAL ARM SENSIN t m TONAL USE 1 AS REQUIRED 12 24 1 P E Crankin amr 1 Figu
24. 0 in v pos ui borvingau 7991 e9 PEJE 891495 2 21 0714 NA QV31 ON aval ON ZA GA zn an 0202 9 2 wn a o lt 9027 uaa PEJE INOLV 3H seueg 02 081 IY 802 021 9 n 1 SA UA 04 SM n ON SA ZA 2 avai ON 4 31 ON a ofaj uf 6 avai ON Y POST pos us RIOLV ID 32H te IId 0 ejp d 20 pips dous sajay 8 0000 9 2408 B 16 Series GLC 80 O M 3SVHd 219 705 OIMLOWIM SOGTVd MN 08 0000 9 2434 005626 XAL 0 8 478 A8 H1 34 TIWLLINI 0830 A38 GW0000A80 5 WOLULN3QI Sv dnouo 35 S3MIM JIdILINW 3i H3H13501 SIYM UNOY 4 0 4q zunys pedinbe jou s jun j 35 Ul peanoes 94D p OL PUD OL S HM diy JUNUS ajo 4 d JUNUS MOJ q 5 Sy G s40 anpuoo ajdninu anb s 5 uie 4edosd LOON
25. Figure 4 17 Main Menu Loop Parameters Parameter etting Range System Voltage Line To Line XXXXX VAC 120 15000V AC System Frequency 50Hz 60Hz Toggle Between 50 60 Hz System Phases 1 Phase 3 Phase Toggle Between 1 amp 3 Phase Neutral Connected Toggle Between Yes No Voltage Sensing Voltage Sensing Pt Ratio Ratio XXX Enter Number 1 208 1 Direct Current Sensing Current Sensing Ct Ratio Ratio XXX Enter Number 1 999 1 Direct Temperature Scale Deg C Deg F Toggle Between Deg C Deg F Pressure Scale PSI KPA Toggle Between Psi Kpa Start Delay XXX Seconds 0 999 Seconds Crank Time XX Seconds 0 99 Seconds XX Seconds 0 99 Seconds Starter Re engage Delay XX Seconds 0 99 Seconds 0 Disabled Number Of Cranks XX Cranks 0 99 Times 0 Continuous Bypass Delay XX Seconds 0 99 Seconds Cool down Delay XX Seconds 0 9999 Seconds Nominal RPM XXXX RPM 0 4000RPM Flywheel Teeth Engine Speed XXX Teeth 0 999 Teeth Sensing Magnetic Pick Up Crank Disconnect XX 96 0 10096 Overspeed XX 96 100 150 Overspeed Transient Seconds 0 0 9 9 Seconds Run Output Fail Safe Yes No Toggle Between Yes No Loss Of Speed Signal Shutdown Alarm Shutdown Toggle Between Alarm Shutdown Common Fail For Not In Auto Yes No Toggle Between Yes No Horn For Not In Auto Toggle Between Yes No Prog Output 1 Common Fail Factory setting Prog
26. GENERATOR OUTPUT RUN CIRCUIT RUN CIRCUIT 19 CURRENT SENSING FUEL SOL GOV IB ated pee velit N 5 SPEED SENSING MAGNETIC PICKUP Cl MP1 MEC 20 IC UE DELETE PHASE C MP2 9 FOR SINGLE PHASE SYSTEMS OIL PRESSURE SENDER GRD a9 1 7 GRD ENGINE TEMPERATURE SENDER 58 257 pr COMMON FAIL CONTACT dd po 0 9 13 26 0 OPERATES ON AN ALARM OR E SHUTDOWN CONDITION REMOTE FAULT RESET 14 274 25 26 27 Not used in MEC 2 CLOSE TO RESET i 15 ON 16 x REMOTE START CONTACT V 99 4 PROGRAMMABLE 17 Jm CONTACT 1 ap 1 90 DIGITAL FAULT INPUT CONTACTS ap 2 2 1 4 bd Megat tle ca qp 3 PROGRAMMABLE 327 CONTACT 2 NU a T Gy 33 34 NE 1 i 7 PROGRAMMABLE VY 3970 contact 3 Gy F Not used in MEC 2 b 36 Gu 9 ML e i e li PROGRAMMABLE ap Ti 4 ap 12 L_29 se O T8 uei ue 1 9 G CONTRAST gin Ic IB 1 VN C WATCHDOG E HE REMOTE START C FAIL 18 gt 38 2408 Operation 4 33 4 34 Operation MN2408 Section 5 Troubleshooting and Maintenance Maintenance MN2408 This manual contains only very minimal engine maintenance instructions Refer to the engine manufacturer s owner
27. SF 100 a p 7204 2202 E 2807 iiis ECOL pm POOL ALON 2604 104 29 S v EC L 03005 OL Zu 9 8L SM 9L ZM EL uL 9 aL S cL Z 1 LL sn vL an u in N N e M a A DWN PA uouJow bubo 101029089 LZEXS 2 5 5 0 S 9 bi ugyuour 7 7 JO 8 uono euuoo 510 uo e qojibDAb eq you AoW 9 H 21 m 1 gt 1 UN E zn 3 9 d 2 A 3 170A 022 v 910 092 zn 170A 112 jOLV IND BA 01A NAA in n 5 5 N ION 9 n m EA SA 3 m sn zn 3 4 0202 9 S 3 1 wn 3 Ww y 170A 2 021 pasi pee veg 39H N14 n IGLv 10334 seues g n in H n c L m foe 9 ama a ZA m 3 ZA 2 d ena CN a 07 681 v 902 00 gj 551 poo wen P558 071A NAA jaov Inzi uer SAM 18110 04 0 91018 JO
28. s 9 uid uo ay uo e qojioao aq 9 Sjojonpuo2 auinbas suonpouddp 9MV 4edoud 2009 1009 LOON 1004 LOOL poyo WOG 295 215 4 y ou seop api oJd suono uuoo 10 01 U29 401D4eueb uo Aina pda ssajun 5 521 M 310N YOLVYSNAD QV3l v mS 4 3 d 7 Qm 2 lt ZH OS a 09 2 Ke 100 te 1001 gt a E 5 ZN LU 1000 otk 574 e 2807 2204 7204 204 7601 c0Z4 A AA SL vL 21 21 11 0 6 8 7 968 6 xog 5 l 23 2408 B 6 Series GLC Figure B 16 Single Phase Connection Diagram Wire 1 0 and Larger w Breaker GWOO00A04 GSVHd 319NISONVeOVIO NULLO3NNUJ eDULVe3N39 379 0
29. 009 1 031 algo ees e l 2 4 o3 13434 9207 e N o 20 1001 1002 1X 2 20 5604 1002 iX 19 7604 2601 0204 2804 5204 2504 1202 424 2604 L 06 eq 09 17 7204 6804 1204 au SL vLELZL ILOL 8 2 9 S C 1 6504 ul 6L SM oL L iu 9 SA GL tA 1A 9n a sn vL zn in N N a a n a vonon BURLUS Joyojeues LZEXS PUD LZPXS 5 s 9 uid Buuojuou 1 1 JO s uonoauuoo SIU uo eq jou 9 0202 SM M SA ZA z sn zn 9M 9A ON M in pos 8 lt a a 170A 914 07 zn Ogv L47 NA n 3AM QV31 ON N QV31 ON A n SM 0502 2 1 sn
30. 1004 im Toor TIS suld MN2408 B 20 Series GLC Figure B 30 Engine Wiring Woodward 4 3L GM WEOO40D WO ONIMIM 3NISN3 O8NVHDd AG 5002 71 80 19 02 71 Q3SIA3N G6Z f0000 YIA 3118 OIJALOWIM 16917000000 YAL O WELT Ada MOM 1934409 OL 9 AJY Ol MOVE LYSASY 22530 puondo 10596 0 002 ILI sth 3980 3980 eng d w Sus 8 8 3 iu oS 3610 5 x6 38107 g IS 34104 E 39104 9 36102 32204 5 lt 3 10 32107 c EE gt 32104 x J 31107 8 32002 amp e a ly als 31104 5 53 4 10 35004 3 a e ES 55019 S m TS 36204 m 34007 J 30044 38002 8 x 30 04 N N t m m EE puoMpoom w GEG BATS 05 T z a a a AVEO 1HM m IM pepielus 32202 5
31. IDMT curve shape selection 2Inom del is Reaction time of IDMT protection for 20096 overcurrent Igen 2 Nominal current Step 0 1 s Range 0 1 20s IDMT is very inverse generator over current protection Reaction time is not constant but depends on generator over current level according following formula Reaction time is limited up to 900 sec 15 minutes IDMT protection is not active for Reaction time values longer than 15 minutes 2 del Nomin current Reaction Time Igen Nomin current Curr unbal Threshold for generator current asymmetry unbalance Step 196 of Nominal current Range 1 10096 of Nominal current Curr unbal del Delay for generator current assymetry Step 0 1 s Range 0 60 0 s Gen V Shutdown level for generator overvoltage All three phases are checked Maximum out of three is used Step 196 of Nominal voltage Range Gen V Wrn 20096 Gen V Wrn Warning level for generator overvoltage All three phases are checked Maximum out of three is used Step 196 of Nominal voltage Range Gen V Wrn Gen V Gen V Wrn Warning level for generator under voltage All three phases are checked Minimum out of three is used Step 196 of Nominal voltage Range Gen V Gen V Wrn Gen V Shutdown level for generator under voltage All three phases are checked Minimum out of three is used Step 196 of Nominal voltage Range 096 Gen V
32. 10mm Expansion Joint and Sealant Material X Slab 222 Re Bar J Boit Foundation Fili With Grout 3 76mm Iron Pipe Use Expansion Bolis Also Acceptable MN2408 General Information 2 5 e Steel spring isolators are a very effective and commonly used Steel spring isolators are typically 95 98 efficient reduces the transmitted vibration 95 98 while a pad type can be 75 88 efficient Spring isolators also level the genset sub base in the event the foundation pad is not perfectly level Spring steel isolators offer the highest level of vibration isolation however higher levels of vibration although not detrimental may be seen on some areas of the genset when mounted on steel springs due to the almost total isolation from the foundation The base of most steel spring isolators contains a non skid pad The base should be mounted to the foundation pad as shown in Figure 2 1 or as recommended by the isolator manufacturer A common practice is to pour a concrete pad directly on top of the floor slab and to mount the genset on this pad The purpose of the pad is to facilitate cleaning around the genset and to provide a more level base When using this method floor strength must support the pad and the genset The pad should be at least 6in 150mm thick and extend beyond the genset in all directions 12in 300mm Weight Of The Genset The dry weight of the entire genset is shown on the Generator Set Specificat
33. 56A 55A 54 32 31 50 29 28 NOTES S S S S S S S S S S S 1 TERMINALS 1A4 36A WIRED DIRECT MEC TERMINAL d 2 TERMINAL SUFFIX A WIRED OUT FOR ACCESS REMOTE Sz START 3 ONE WIRE CONNECTOR RUN BONDING CUSTOMER CONNECTIONS CIRCUIT BREAKER BOX JUMPER CIRCUIT BREAKER TERMINAL STRIP B o 11 L2 L3 NOTE1 m 3 G N mm Line Gen IDENTIFICATION LOAD PHASE WRES NOTE 4 LOAD GND LOAD GIG 3 LOCAL amp NATIONAL SKE 5 AMPACITY SIZE E FETRIG TEMP RISE 75C 75 75 75 CUSTOMER CONNECTIONS CONDUCTORS CU CU CU CU NOTE 2 CONNECTOR SCREW OR SOCKET SCREW SCREW SCREW 12 AWG WI2 AWC 2 AWG s CONN RANGE SEE NAMEPLATE _ 1 awe 1 0 awe 1 0 AWG L t2 1 TORQUE SEE NAMEPLATE NOTE 5 NOTE 5 NOTE 5 SUME hc E NOTES CUSTOMER CONNECTIONS 1 TERMINAL L3 NOT USED ON SINGLE PHASE UNITS NOTE 2 2 ONE WIRE CONNECTOR 3 GROUNDING ELECTRODE TERMINAL 4 GROUNDING ELECTRODE CONDUCTOR 5 410 412 AWG 35
34. 8 AWG 40 in lb 6 4 AWG 45 in Ib 3 1 0 AWG 50 in lb BONDING JINDER CUSTOMER CONNECTIONS CIRCUIT BREAKER BOX CIRCUIT BREAKER GROUND PAD NEUTRAL PAD 1 12 13 L1 L2 L3 NOTE1 G N N alo OO NOTEI Note 3 N Line Gen IDENTIFICATION LOAD PHASE WIRES NOTE 4 LOAD GND LOAD LOAD N AMPACITY Size LOCAL amp NATIONAL ELECTRIC CODE CUSTOMER CONNECTIONS TEMP RISE 75 75 75 75 75 2 575 ls CONDUCTORS CU CU CU CU CU C CONNECTOR SOCKET HEAD 6 AWG 6 AWG 44 4 AWG Lodd CONN RANGE SEE NAMEPLATE 350 350 500 500 KCMIL CUSTOMER Lt U L3 TORQUE SEE NAMEPLATE 275 in lb 275 375 in Ib 375 in lb CONNECTIONS NOTE 2 TIAS T NOTES CUSTOMER CONNECTIONS 1 TERMINAL L3 NOT USED ON SINGLE PHASE UNITS NOTE 2 2 ONE WIRE CONNECTOR 3 GROUNDING ELECTRODE TERMINAL 4 GROUNDING ELECTRODE CONDUCTOR BW0440D B 2 Series GLC MN2408 FLW LINDYIO 32 38 1 Y3WOLSNI 279 ESTE OOSEZE NGL 0 8 GaSW3ay 8 Y 02 OILOWISJ SOGTIVG 5318 1 9 S3ION 03538 0830 34 BWO440D 1 M0193NNOO 3HIM INO 55322 M04 LNO Q3HIM 6 TVNINN3L Z TWNINYSL 19340 9 STVNIWM3L l 1 300319313 9NIONDONO 7 15310
35. WO p eS 4 1 Digital Engine Controller Description 4 1 Alarms 3 traded aar end x aded ous we bd e Ba eb Re Ren Gen 4 4 Inputs and Outputs e e ase at vs taa Mi bd add ed ones 4 5 Analog Inputs s mote oce e tote gee eub Er xe Xe te adis 4 6 Set bae ed 4 6 Operator Control Panel MICROPROCESSOR Engine Controller Only 4 13 Operating Proced ts iios ie eee wee ieee oe eA LER bees 4 14 Manual o Ru LA pt ele tre de Rha e CEN ai athe Gee 4 14 Automatic Start Stop nee Yon M I ER AUR Iu Meee eae 4 14 Automatic Fault Shutdown 4 4 15 Automatic Mains Failure 21 1 4 15 Standard eR Ee ERR EU pde ae deve Gon alse 4 17 Output Contacts d PME C 4 20 Display Modes 2 riga fuel Sues tage odie cee oun MEE imb Ed Re eR Mon iE YR 4 21 Operating GER PEE 4 21 Display ios ELO ERI ee ee ee ERAT E 4 21 uae ME EU 4 22 Generator AC Metering
36. ebD3oA 4 j01D4eueb uo 40j100eu85 74 l 8496 2 L V0000M9 B 4 Series GLC Figure B 14 Single Phase One Breaker Connection Diagram GW0000A41 UW 3svHd 319NIS NVNOVIO NOLLO3NNOO MOLV33N39 219 1 70000 9 33N 0 0000 24 313 2801 YAL 2002 92 80 12 50 01 0351 3 OPH 48 Hl AZM IALTA 890172 135034 Yad 2530 38 NOLLOS 1 55323 LON 0931 3lIHM Ol 193NNOO 1 dOl ATINWSSIOIN LON 0 31 MOTI3A OL 123 02 1 04 SOLIVH3N39 dvs v vd ueg eun NOlldO 5 dui junus pedinbe jou s pun D ay jo ay Ul pejnoes puo 0 duy junus puondo 5 junus 5 sy LZEXS PUD ZvXS SJojp nbe 20 9 uid eboweN 4oio nbaj eui uo eq jou Jo 9 e dnjnuu auinbau suonoouddo 2 1edoud 104 Z009 1009 LOON LOOZ 71001 10 poyo w 9 WO 295 u
37. te Dede 1 Battery Charger maar UV NR EUR E TRU uM Educa Fus 1 Battery ____ _ ___ A 3 Engine Block Heater ERA WIR RW e Wife REM e DATE PE 5 LI 6 Fuel Strainers amp Fuel Lines XR ee UNI era E ues p EX REX 7 E codice dta 8 Remote Li RII 9 Radiator Duct Flange REP ole PR ae xe RR ERA RR EE 10 sse e Oe RERO qut e E uS LU E IEEE ER PR LEVIA edel 11 Appendix Series GLC Parts amp Wiring B 1 GLC Circuit Breaker amp Electrical Data B 1 CA IU M aaraa ea a E e a e ae Aa AE a eaa N EAA A E EA ER RASENE B 2 Wiring DIagrams 2e ebbe bete ie ute ta etu ebd eo Wb LER e V o E S B 2 Start Up Inspection FOr sisan cemere eR EE TVAE ERA ERU B 25 ii Table of Contents MN2408 Section 1 Product Safety Information Safety Notice Responsibility Be sure
38. 293105 9 D S aasn LON jo 1u014 avn fox 2019414910 ORO amp zm r F Mn Sa A f dn xold 5 SI aneuboy 38204 GQ07003M Series GLC B 21 MN2408 Figure B 31 Engine Wiring Woodward 5 7L GM WE0043D ae NEN 8 A8 56002 22 0 40 95 01 35 34 96 N 0000N 9 23114 1160000000 01 YO 3 WI 05 ORLLOWIM 041 31131079 3538 0530 LW vi el 21 01 Nm 0 ORD Josuas 3uDJoo 3980 39807 enig lt 5 2 amp 3610 38107 3 107 39107 36107 37204 BV LOL EXT SON Lo 1 SL z Xu 31107 mam 8 lt m dau Mb 32001 als i 2 E ale N30N35 3110Z 5359 10 3500 3 T e 55020 S QNS 37002 1
39. 9 lt ZH 0S ZH 09 A SIL vi 2121 1 1 0168 49 S v g 70 0000 9 Series GLC 7 MN2408 Figure B 17 Single Phase Connection Diagram Wire 1 0 and Smaller w Breaker 0000 69 5 JIONIS NVYOVIG NOLLO3NNOO MOLVN3N39 219 89v0000M9 338 09 21419414 005626 01 0 8 v 035384 A8 8 SNOISIA3M ISIN 22530 ARN uag euri o 5 83 13901 S3MIM 31704 dui junus pedinba jou si yun ji ay 291 paunoss 720 EFO dui junus Jouondo suayoasq dui punys uwous sy LZEXS puo ZvXS 5 si 9 Jojbjnbaj y uo ejqojio o eq jou Kou 9 anb s 4edoud 20 2009 1009 LOON 71000 71001 20 oyo Way 3 995 jp3isKud y 3ou seop j oj uMous slona uuoo JojpJeuas uouypuoj eboMeN uo
40. Continued on next page MN2408 Warning Statements Continued Battery Safety WARNING WARNING WARNING WARNING WARNING WARNING MN2408 Installation and servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions Keep unauthorized personnel away from batteries Do not dispose of battery or batteries in a fire The battery is capable of exploding If the battery explodes electrolyte solution will be released in all directions Battery electrolyte solution is caustic and can cause severe burns and blindness If electrolyte contacts skin or eyes immediately flush the area with water and seek medical attention quickly Do not mutilate the battery The battery contains electrolyte solution which is caustic and can cause severe burns and blindness If electrolyte contacts skin or eyes immediately flush the area with water and seek medical attention quickly A battery presents a risk of electrical shock hazard and high short circuit current The following precautions are to be followed when working on batteries 1 Remove watches rings necklaces and all other metal objects 2 Use tools with insulated handles The battery electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive The following precautions are to be followed when working on batteries 1 Wear full eye protection safety
41. FAX 303 595 3772 9980 PARK MEADOWS DRIVE SUITE 214 LONE TREE CO 80124 6738 PHONE 303 339 0629 FAX 303 339 9633 CONNECTICUT WALLINGFORD 65 SOUTH TURNPIKE ROAD WALLINGFORD CT 06492 PHONE 203 269 1354 FAX 203 269 5485 FLORIDA AMPA PUERTO RICO VIRGIN ISLANDS 3906 EAST 11TH AVENUE AMPA FL 33605 PHONE 813 248 5078 FAX 813 247 2084 GEORGIA ATLANTA 62 TECHNOLOGY DR ALPHARETTA 30005 PHONE 770 772 7000 FAX 770 772 7200 5490 MCGINNIS FERRY PLACE SUITE 133 ALPHARETTA GA 30005 PHONE 770 752 4254 FAX 770 752 4257 ILLINOIS CHICAGO 4 SAMMONS COURT BOLINGBROOK IL 60440 PHONE 630 296 1400 FAX 630 226 9420 INDIANA COLUMBUS 3300 TENTH ST COLUMBUS IN 47201 PHONE 812 378 2556 FAX 812 378 2555 NDIANAPOLIS 5525 W MINNESOTA STREET NDIANAPOLIS IN 46241 PHONE 317 246 5100 FAX 317 246 5110 IOWA ES MOINES 800 DIXON STREET SUITE C ES MOINES IA 50316 515 263 6929 AX 515 263 6515 NSAS 030 BOB BILLINGS PKWY STE B LAWRENCE KS 66049 PHONE 785 749 4339 FAX 785 749 4217 MARYLAND BALTIMORE 6660 SANTA BARBARA RD SUITE 22 24 ELKRIDGE MD 21075 PHONE 410 579 2135 FAX 410 579 2677 MASSACHUSETTS BOSTON 6 PULLMAN STREET WORCESTER MA 01606 PHONE 508 854 0708 FAX 508 854 0291 MICHIGAN DETROIT 33782 STERLING PONDS BLVD ERLING HEIGHTS MI 48312 HONE 586 978 9800 AX 586 978 99
42. Improper use can cause serious or fatal injury Only qualified personnel should attempt the start up procedure or troubleshoot this equipment System documentation must be available to anyone that operates this equipment at all times Keep non qualified personnel at a safe distance from this equipment Only qualified personnel familiar with the safe installation operation and maintenance of this device should attempt start up or operating procedures Always stop engine before making or removing any connections A Always stop engine and allow it to cool before refueling When your generator is delivered it becomes the responsibility of the owner operator of the generator set to prevent unsafe conditions and operation of the equipment Some responsibilities include but are not limited to the following 1 Itis the responsibility of the owner operator of this generator to ensure that this equipment is correctly and safely installed 2 Itis the responsibility of the owner operator of this generator to ensure that this equipment when installed fully complies with all federal state and local codes 3 Itis the responsibility of the owner operator of this generator to ensure that any person operating this equipment has been properly trained 4 Itis the responsibility of the owner operator of this generator to ensure that any person operating this equipment has access to all manuals and information required for the safe use and o
43. YES Programming sub menus are enabled when YES is displayed and a valid password number is entered PASSWORD Press INCREMENT DECREMENT to change the password Press ENTER when the correct number is displayed Read Only Mode User can view the parameters but cannot change any values The factory setting for this level is one 1 Read Write Mode User can view and modify any parameter value The factory setting for this level is two 2 Master Read Write Mode User can view and modify any parameter value and view modify the security password level numbers Contact Baldor for master password if required The values of the parameter settings for your generator set can be recorded for future reference using the Configuration Data Sheet shown in Figure 4 16 After the correct password number is entered the you may choose one of four programming menus Press INCREMENT or DECREMENT to find the desired menu then press ENTER MAIN MENU LOOP ANALOG FAULT MENU LOOP DIGITAL FAULT MENU LOOP CALIBRATION MENU LOOP 4 24 Operation MN2408 Navigation Hints Programming parameters are displayed in the same order as the Programming Sheets see Figures 4 17 to 4 20 To skip over parameters that do not require changes push and hold the ENTER push button until the desired parameter is displayed The EXIT push button may be used to scroll backwards through the programming parameter loops To change a parameter value use the INCR
44. alarm or shutdown pickup and dropout voltage setpoints i e adjustable hysteresis and transient time delay settings The generator output is monitored for an under frequency condition The under frequency sensor is programmable for type of fault action alarm or shutdown frequency setpoint and transient time delay settings A magnetic pickup engine speed sensor measures engine speed The engine speed sensor allows the controller to perform the following control functions Overspeed shutdown Crank Disconnect control Loss of speed signal detection Starter Re engage control RPM display Operation 4 19 Output Contacts output contacts non powered i e dry contacts and rated 10A 240VAC 8A 28VDC resistive inductive 0 4 Output contacts are not fused therefore external overcurrent protection maximum 10 is required for all control circuits using these contacts Contacts are shown in a de energized state and will change state upon activation Run Note Crank Note Programmable Contacts Energize To Stop Switch Not In Auto Engine Ready Preheat GEN Ready To Load Utility Ready To Load Engine Running Engine Run Fuel Airflap ATS Test The Run contact is a Form A dry contact to control the engines Run circuit This typically includes external control devices such as Fuel Rack Solenoids or electronic governors An additional pilot relay will be required to energize hig
45. concerned with fire rated walls a location that minimizes the possibility of damage to the genset and interruption of the emergency system due to storms foods fire vandalism etc Codes often deal with the need to maintain certain temperatures in the genset room and with fuel system location The most important codes in the USA are the National Fire Protection Association Code Numbers 99 and 110 but local codes must also be observed MN2408 Foundation Design WARNING An open bottom stationary engine generator set must be installed over noncombustible materials and shall be located such that it prevents combustible materials from accumulating under the generator set Foundation Checklist A Evaluate if a separate isolated foundation is required for the application B Observe local codes on soil bearing capacity freezing and thawing C Design the separate foundation for the genset and specify the appropriate concrete mix D Determine if the application requires vibration isolators and if so order as a factory option The foundation must be strong enough to support the weight of the genset and its associated equipment must prevent any deflection of the genset base and absorb vibration produced by the rotating and reciprocating masses Setting The Genset On An Existing Concrete Floor Slab If an existing floor is used the floor slab must be strong enough to carry 1 50 times the genset wet weight including coolant and oil to acco
46. 30 6 2 QTS BCI Group 31 925 GLC60 SAE 30 5W 30 6 2 QTS BCI Group 31 925 GLC80 SAE 30 5W 30 6 5 QTS BCI Group 31 925 GLC100 SAE 30 5W 30 6 5 QTS Group 31 925 GLC125 SAE 30 5W 30 6 5 QTS BCI Group 31 925 MN2408 Receiving amp Installation 3 13 Post Installation Checks When the initial installation is complete these checks must be performed before starting the engine These checks are not required before each start only after the initial installation 1 Generators that have been in transit or storage for long periods may be subjected to extreme temperature and moisture changes This can cause excessive condensation and the generator windings should be thoroughly dried before bringing the generator up to full nameplate voltage If this precaution is not taken serious damage to the generator can result Caution Do not apply high voltage to windings do not start the generator in a moisture saturated condition Moisture can cause insulation breakdown making it necessary to return the generator for repair Note 0500 1 1 1 1 1 1 1 2 2 These precautions are especially necessary in locations such as seaboard installations and other high humidity areas Some installations will be in atmospheres that are much more corrosive than others Verify that the transfer switch is in Utility Power mode No power must be present at the generator or transfer sw
47. 8 padinbs jou s yun D jJ 1000 0 CCOZ dui junus gt lt N LZEXS 2 5 5 s 9 uid Y 403o nbaJ ay uo aq you 20 9 7807 2404 ejdnjnuu 10 2009 71009 LOON 1002 1001 poyo We x 995 uonb2o boisKud lt uonbuuolu 2 uo a 55 dIX 9 561 IV 310N 720 7604 OL 617191211101 6 B8B L 9 S v 7 ei lt lt 0 442 0000 9 2408 B 10 Series GLC Figure 20 Three Phase Connection Diagram 09 ODRLLOWTM HOGIVg 3SVHd 219 9002 01 80 11 00 81 0351 3 0 NC0000NVOON 23114 021662000000 MdL O NOISH3A 9 1 A38 52 1177 TIV 310N Q3 3 S 2530 38
48. FJOtPDMPERPHASE 1 7000 30 S TSOEPDMPERPHASE 1230 1200 20 S WHDEPDMPERPHASE 1 7400 FIJO EPDM PER PHA 1900 1500 RIV EPDWTPER PHASE 18 2000 8 2 5 PHASE 235 2500 P 0A EPDTPER PHASE 2850 3000 250 7 MIUEPDWPERPHASE _ 355 4000 8 300 9 4470 EPDM PER PHA 4275 Wiring Diagrams Wiring diagrams for these generators are contained on the following pages of this appendix MN2408 Series GLC B 1 Figure 11 Customer Interface Connection Diagram elolelelelelooioloeleleoioioeioeiooo CUSTOMER CONNECTIONS CONTROL PANEL ENCLOSURE S S S S S TERMINAL STRIP 91A 52 16 17A 1A 2 gt 4 5 7 10A 11A 12A 36A 55 54 53A 52A 51A 29A 28A 27 26A 25A ALL TERMINALS 9 9 9 0 O O O O O O O O O O O O IDENTIFICATION AS SHOWN MEC MANUAL gt xU gt oz AMPACITY SIZE LOCAL amp NATIONAL ELECTRIC CODE S START a NEU TEMP RISE 75C RUN o CONTACT CONDUCTORS CU CONNECTOR SCREW MEC2 CONN RANGE 22 10 Y S TORQUE 7 8 in lb ENTIRE WIRE RANGE 51A 52A 15A 16A 17A 1A 2A gt
49. GWOO00A05 n n SUN SUR UOuDJ0N SbuppuoN 15000 9 1001309 LZ XS 2 6 9 uid 1 1 S uonseuuos siy 0 uo aq jou 9 NOlLdO 3151 LNNHS NON 3009 303 0350 IIM NN TW 23 n 3NOQ 38 OL junus y padinba you yun j eu Jo y U peun2es aud 00 OL duy junus 52930929 dij junus umous sy suoyonpuoo 40 LOON 2009 1009 4006 71002 LOOL Seu poyo uue WOg ees uonp2o boisKud ay jduu jou Y uonouuojui uoaeuuoo s onosuuoo 4oib nBai 9040A 104029099 21903 995 uo peyou ssejun 47 2 521 M IV
50. HIGHWAY ENNSAUKEN NJ 08110 PHONE 856 661 1442 856 663 6363 PITTSBURGH 159 PROMINENCE DRIVE NEW KENSINGTON PA 15068 PHONE 724 889 0092 FAX 724 889 0094 TENNESSEE MEMPHIS 4000 WINCHESTER ROAD MEMPHIS TN 38118 PHONE 901 365 2020 FAX 901 365 3914 TEXAS ADDISON 3939 BELT LINE ROAD 250 ADDISON TX 75001 PHONE 972 499 7746 499 7747 FAX 972 242 1505 DALLAS 3040 QUEBEC DALLAS TX 75247 PHONE 214 634 7271 FAX 214 634 8874 HOUSTON 4647 PINE SUITE 135 HOUSTON TX 77041 PHONE 713 895 7062 FAX 713 690 4540 UTAH SALT LAKE CITY 2230 SOUTH MAIN STREET SALT LAKE CITY UT 84115 PHONE 801 832 0127 FAX 801 832 8911 VIRGINIA RICHMOND 6767 FOREST HILL AVE STE 305 RICHMOND VA 23225 PHONE 804 545 6848 FAX 804 545 6840 WASHINGTON KIRKLAND WA 550 KIRKLAND WAY STE 206 KIRKLAND WA 98033 PHONE 425 952 5000 FAX 775 255 8019 WISCONSIN MILWAUKEE 2725 SOUTH 16380 STREET NEW BERLIN WI 53151 HONE 262 784 5940 AX 262 784 1215 WAUKESHA N14 W23777 STONE RIDGE DRIVE SUITE 170 WAUKESHA 53188 PHONE 262 347 2000 FAX 262 437 0258 INTERNATIONAL SALES FORT SMITH AR BOX 2400 FORT SMITH AR 72902 PHONE 479 646 471 FAX 479 648 5895 CANADA EDMONTON ALBERTA 4053 92 STREE EDMONTON ALBERTA T6E 6R8 PHONE 780 434 4900 FAX 780 438 2600 11428 168 STREET EDMONTON ALBERTA TSM 3T9 PHONE 780 822 7865 FAX 780 822 7878 MISSISSAUGA ONTARIO 244 BRITANNIA ROAD EAST MISS
51. Not In Auto Overspeed Engine Ready Loss Of Speed Signal Engine Run Fuel Low Bat Voltage Preheat High Bat Voltage Engine Running Weak Bat Voltage ATS Test Low Oil Press 1 Alarm Common Alarm Common Shutdown Low Oil Press 2 Shutdown High Eng Temp 1 Alarm High Eng Temp 1 Shutdown The hourmeter may be reset to zero hours when yes is programmed Note This programming prompt is only accessible while using the Master programming security password Analog Fault Menu Loop The controller s analog fault settings are described as follows Level Action Alarm Latch Bypass On Start Delay Transient Delay Times 4 26 Operation Sets the actual analog signal setpoint at which the selected fault type will be activated Note For AC voltage fault circuits two levels i e pick up amp drop out must be programmed Allows a fault to be either an Alarm fault or a Shutdown fault If an fault was set as an Alarm it may be selected as a Latching alarm or Non latching alarm A Latching alarm is not cleared until a reset command clears it Note This value only appears if alarm faults are programmed Shutdown faults are automatically set as latching Allows the alarm or shutdown fault to be disabled until after the bypass timer has expired Faults that are not delayed are enabled at all times i e engine running or stopped Allows the selected fault to be disabled until the delay period has expired Delay times are 0 0 to 999 9 seconds
52. Operation 4 3 Alarms Following alarms are available Sensor fail FLS see Table 4 10 Sensor fail is detected when measured value is 696 out of selected sensor characteristic Sensor fail is indicated by symbol instead measured value Warning WRN see Table 4 10 When warning comes up only alarm outputs and common warning output are closed Shut down SD see Table 4 10 When the shut down alarm comes up InteliLite opens outputs GCB CLOSE OPEN FUEL SOLENOID STARTER and PRESTART to stop the engine immediately Alarm outputs and common shutdown output are closed Active or not reset protection disables start Table 4 10 Possible Warnings Events specification Protection type Wrn Oil press WRN Sd Oil press SD Wrn Water temp WRN Sd Water temp SD Wrn Wtemp Low WRN Wrn Fuel Level WRN Sd Fuel Level SD Battery voltage lt gt WRN Battery flat SD Start fail SD Vgen lt gt SD Vgen unbl SD Fgen lt gt SD Igen unbl SD Overload SD RPM over SD RPM under SD PickupFault SD Stop fail SD WrnServiceTime WRN Emergency Stop SD ECU Common Warning WRN ECU Shutdown SD 4 4 Operation MN2408 Inputs and Outputs Any Binary input or output can be configured to any controller terminal Inputs are BI6 Outputs are BO1 BO6 or changed to different function by LiteEdit software There is fixed 1 sec delay when any binary input is configu
53. Policy represents Baldor s sole and exclusive warranty obligation with respect to Baldor products Baldor s liability to a customer or any other person shall not exceed Baldor s sales price of the applicable Baldor product BALDOR DISCLAIMS ALL OTHER EXPRESSED AND IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY Warranty Period Generator Series Labor Parts Portable Products Premier Powerchief 1 Year 3 Years DG Series Towable Products TS 1 Year or 3 000 Hours 3 Years or 3 000 Hours POW R LITE Light Towers 1 Year or 3 000 Hours 3 Years or 3 000 Hours Light Fixture Lamps and Ballasts are excluded from any warranty coverage 3600 RPM Standby Systems 1 Year or 1 000 Hours 3 Years or 1 000 Hours Some AE Models 1800 RPM Standby Systems 1 Year or 3 000 Hours 3 Years or 3 000 Hours Some AE Models DLC GLC Industrial Standby Systems 1 Year or 1 000 Hours 2 Years or 1 000 Hours Industrial Prime Power Systems 1 Year or 1 000 Hours 1 Year or 1 000 Hours International 1 Year or 1 000 Hours 1 Year or 1 000 Hours For products covered under labor coverage travel expenses will be allowed up to 7 hours straight labor or 300 miles whichever occurs first and only applies to permanently wired and mounted products AE DLC GLC IDLC You must save the purchase receipt Proof of purchase date serial number and model number will be required for all port
54. S Josuag 3001000 sh 39807 39807 ania em Vs eic S a 31202 8 5 32204 w 36107 8 2 61 2 8 lt 3rnor 39102 3 lt 17 32707 s 3 10 lt lt 361 S30N3S 30102 3580 W 42 32104 3104 _ 31102 i l 8 T 550155 S INOZ 10 a 3 9 9 slg m d YOLVNUSLTV suo quau 88019 z 3 36204 m S 37007 14 38007 eG Bubu E AN3LING E 4 g S 941 isd oyu s nid oi jejey uo ssanu09 gi 203 saduinp 31000 NOILINOT Sd piousjos 49jJD S ADIS YIQNVHO r Gcv003M Series GLC B 23 MN2408 B 24 Series GLC MN2408 UNITED STATES ARIZONA PHOENIX 4211 5 43RD PLACE PHOENIX AZ 85040 PHONE 602 470 0407 FAX 602 470 0464 ARKANSAS CLARKSVILLE 1001 COLLEGE AVE CLARKSVILLE AR 72830 PHONE 479 754 9108 FAX 479 754 9205 CALIFORNIA LOS ANGELES 6480 FLOTILLA COMMERCE CA 90040 PHONE 323 724 6771 FAX 323 721 5859 HAYWARD 21056 FORBES STREET HAYWARD CA 94545 PHONE 510 785 9900 FAX 510 785 9910 COLORADO DENVER 3855 FOREST STREET DENVER CO 80207 PHONE 303 623 0127
55. by means of approved transfer switch equipment to isolate the electrical circuit from the utility distribution system when the generator is operating Failure to isolate the electrical circuits by such means may result in injury or death to utility power workers due to backfeed of electrical energy onto the utility lines Circuit overload protection must be provided in accordance with the National Electrical Code and local regulations Check Ground Fault Circuit Interrupt GFCI receptacles monthly by using the Test and Reset buttons Only a professional experienced technician should install a fuel supply system LPG and natural gas fuels are flammable and can cause fire explosions injury or death Fuel supply lines should be kept away from sharp objects to prevent rupture Comply with all NFPA regulations and local codes for shut off valves regulators fuel line type connectors etc Have electrical circuits and wiring installed and checked by licensed electrician or qualified technician Electrical shock can cause serious or fatal injury Incorrect installation of this generator set could result in property damage injury or death Connection of the generator to its fuel source must be done by a qualified professional technician or contractor An open bottom stationary engine generator set must be installed over noncombustible materials and shall be located such that it prevents combustible materials from accumulating under the generator set
56. can be checked 23 After the operation checks are made stop the engine move the Master Control Switch to the Stop position and wait at least 2 hours for the engine to cool When the engine is cool check engine oil and coolant levels as instructed in the engine operation manual 24 Close all enclosure covers The post installation checks are now complete MN2408 Receiving amp Installation 3 15 3 16 Receiving amp Installation MN2408 Section 4 Operation Digital Engine Controller Description EMO046A21 MRS17 LED Indicators Manual Run Start Stop Display Page Mode lt and gt Horn Reset Fault Reset and V Enter Enter A and V Figure 4 8 Operator Control Panel Operating Modes and Horn amp Fault Reset BALDOR GENERATORS cued pec Manual C Display Ba x S RESET wamm top LED Indicators Note The operator control panel is equyipped with a heater element that allows the LCD display to operate to 40 C not the entire generator set see generator specifications This heater operates from the main battery power Alarm red Alarm shutdown condition occurred Annunciates amp shuts down generator Not In Auto red Control is not in auto mode and cannot provide standby power Running green Generator is running no alarms or warnings Warning yellow A warning condition has occurred Annunciates only Ready Auto green Control is in Auto mo
57. engine exhaust system 10 After the exhaust system is installed it should be inspected on a regular basis to assure there are no toxic exhaust gas leaks In some areas this inspection may be provided by your local public service 11 A carbon monoxide tester may be installed to detect the presence of the deadly gas during times when you are in the building with the engine running during testing or maintenance Never allow the exhaust outlet to be positioned so that the exhaust gases are directed towards any openings or air entry routes doors windows vents etc of an occupied building When discharging the hot exhaust gases out of the building do not direct them towards anything that could catch fire or explode Exhaust fumes gases are extremely dangerous and can cause severe illness or death Never breath exhaust fumes produced by a running engine Only run the engine outdoors where ventilation is plentiful Exhaust gases contain carbon monoxide a colorless odorless and extremely dangerous gas that can cause unconsciousness or death Symptoms of carbon monoxide poisoning include dizziness nausea headaches sleepiness vomiting or incoherence If you or anyone else experiences these symptoms get out into fresh air immediately Stop the engine and do not restart the engine until it has been inspected and if necessary repaired or reinstalled in a well ventilated area Receiving amp Installation 3 5 Installation The generator
58. flat washer lock washer and nut c Repeat steps a and b for the other Battery Hold Down Rod Figure 3 7 Battery Installation The and terminals of your battery may be different than shown Be sure that the Positive lead is connected to the positive terminal of your battery Washers amp Nut a Battery Hold Down Bar Install away from terminals Battery Battery Hold Down Rod Battery Tray Connect the positive lead to the positive battery terminal Connect the negative lead to the negative battery terminal Do not lay tools or metal parts on top of batteries Connect charging source to the battery terminals Disconnect the battery s ground terminal before working in the vicinity of the battery or battery wires Contact with the battery can result in electrical shock when a tool accidently touches the positive battery terminal or wire The risk of such shock is reduced when the ground lead is removed during installation and maintenance Recommended Engine and Battery When replacing batteries use only the recommended battery for your generator see Table 3 7 Table 3 7 MODEL SUMMER WINTER OIL RECOMMENDED AMPS COLD OIL OIL CAPACITY BATTERY CRANKING GLC10 25 SAE 30 5W 30 5 0 QTS BCI Group 31 675 GLC30 SAE 30 5W 30 6 0 QTS BCI Group 31 925 GLC35 SAE 30 5W 30 6 0 QTS BCI Group 31 925 GLC45 SAE 30 5W 30 6 0 QTS BCI Group 31 925 GLC50 SAE 30 5W
59. for corresponding input temperature or pressure Overspeed shutdown occurs at normal Controller has failed or input from Verify the adjustments Replace controller if failed speed Magnetic pickup is incorrect Service Service for your generator can be obtained from to a qualified generator service center Please have the following information available and ready The model number and serial number of the generator set A complete and accurate description of the problem Parts Parts for your generator can be obtained from to a qualified generator service center Please have the following information available and ready The model number and serial number of the generator set A complete and accurate description of the part part number if known Note Engine parts can usually be obtained from a local distributor by using the information in the engine manufacturer s owner s manual 5 4 Troubleshooting and Maintenance MN2408 Appendix Options amp Accessories Battery Charger BTCGR6 Battery Charger 12 Volt 6 Amp Float Includes 6 ft power cord with grounding plug for AC input power and 4 ft power cord with ring terminals for DC output UL Listed BTCGR10A Battery Charger 12 Volt 10 Amp Float Includes terminal strip for AC input power and DC output UL Listed Figure A 1 Recommended Mounting Locations GLC30 45 Battery Charger GLC60 105 Battery Charger Mounting Locations Mounting Locations Engine Control
60. generator the breaker box is mounted to the generator prior to shipment If the optional circuit breaker protection was not ordered see GLC Circuit Breaker amp Wire Size Data in Appendix A for recommendations Proper lead wire from the circuit breaker to the automatic transfer switch or load switching device is mandatory See transfer switch information for connection information When connecting the generator output to an electrical load a UL listed circuit breaker with the appropriate ratings must be provided within 25 feet of the generator set Use only copper wires Generator Rating Input Breaker Rating at 115 FLA 1 Phase AMPS 3Phase Amps 240VAC 3 Phase Amps 480VAC Catalog No Kilowatt kw Rating LPV Nat Gas Nat Gas LPV Nat Gas LPV Delta Wye Delta Wye Delta Wye Delta Wye Delta Wye GLC10 10 50 GLC15 15 70 GLC20 20 100 GLC25 25 125 GLC30 30 110 110 110 60 60 GLC35 35 125 125 125 60 60 GLC45 45 150 150 175 70 80 GLC50 50 175 175 175 90 90 GLC60 60 200 200 200 225 100 110 GLC80 80 300 300 300 150 150 GLC100 100 300 300 350 150 175 GLC125 125 450 450 400 225 200 MN2408 Receiving amp Installation 3 9 Transfer Switch Considerations The following are general considerations for the safe use of a transfer switch 1 The transfer switch should be located inside the building near the main breaker box or the disconnect box 2 The
61. incremented Enter pushbutton used to scroll forward through the status menus or programming prompts to the next item Note The longer the push button is held down the faster the menu prompts appear When pushed initiates a manual start signal to start the engine The engine will start and operate continuously providing no shutdown faults are active All protective circuits are operative in this mode There will be no cool down cycle at the end of a manual run sequence On when the Run switch is used to start the engine generator set When pushed sends a stop signal to the engine to stop the engine On when the OFF Switch is used to stop the engine Operation 4 13 Operator Control Panel Continued Auto Switch Auto LED Load Test Switch Load Test LED When pushed initiates automatic operation of the engine generator set Starting and stopping of the engine is controlled by a remote contact transfer switch When the remote start signal is removed the engine will continue to run for the cool down period if selected then stop Pushing the Off switch will stop the engine immediately even if the cool down period is not complete On when the Auto Switch is used to start automatic operation When pushed initiates a load test of the generator set with the associated transfer switch Only operative for AMF connections or if one of the programmable output contacts is configured for ATS Test and the remote transfer switch
62. is connected to utility power so the battery is charged continuously while the genset is not running The battery charger should be connected to the utility power emergency circuit The batteries on prime power gensets are charged by the engine mounted alternator if equipped The output of the battery charger or the belt driven alternator must be connected directly to the battery or to the battery terminals on the starter to prevent the electronic governor from acting erratically Make control connections to the genset control using a conduit with a flexible section at the genset to avoid damage due to genset vibrations The wire size wire gauge of the cables connecting the starter to the batteries must be large enough to ensure proper voltage at the engine starter motor during cranking The total cranking circuit resistance includes the resistance of the cables from the starting motor to the battery and the resistance of all relays solenoids switches and connections The resistance of various sizes of cables is shown in Figure 2 10 For purposes of calculating cranking circuit resistance to select cable size the resistance of each connection can be taken as 00001 ohms and the resistance of each relay solenoid and switch can be taken as 0002 ohms Figure 2 10 illustrates an example of a typical cranking circuit resistance calculation Figure 2 10 Typical Battery Cable Calculations 4 3 2 0 00 Maximum Allowable Resist
63. is internally generated Oil Bypass Timer Complete output relay will energize when the controller s oil bypass delay timer expires following a normal start sequence Common Alarm Common Fail Common Shutdown EPS Supplying Load 4 20 Operation The output relay will energize when any alarm fault has been activated The output relay will energize when any alarm or shutdown fault has been activated The output relay will energize when any shutdown fault has been activated The output relay will energize when the engine is running and the generator is supplying current to the load more than or equal to 10 of nominal CT ratio MN2408 Display Modes controller is in the display mode at all times except when in the programming mode display screens and menus may be selected by pressing the Enter or Exit keys to access Operating Status Display Fault Display Timer Countdown Generator AC Metering or Programming Menus The LCD display shows the status of the generator output Operating Status The controller will power up into an Emergency Stop failure mode preventing possible engine operation The controller must be manually reset before normal operation can be established To reset the Emergency Stop condition press the OFF push button first then press both INCREMENT and ENTER push buttons simultaneously The controller will then reset if a remote emergency stop condition is not activated The Utility Ready to
64. pos ves TUA NTA uor voaa 9110404 0 2 621 01A NA lt w o Solos eh L 0 9 wf olof wu uonoeuuo2 J0 9D JO ajpjd Jo pupa 4095 sajyay 9 V0000M9 Series GLC B 15 MN2408 Figure B 25 Three Phase Connection Diagram Wire Larger than 1 0 w o Breaker CW0000A78 82 O M HOLVN3N39 3SVHd 279 SLVOUDOMO 33U Uu D 009622 01 0 8 v 035 34 418 34 OIMLOWIM SOGIVG WUN ATE 2 3 aad SISSVHO 9 u 1 39 093 21 121 EO 3 OOOO J e a ee ago 894 1658 CY 9 SbonaN 4 8A 911040 j papasu euo sing EY H 09 285 4 OCOLIT o jeje a TOON JoyojnBay SIONN N MEE 0 31d TON e qo qu Sv dnoso assn 1001 R4 SIYM FIdILINW 31 z M3HL39OL 53
65. set beside heat generating equipment or directly below water or steam pipes or in the vicinity of corrosive substances or vapors metal particles and dust Heat can cause engine problems to develop and unwanted substances can cause rust or generator failure over time Do not apply high voltage to windings do not start the generator in a moisture saturated condition Moisture can cause insulation breakdown making it necessary to return the generator for repair Use only original equipment or authorized replacement parts Using the correct parts will assure continued safe operation as designed Do not support the generator from the top of the frame or enclosure Do not tamper with or change the engine speed Engine speed is factory set to produce the correct voltage and output frequency Never operate the engine without a muffler The engine is designed to have the correct exhaust components installed and operating without these components can present a fire hazard cause excessive exhaust gases and cause damage to engine Inspect muffler periodically and replace if necessary The Programmable Output Contacts selection must agree with the external control wiring prior to energizing the controller Failure to do so may cause severe equipment damage 1 6 Product Safety Information MN2408 Section 2 General Information Thank you for purchasing your Baldor Generator Set This manual contains information you need to safely and efficiently ins
66. span calibration setting is complete re confirm the zero calibration points If the zero calibration setpoint needs further adjustment the span calibration point must also be re calibrated Battery Voltage Calibration To accurately calibrate the MEC 2 battery voltage sensor an external test DC voltmeter is required with an accuracy of 0 5 or better BAT VOLTS SPAN 99 24 6V Displays the type of calibration function SPAN Displays the calibration correction factor number 0 255 used to obtain the correct voltage reading Displays the actual battery voltage measurement that will be the same value as shown on the MEC 2 display menu This voltage reading may be calibrated higher or lower by changing the correction factor SPAN Calibration Energize the battery supply voltage to the controller and connect the external test DC voltmeter to the battery terminals B and B In the programming mode scroll to the battery span calibration point Use the INCREMENT or DECREMENT push buttons to adjust the correction factor number while observing the displayed battery voltage level on the MEC 2 Adjust the correction factor number to obtain an identical voltage reading as measured with the external DC voltmeter With the correct voltage displayed press the ENTER push button to accept the correction factor number Record the correction factor number on the programming sheet for future reference 4 28 Operation MN2408 Engine Temperature amp Oil Press
67. that you are completely familiar with the safe operation of this equipment This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment Improper use can cause serious or fatal injury Always disconnect all electrical loads before starting the generator Installation and repair procedures require specialized skills with electrical generating equipment and liquid cooled engine systems Any person that installs or repairs this generator must have these specialized skills to ensure that this generating unit is safe to operate Contact Baldor service department for repairs or any questions you may have about the safe installation and operation of this system The precaution statements are general guidelines for the safe use and operation of this generator It is not practical to list all unsafe conditions Therefore if you use a procedure that is not recommended in this manual you must determine if it is safe for the operator and all personnel in the proximity to the generator and connected loads If there is any question of the safety of a procedure please contact Baldor before starting the generator This equipment contains high voltages Electrical shock can cause serious or fatal injury Only qualified personnel should attempt the start up procedure or troubleshoot this equipment This equipment may be connected to other machines that have rotating parts or parts that are driven by this equipment
68. transfer switch must be kept away from any location that might allow water to get on it 3 Ifthe transfer switch is mounted outside it must be protected from the environment and it s elements 4 not mount the transfer switch on the generator set 5 Do not mount the transfer switch where flammable liquids or vapors are present Figure 3 4 Basic Power Transfer System Utility Power Generator Power Remote Start 1 12 N pe ibd Fuses or Fuses or Main Panel Circuit Circuit Breakers Breakers L o 77 Mechanical 6 Interlock Transfer p i 4 Ground Switch L1 L2 N Power To Load Remote Start Connect the remote start start contact from transfer switch to GLC Remote Start terminals Single Phase Power Connections Output power connections must be fused within 25 feet of the generator If the wires to the transfer switch are shorter than 25 feet connect L1 L2 and N to the transfer switch being sure to follow NEC and local codes If the wires to the transfer switch are longer than 25 feet UL requires that branch circuit protection be provided Power connections are made at L1 L2 Neutral and Ground points indicated in the Customer Connections area shown in Figure 3 5 3 10 Receiving amp Installation M
69. 0000 9 33 4 705 SOGTIVd 009626 NGL v0 8 v 0383H A8 3 17 38 SNOISIA3M 2SIN 2830 38 usp four NOlldO dlML 5 10Nna JMVOILN3GI 3 ldIl SY dn s5 4350 jaw SJAA 3ldIl W 3I ASHLADOL S3a I 31702 JexoeJq dii junus padinbs jou si jun D j Jo Ul 220 00 PUD dui junus jouondo sjexpalq diui JUNYS uwous sy LZEXS 2 5 5 40j s 9 aui uo you 20 9 uio amy 4edoad 20 2009 1009 LOON 1002 1001 poyo 995 uonb2ao jOdISkyd janjan ay jou uonbuuoju uonoeuuoo 5 suono8uuoo pesoq 55 dIX 2 5601 94M IN ALON ueg aur aves SISSVHO 1 39 0931 v L 1 009 4 105 PIa 4
70. 15S T cor zan ory rk PE i 29 3j 3402 e pro cin ae d r 5 so 8 71 91020 129 5202 207 1 9 d eF 8207 1104 902 tte M RI ee a da BB var ue 4 38 9 5 8 o 1052 s zi 9004 0002 8 lt gt FEOL lt g 48444 TOL pI lt gt Saaz FOL FOL 3 l OL 2 8 TOL 5 5 902 sO SOL S c or 2 5 83 S 7s en eS E 9 0507 E TOL Ns B 2501 OvOL 7600 E a 5 507 or N D Ao ot 1900 oa 20 602 82 56 co o 975 Sox 0 5 00950 CONTROL BOX CONNECTION DIAGRAM W THOMSON BALDOR ELECTRIC Co REF BNOO9SO 8 RWSED 12 00 20 08 12 2004 TUR 2556 IPLE 0001909 DESC REVERSE PICK UP LEADS RED AND SHEID REV LR Series GLC B 19 MUNI AB 9002 81 90 070 aasa GesNvOOOONYDRN mu 840662000000 80 NOSSA MD AH 92 ODLLOWTM NOCTIVH 59 W3HIO NO SNMYMO NOW SIAM 2530 738 BWO438D Figure B 29 Control Box Connections with MEC2 Controller 2 0
71. 2 7 2 10 General Information MN2408 Transfer Switch Transfer Switch Checklist A Locate transfer switch in a clean dry place near the emergency load B Provide a circuit breaker between the genset and the transfer switch C Puta flexible connection between the conduit and genset D Observe applicable codes in wiring in the transfer switch and genset The transfer switch connects the genset to the emergency power system The emergency power system may include several gensets and several transfer switches Typically the genset is wired to the emergency power system through a transfer switch as shown in Figure 2 8 Figure 2 8 Typical Emergency power System Installations Genset Genset Genset Utility or Power Source Utility or Normal Power Source Overcurrent g Protection Main CY YY YY Disconnect TS4 15 2 J Overcurrent Protection Overcurrent Overcurrent Protection Protection e p z Disconnect 1 0 I Ema 5 Transter Transfer Ps Load Switch 1 Switch 2 Non emergency Overcurrent Power Loads Level Level 2 Protection Transfer 1 Loads Loads Switch Non emergency Load L3 Multiple Gensets can be arranged either in parallel or separately connected to dedicated emergency loads Figure 2 8 also shows a typ
72. 2009 1009 1006 1002 1001 WOE 99S parsKud pnjoo ay jdw jou seop 2 uonaeuuo UMOYS Suon3euuos 2 9140 295 1 uo pasog Apa 2 9 56 FIM L 31ON Figure 26 Three Phase Connection Diagram Wire 1 0 and Smaller w o Breaker elo SISSVH3 lem disce 009 MO1VN3N39 QV31 zl WD PRI 33434 N 2 xog 4 317 21 21110 6 9 S 10 SP SIPA 5 401 91 2991 Woo e qo ees 9 42 ___ aboman Wag 81901 ojeg zH 09 BON 99S 9707 zt IZEXS puo SM 9L ZM 1 m 9 9L En 21 lA m sn n in N N 1 M n n WPN PUW 107013039 ZvXS s 9 uid ULAOPUOW 1 1 S 0 uo eq jou 9 wn 104 9ir Ovz en L A 089 122 IIA
73. 69 RAND RAPIDS 68 THREE MILE ROAD NW RAND RAPIDS MI 49504 HONE 616 785 1784 616 785 1788 5 MINNEAPOLIS 21080 134TH AVE NORTH ROGERS MN 55374 PHONE 763 428 3633 FAX 763 428 4551 MISSOURI ST LOUIS 422 INDUSTRIAL DRIVE MARYLAND HEIGHTS MO 63043 PHONE 314 298 1800 FAX 314 298 7660 KANSAS CITY 1501 BEDFORD AVENUE NORTH KANSAS CITY MO 64116 PHONE 816 587 0272 FAX 816 587 3735 NEW YORK UBURN NE ELLIS DRIVE UBURN NY 13021 HONE 315 255 3403 315 253 9923 RTH CAROLINA REENSBORO 220 ROTHERWOOD ROAD REENSBORO NC 27406 HONE 336 272 6104 336 273 6628 OHIO NCINNATI 2929 CRESCENTVILLE ROAD WEST CHESTER OH 45069 PHONE 513 771 2600 X 513 772 2219 LEVELAND 29 FREEWAY DRIVE JACEDONIA OH 44056 HONE 330 468 4777 X 330 468 4778 9525 CHAGRIN BLVD SUITE 208 EVELAND OH 44122 ONE 216 360 8296 X 216 360 4172 LAHOMA ULSA 2 EAST DAWES BIXBY OK 74008 PHONE 918 366 0320 FAX 9 OREGON PORTLAND 20393 SW AVERY COURT UALATIN OR 97062 PHONE 503 691 9010 FAX 503 691 9012 PENNSYLVANIA KING OF PRUSSIA 060 FIRST AVE STE 400 KING OF PRUSSIA PA 19406 PHONE 610 768 8018 FAX 215 672 5759 n 2 VOQO gt 20250 n n gt VOR PPZ rr 2 8 366 9338 Baldor District Offices PHILADELPHIA 1035 THOMAS BUSCH MEMCRIAL
74. 8 9 9 145 2 4 1 GLC45 584 16 5 242 6 9 GLC15 438 12 4 189 3 5 4 GLC50 731 20 7 269 8 2 GLC20 528 15 0 233 4 6 6 GLC60 780 22 1 321 9 1 GLC25 618 17 5 277 5 7 9 GLC80 1012 28 7 425 12 GLC30 526 14 9 197 5 6 GLC100 1133 32 1 487 13 8 GLC35 575 16 3 240 6 0 GLC125 1651 46 8 852 16 5 3 6 Receiving amp Installation General Considerations 1 Agenerator set needs the engine to deliver 2 hp of energy to the alternator for every 1000 watts of electric output power example an 8000 watt generator needs the engine to deliver 16 hp of energy to the generator end 2 Anengine needs 10 000 BTU s of fuel energy per horsepower of engine power to provide a sufficient supply of fuel example a 16 Hp engine needs 160 000 BTU s of fuel energy for it to work properly This fuel must be supplied to the regulator on the generator set at a pressure of 6 oz 11 inches of water column To achieve this 6 oz pressure in a L P System you will normally have to reduce the tank pressure by means of a primary regulator or a regulator system of 2 or more regulators 3 There are 2 516 BTU s in one cubic foot of Propane LP Fuel There are 1 096 BTU s in one cubic foot of Natural Gas 4 There are 36 39 cubic feet in one gallon of Propane There are 57 75 cubic feet in one gallon of Natural Gas 5 There are 8 58 cubic feet per pound of Propane There are 23 56 cubic feet per pound of Natural Gas 6 When installing the piping for t
75. BALDOR GENERATORS GLC Generator Gaseous Liquid Cooled GLC10 15 20 25 30 40 45 60 65 100 and 105 Installation amp Operating Manual 2 08 MN2408 Any trademarks used in this manual are the property of their respective owners WARNING CALIFORNIA PROPOSITION 65 WARNING Engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects and other reproductive harm WARNING CALIFORNIA PROPOSITION 65 WARNING Battery posts terminals and related accessories are known to the state of California to cause cancer birth defects and other reproductive harm Table of Contents Section 1 Product Safety Information 1 1 Safety xe ob v ne Outed See ee Ri pena v EU pe fete dece dite aa eR Ee ttd 1 1 Responsibility 5 ner CH agai wean x RR E Mies 1 1 IMPORTANT SAFETY INSTRUCTIONS 1 2 Calition Statements tre Rc t ee c RR c t RC RR 1 6 Section 2 General Information coco ern f VERE Y eed Mi eR REIN Vau MEE xu eO xe 2 1 Limited Warranty ooi ere eph ER RE CC nce eee eR 2 1 Installation Guideliries fac sede ei we eee dae M ERN ERU CERA NR IRA DREAM ebd 2 3 Site Plann
76. C B 11 MN2408 Figure 21 Three Phase Connection Diagram with PMG ONIMIM NOLVMH3N39 3SVHd 219 9 1002 87 90 10 85 1 035 34 OZ6N 0000N VOcN 3114 705 HOTCIVd 155927000000 MQL 0 NOISH3A 2411 A34 NOISNSNOD OL 22018 WH3L OL 5 GOV 2530 34 GWO000A34 CEOL 7204 SISSVHO 2009 NOILdO 5 NOO9 804 yoa 0350 38 38 39VL 0 ann ON Ou fn 3NO QUIM 3dAL VSO Jexoeuq dui junus peddinba pun D p 293 JO y Ul pejnoes 940 S94lM dig junus jpuondo m dui junus o eq uwous sy sjoyonpuoo ejdnjnu eumbeJ suonpojddo uibus LOON 2009 1009 LOOS 1000 LOOL 20 Du uuej WOG ees uonpoo Do s ud y Ajdw seop y uonDuuoju uonoeuuoo epi o4d j0jo nbej 10j049u99 40 295 jeumoojnubui uo pesoq Kioa sse un 2 50 M 310 00 8
77. EMENT or DECREMENT push buttons to scroll through the available options or to adjust a value as desired and press the ENTER to accept the new value Note If programming mode is terminated before the last change is accepted pressing ENTER that parameter value will remain unchanged Main Menu Loop The Main Menu Loop contains general system configuration programming such as system input voltages currents transformer ratios as well as standard operating time delay functions System Voltage System Frequency System Phases Neutral Connected Voltage Sensing Ratio Current Sensing Ratio Temperature Scale Pressure Scale Start Delay Crank Time Rest Time Set to nominal system voltage as expressed in phase to phase voltage i e a 347 600 volt system would be entered as 600 The programmable range of values is 120V 15 000V Set to nominal system frequency of either 50 HZ or 60 HZ Set to match the power distribution system used on the generator set i e either single phase or 3 phase system Set to Yes if generator s neutral conductor is connected to controller terminal TB1 VN and it is desired to display line neutral AC voltages for a 3 phase 4 wire system For direct voltage sensing wiring connections from 208 to 600 volts enter 1 i e a ratio of 1 1 When potential transformers are utilized for voltage sensing enter the calculated transformer ratio e g when using 600 120 transformers enter a number of 5 For current s
78. FACH 73 CHUTZENSTRASSE 59 H 8245 FEUERTHALEN WITZERLAND 41 52 647 4700 41 52 659 2394 TAIWAN F NO 126 WENSHAN 3RD STREET ANTUN DISTRICT AICHUNG CITY 408 R O C HONE 886 4 238 04235 FAX 886 4 238 04463 UNITED KINGDOM 6 BRISTOL DISTRIBUTION PARK HAWKLEY DRIVE BRISTOL 8532 U K PHONE 44 1454 850000 FAX 44 1454 859001 VENEZUELA AV ROMA QTA EL MILAGRO URB CALIFORNIA NORTE CARACAS 1070 VENEZUELA PHONE 58 414 114 8623 FAX 58 412 322 5790 c 2 lt gt gt UO OO 12 WARNING CALIFORNIA PROPOSITION 65 WARNING Engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects and other reproductive harm WARNING CALIFORNIA PROPOSITION 65 WARNING Battery posts terminals and related accessories are known to the state of California to cause cancer birth defects and other reproductive harm 2 408 020 8 BALDOR GENERATORS BALDOR ELECTRIC COMPANY World Headquarters P O Box 2400 Fort Smith AR 72901 2400 479 646 4711 Fax 479 648 5792 www baldor com All Rights Reserved Printed in USA Baldor Electric Company 2 08 MN2408
79. G WARNING WARNING WARNING WARNING WARNING Warning WARNING WARNING WARNING WARNING WARNING WARNING 1 4 Product Safety Information Installation and servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions Keep unauthorized personnel away from batteries Disconnect the battery s ground terminal before working in the vicinity of the battery or battery wires Contact with the battery can result in electrical shock when a tool accidently touches the positive battery terminal or wire The risk of such shock is reduced when the ground lead is removed during installation and maintenance An open bottom stationary engine generator set must be installed over noncombustible materials and shall be located such that it prevents combustible materials from accumulating under the generator set Installation and repair procedures requires specialized skills with electrical generating equipment and small engine systems Any person that installs or performs repairs must have these specialized skills to ensure that the generator set is safe to operate Contact Baldor for installation or repairs Be sure all wiring complies with the National Electrical Code NEC and all regional and local codes or CE Compliance Improper wiring may cause a hazardous condition and exposure to electrical hazards can cause serious injury or death Be sure the system is properly g
80. ISSAUGA ONTARIO 147 156 PHONE 905 890 5110 FAX 905 890 5540 12 IMBERS U OAKVILLE ONTARIO 2750 COVENTRY ROAD OAKVILLE ONTARIO L6H 6R1 PHONE 905 829 3301 905 829 3302 ORVAL QUEBEC 5 RUE LINDSAY ORVAL QUEBEC 256 HONE 514 422 8818 AX 514 422 8982 ONTREAL QUEBEC 844 WILLIAM STREET ONTREAL QUEBEC H3J 1R5 HONE 514 933 2711 AX 514 933 8639 ANCOUVER RITISH COLUMBIA 538 KEBET WAY ORT COQUITLAM RITISH COLUMBIA V3C 5M5 HONE 604 421 2822 FAX 604 421 3113 WINNIPEG MANITOBA 54 PRINCESS STREET WINNIPEG MANITOBA R3B 1K2 PHONE 204 942 5205 FAX 204 956 4251 AUSTRALIA NIT 3 6 STANTON ROAD EVEN HILLS NSW 2147 AUSTRALIA HONE 81 2 9674 5455 AX 61 2 9674 2495 NIT 8 5 KELLETTS ROAD OWILLE VICTORIA 3178 USTRALIA HONE 61 3 9753 4355 FAX 61 3 9753 4366 EL SALVADOR RESIDENCIAL PINARES DE SUIZA POL 15 44 NVA SAN SALVADOR EL SALVADOR PHONE 503 2288 1519 FAX 503 2288 1518 CHILE LUIS THAYER OJEDA 166 OF 402 PROVIDENCIA SANTIAGO CHILE PHONE 56 2 290 0762 FAX 56 2 290 0762 CHINA 5299 BEI SONG ROAD SONGJIANG 201611 SHANGHAI CHINA PHONE 86 21 5760 5335 86 21 5760 5336 NIT 905 STH FLOOR OWER B WANDA PLAZA 93 JIANGUO ROAD HAOYANG DISTRICT 100022 CHINA 86 010 58205516 86 010 58204231 RMANY ESELSTRASSE 22 85551
81. KIRCHHEIM UNICH GERMANY HONE 49 89 90 5080 AX 49 89 90 50 8492 ERMANN HEINRICH GOSSEN STRASSE 3 50858 KOLN GERMANY HONE 49 2234 37941 0 FAX 49 2234 37941 64 INDIA 14 COMMERCE AVENUE MAHAGANESH COLONY PAUD ROAD PUNE 411038 MAHARASHTRA INDIA PHONE 91 20 25452717 25452718 FAX 91 20 25452719 0 UU UU DAC n gt 2 m I nuzcoc Uc ITALY BALDOR ASR AG SUCCURSALE DI MENDRISIO A BORROMINI 20A H 6850 MENDRISIO WITZERLAND HONE 0041 91 640 99 50 AX 0041 91 630 26 33 PAN A BLDG 802 21 1 TSURUYA CHO KANAGAWA KU YOKOHAMA 221 0835 JAPAN PHONE 81 45 412 4506 FAX 81 45 412 4507 KOREA RM 1715 SUSEO TOWER 725 SUSEO DONG GANGNAM GU SEOUL 135 757 KOREA TEL 82 2 2226 9369 82 2 2226 9368 MEXICO LEON GUANAJUATO KM 2 0 BLVD AEROPUERTO LE N 37545 GUANAJUATO M XICO PHONE 52 477 761 2030 FAX 52 477 761 2010 MIDDLE EAST amp NORTH AFRICA VSE INTERNATIONAL CORP P BOX 5618 BUFFALO GROVE IL 60089 5618 PHONE 847 590 5547 FAX 847 590 5587 SINGAPORE 18 KAKI BUKIT ROAD 3 303 09 ENTREPRENEUR BUSINESS CENTRE SINGAPORE 415978 PHONE 65 6744 2572 FAX 65 6747 1708 PANAMA RICARDO J ALFARO DIFICIO SUN TOWERS MALL 02 LOCAL 55 UDAD DE 507 236 5155 507 261 5355 SWITZERLAND OST
82. Load programmable output will energize if the remote start contact is open The Main LCD Display will be shown Apply Power and Main LCD Display Freq Reset faults 000 000 000 Press Enter key Show Operating Status screens Controller is in Auto position and there UNIT READY are no active faults Press 7 or key Scroll to next Controller is in OFF position from the SWITCH IN OFF front panel keypad push button Press 7 or key Scroll to next Engine is running and all conditions are UNIT RUNNING normal Press or key Scroll to next A shutdown fault is active The specific UNIT SHUTDOWN fault will be automatically displayed Press 1 or key Scroll to next One or more faults are active The UNIT ALARM display will automatically scroll through all active faults at a two second rate Fault Display The fault display menu is automatically displayed when an alarm or shutdown fault is activated The specific alarm or shutdown fault label will be displayed and if multiple alarm conditions are present the display will automatically scroll through all active faults MN2408 Operation 4 21 Timer Countdown Timer countdown menus are automatically displayed when specific time delay function occurs during a control sequence When a time delay begins the LCD display will show the time delay function name i e Engine Start Delay and the current time remaining in the countdown sequence When the timing function h
83. MN2408 Digital Fault Menu Loop controller s digital fault settings are described as follows Caution The Digital Fault Label selection must agree with the external control wiring prior to energizing the controller Failure to do so may cause severe equipment damage Digital Fault Label Select the desired fault label these are stored in non volatile memory Air Damper Tripped High Oil Temp Bat Charger Input Fail High Winding Temp Bat Chrg Trouble Low Coolant Level Breaker Tripped Low Engine Temp DC Fail Low Fuel Level Failed To Sync Low Fuel Press Gen Breaker Open Low Oil Level Ground Fault Low Oil Pressure High Bearing Temp Remote Emerg stop High Cooler Vibration Reverse Power High Engine Temp Basin Rupture High Engine Vibration ATS In Bypass High Fuel Level Fuel Leak High Cil Level Low Fuel Press No Load Test Bat Charger Fail Highintkmanftemp Vent Damper Fail High Fuel Level Fail To Sync Blank i e no text for unused inputs Action Allows a fault to be either an Alarm fault or a Shutdown fault Note Any activated alarm or shutdown fault will energize the Common fail fault and sound the alarm horn Alarm Latch If an fault was set as an Alarm it may be selected as a Latching alarm or Non latching alarm A Latching alarm is not cleared until a reset command clears it Note This value only appears if alarm faults are programmed Shutdown faults are automatically set as latching Allows the digital fault circu
84. MN2408 Options amp Accessories A 3 Silencers Industrial Silencer GLCIS 3SU GLCIS 4SU GLCIS 6SU GLCIS 7SU Critical Silencer GLCCS 4SU GLCCS 6SU GLCCS 7SU A 4 Series GLC Refer to enclosure procedure to install silencer when enclosure is present Industrial Silencer for Open Skid Mount Units Provides silenced exhaust for up to 11 dBA sound attenuation Kit includes engine adapters flex pipe clamps silencer and rain cap Critical Silencer for Open Skid Mount Units Provides silenced exhaust for up to 18 dBA sound attenuation Kit includes engine adapters flex pipe clamps silencer and rain cap Figure A 4 Exhaust Output GLC60 65 Open Critical t GLC60 105 Open Industrial GLC10 25 13 l GLC30 45 e GLC60 90 GLC100 105 ak Female NPT Extension Frame lt Clamp To Exhaust Output GLC30 45 Open Industrial Critical GLC100 105 Open Critical GLC30 45 qr GLC60 90 4 a GLC100 105 j ES Female NPT Extension lt Clamp Flange Extension To Exhaust Output 1 lt Clamp To Exhaust Output Silencer refer to Figure A 4 for specific details 1 Attach the Silencer to the Exhaust Output of the engine refer to Figure B 4 2 Use correct size clamp to attach extension pipe to Exhaust Output pipe from engine 3 sure the Extension pipe fits securely over Exhaust Output pipe so that no exhau
85. N2408 Figure 3 5 Single Phase Connections From Alternator s Factory Wired Bond Jumper Note Remove the Bonding le 5 jumper to meet codes if required NEUTRAL Neutral L1 L2 i LOAD Connections m AC Power Connections Ground Connections Customer Connections EE equ ee a Figure 3 6 Three Phase WYE and DELTA Connections Parallel WYE Term REGULATOR VL N V Block Leod Lead UIE LYS 159 208 A NO LEAD 139 240 VOLT B NO LEAD LEAD 2 6 V2 V6 06 02 wi 5 7030 7v5 L2 vs 3 w5 L1 unus 2 Series Delta Biock Leod ATOR veu ar i L1 W6 U1 L2 us 2 L3 ve 3 7030 D 2 5 U2 US M we ae L3 12 G NO LEAD N H NO LEAD NSeries WYE m L1 ut L2 vi L3 w U6 V6 6 U2 US 2 2 V5 3 G w2 5 7050 H N MN2408 Receiving amp Installation 3 11 Battery Charger Considerations 1 Mount the battery charger on the generator or as close to the generator as possible 2 If you mount the battery charger inside the building mount it near the main breaker box or disconnect box 3 If you mount the batte
86. NALOG INPUT 2 Step 1 Range 100 Water temp Water temp Low del Delay for ANALOG INPUT 2 Wrn Wtemp low Step 1 s Range 1 180 s Water temp del Delay for ANALOG INPUT 2 alarm Step 1 s Range 0 180 s Wrn Fuel Level Warning threshold level for ANALOG INPUT 3 Step 1 Range Sd Fuel Level 10000 Sd Fuel Level Shutdown threshold level for ANALOG INPUT 3 Step 1 Range 100 Wrn Fuel Level Fuel Level del Delay for ANALOG INPUT Step 1 s Range 0 180 s Batt overvolt Warning threshold for high battery voltage Step 0 1 V Range Batt undervolt 40V Batt undervolt Warning threshold for low battery voltage Step 0 1 V Range 8V Batt overvolt Batt volt del Delay for low battery voltage alarm Step 1s Range 0 600 s NextServTime Counts down when engine running If reaches zero an alarm appears Step 1h Range 0 65535h MN2408 Generator Protect Setpoints verload Threshold for generator overload in of Nominal power Step 196 of Nominal power Range 0 20096 Overload Wrn Threshold for generator overload warning in of Nominal power Step 196 of Nominal power Range 0 20096 Overload del Delay for generator overload alarm Step 0 15 Range 0 60 0 s Ishort Shutdown occurs when short circuit limit Ishort limit is reached Step 1 6 of Nominal current Range 100 500 21 del
87. Output 2 Common Fail Factory setting Prog Output 3 Common Fail Factory setting Prog Output 4 Prog Output 5 Common Fail Factory setting Prog Output 6 Common Fail Factory setting Common Fail Factory setting Warm up Delay 0 99 Seconds Neutral Delay 0 99 Seconds Return Delay 0 999 Seconds Reset Run Hours Access by Master Password Only Yes No Toggle Between Yes No MN2408 Operation 4 31 Figure 4 18 Analog Fault Menu Loop Parameters Fault Name Input Analog Fault etpoint Level Setpoint Level Action Alarm Latch Bypass On Transient Type E Enable Pick up Drop out S Shutdown Y Yes Start Delay Sec D Disable A Alarm N No Y Yes N No Under Voltage AC Voltage E 5 Y 5 0 Under Frequency AC Frequency S Y Y 5 0 Weak Battery DC Voltage E 18 0 N A N 3 0 Low Battery DC Voltage E 25 6 N A A N N 120 0 Voltage High Battery DC Voltage E 30 4 N A A N N 10 0 Voltage Low Engine Temp Temp Sender E 95 F N A Y N 5 0 High ENG Temp 1 Temp Sender E 198 F N A Y Y 2 0 Alarm High ENG Temp 2 Temp Sender E 206 F 5 Y Y 2 0 Shutdown Low Oil Press 1 Press Sender E 30PSI N A Y 2 0 Alarm Low Oil Press 2 Press Sender E 20PSI N A S Y Y 2 0 Shutdown Indicates parameter is non programm
88. RAMMABLE OUTPUT 3 MUST BE PROGRAMMED FOR UTILITY READY TO LOAD PROGRAMMABLE OUTPUT 4 MUST BE PROGRAMMED FOR GENERATOR READY TO LOAD ALL COMPONENTS SHOWN EXTERNAL TO THE MEC 2 20 ARE OPTIONAL ITEMS 3 POLE CHANGEOVER SWITCH SHOWN 7 FOR OTHER SYSTEM VOLTAGE APPLICATIONS CONSULT FACTORY AC COIL SPIKE SUPPRESSION DEVICES ARE REQUIRED MN2408 Operation 4 15 4 16 Operation When the controller is applied in an Auto Mains Failure AMF application with a transfer switch it must be wired as shown in Figure 4 14 Programmable output must be selected for Utility Ready To Load and programmable output 4 must be selected for Gen Ready To Load After the controller is programmed the AMF sequence of operation will be as follows Utility Normal Condition 1 Remote Start input signal terminals 16 4 17 is not activated i e normal 2 Utility Ready To Load output is energized i e signal to transfer switch to transfer to utility power 3 Generator Ready To Load output is de energized Utility Power Failure Conditions 1 Remote Start input signal is activated i e remote start contact closes when utility power fails as sensed by utility voltage sensor 2 Engine starts after the Engine Start Delay timer Utility Ready To Load output stays energized 3 After the engine has started and the generator output rises above the programmed voltage and frequency limits a Warm Up timer is initiated 4 Aft
89. RENT 1 phase system PHASE B CURRENT Amps c Displays generator load current as follows 3 phase system PHASE C CURRENT 1 phase system not applicable Generator Frequency Hourmeter Display FREQ 60 1Hz HOURS 56788 Hrs FREQ Displays generator frequency in hertz HZ The frequency is displayed with a resolution of 1 10 of a hertz HOURS Displays unit operating hours MN2408 Operation 4 23 Engine Parameter Display Two engine operating parameter screens are provided Battery Voltage Engine Speed BATTERY 27 0 Tachometer SPEED 1800 rpm Battery Displays battery voltage in DC volts The voltage is displayed with a resolution of 1 10 of a volt Speed Displays engine speed in revolutions per minute RPM Engine Temperature Oil Pressure ENG TEMP 57 OIL PRESS 200 ENG TEMP Displays engine temperature in either degrees Celsius or Fahrenheit as selected OIL PRESS Displays engine oil pressure in either pounds per square inch PSI or in Kilopascals KPA as selected Program Menus The programming menu is used to change values such as time delays analog fault settings digital fault settings Access to the programming sub menus may only be obtained with a security password number The sub menus are organized as follows Program Menu PROGRAM MENU N Displays two messages that be toggled between YES and NO by pressing the INCREMENT push button NO Programming sub menus are disabled when NO is displayed
90. S 9 uid bunopuow 1 1 stu 10 UO eq you 9 SM m f 02 2 1 a g sn n 3 an Ni g 8 LWA 914 082 poe 094 122 9990 Ux TIA NA in n Seues wno N wo 9 a a a ZARA an A cn zn 3 WW ZA m 060 9 9 2 E 1 s i g v poe yos A S NA 7991 190 d Dileg seues g enn n 1 s 002 9 SM IM 3 M 3 G 2 IM anger omo Quo 10 LN 002 021 pssi pos E A 79190 Qus uonoeuuoo KJOJODJ 21004 20 dous Jajay 0000 0 Series GLC B 13 MN2408 Figure B 23 Three Phase Connection Diagram Wire Larger than 1 0 w Breaker GWOO00A44 YOLVYANSD 3SVHd 2179 VEVOUDOMO 33U au 00562 01 0 8 035 34 418 A8 2 A38 SNOISIA3H 2SIN 0538 A38 5 FEEN 2
91. Selects if a common fail alarm condition is to be activated during manual operation Horn For Not In Auto Warm up Delay Neutral Delay Note Return Delay The Horn may be programmed to sound when the controllers operating mode is switched from the Auto position If the Horn is not to sound select program setting No The WARM UP Delay menu appears when the Gen Ready To Load programmable output is selected typically for AMF application Set to the desired time in seconds which the generator requires to effectively warm up before accepting load This is typically set for 3 seconds The Warm Up Delay is initiated after the generator is above programmed voltage and frequency limits per the analog programming menus The Neutral Delay menu appears when the Utility Ready To Load programmable output is selected typically for AMF application The Neutral Delay timer is used when transferring between the available power sources When transferring from the utility supply to the generator supply the Neutral Delay timer will start when the Utility Ready To Load output de energizes When the Neutral Delay time period expires the Generator Ready To Load output is energized The purpose of the Neutral Delay timer is to prevent out of phase transfers which may be caused by a fast transfer and the two sources of supply are out of synchronism The Neutral Delay timer ensures the load voltages decay before the transfer is initiated Set to the desired ti
92. Start RPM RPM 2 n BO Starter IDLE RATED Idle time Min stab time d Electric protections active Start Fail Voltage autodetection BO STARTER GCB Stabil time CloseDelay BO GCB close open opened closed Operation 4 7 Idle time 4 8 Operation Table 4 15 Engine Setpoints Continued ooling time Runtime of the unloaded gen set to cool the engine before stop Step 1s Range 0 3600 s AfterCoolTime Runtime of engine after cooling pump Binary output Cooling pump is closed when the engine starts and opens AfterCool time delayed after gen set stops Step 1s Range 0 3600s CoolingSpeed Selects the function of the Binary output IDLE NOMINAL during engine Cooling state NOMINAL Cooling is executed at Nominal speed and generator protections are active IDLE Cooling is executed at Idle speed and generator protections are switched off Hint Binary output IDLE NOMINAL must be configured and connected to speed governor Engine Idle speed must be adjusted on speed governor D function ENABLED The D terminal is used for both functions running engine detection and charge fail detection CHRGFAIL The D terminal is used for charge fail detection only DISABLED The terminal is not used Note Magnetization current is independent of this setpoint value 6 Engine Protect Setpoints ECUFreqSelec
93. Tanks Diesel Only Locate the fuel storage tank as near the genset as possible This will minimize the cost of fuel system installation and will maximize fuel system reliability Controls and Transfer Switch Locate the control switch gear as close to the emergency loads and the genset as practical This will minimize the chances that a failure of the power line to the emergency load will go undetected In locating the switchgear accessibility for service and maintenance must be considered Genset Noise Internal combustion engines produce noise so the room should be located away from occupied buildings In addition the genset room can be treated to reduce noise transmission In locating the genset room both engine fan and exhaust noise must be considered If noise within the genset room or noise transmitted to the surrounding parts of the building are a concern then the room must be made large enough to allow for installation of noise attenuating walls and noise absorbing walls Light weight concrete blocks filled with sand or special sound block concrete blocks are commonly used Noise attenuating tight fitting windows and doors also help reduce noise transmission to the rest of the building A double walled room should be considered Vibration isolators under the genset rails will also reduce the transmission of noise through the floor Code Requirements Building and safety codes deal with engine location These requirements are
94. UN Customer 1 0 Connections 2 13 14 15 9 1 n we 56 55 5 o85 Sle 9 E 2 Er gt 17 2 oD GEOL co Sp ox 8 e gt 2 202 fer gt Z ES 3 Ww E 207 E H 5 8 bl 2 5 T4 3204 2 2 852 520 TLSE MEE 58 255 5 TEOL amp ESE ue gt 1 0585 ms law 1570500 0602 ou go e HR E 1 Sec Sr HM 5255 9999 28771 52853 S fr xP Tro 698 afz 9 IS D or 2 wos 020 VOL e a o 50 5802 SB 5 Em amp E S 9 8 gt 7904 SQ 5 LL 2904 2 6 TOOL 5 e 0902 Sr R 9 as 6500 Se S 850 S Ses 5 1504 5 2 gt 9504 EE us s Era 9 9 5 72 E 3 uS 6 9 aw 002 I EE 8 O 5 0104 ENS 4 ax 5 0 4 5 X E 2 2 lt 1004 9002 SH o Olg x8 9 9 3 9 300r 5 1 5 9 9 g gt TOL 9 9 s ne 9 9 c 2104 9 0 5 e ior 9 9 5E as 5104 C9 Qu 3X m Sio 9 Sa 185 DES 3102 I n E 0007 S Sm RE si sid mu 8 DE mr4 u e 8 E n S Oe
95. UT 1 alarm detection Step 1 Range 100 to 10000 1 del Delay for IOM ANALOG INPUT 1 alarm Step 1 s Range 0 180 s AnlInIOM 2 lev1 The level for IOM ANALOG INPUT 2 alarm detection Step 1 Range 100 to 10000 AnlInIOM2 lev2 The level for IOM ANALOG INPUT 2 alarm detection Step 1 Range 100 to 10000 AnlInIOM 2 del Delay IOM ANALOG INPUT 2 alarm Step 1 s Range 0 180 s AnlInIOMS lev1 The level for IOM ANALOG INPUT 3 alarm detection Step 1 Range 100 to 10000 AnlInIOMS lev2 The level for IOM ANALOG INPUT 3 alarm detection Step 1 Range 100 to 10000 AnlInIOMS del Delay for IOM ANALOG INPUT 3 alarm Step 1 s Range 0 180 s AnlInIOMA lev1 The level for IOM ANALOG INPUT 4 alarm detection Step 1 Range 100 to 10000 AnlInIOMA4 lev2 The level for IOM ANALOG INPUT 4 alarm detection Step 1 Range 100 to 10000 AnlInIOMA del Delay IOM ANALOG INPUT 4 alarm Step 1 s Range 0 180 s The protection of IOM PTM inputs is activated by over crossing the limits Calibr AInIOM 1 4 Calibrating constant to adjust the measured value of IOM PTM analog inputs Physical dimension of calibrating constant is corresponding to Analog input Step 1 Range 1000 to 1000 4 10 Operation MN2408 Digital Engine Controller Description EM0046A21 MRS17 Continued Figure 4 11 Controller Connection Diagram GENERATOR DIESEL GAS ENGINE
96. Wrn Gen V del Delay for generator under voltage and over voltage alarm Step 0 15 Range 0 605 Volt unbal Threshold for generator voltage unbalance alarm Step 1 of Nominal voltage Range 0 100 of Nominal voltage Volt unbal del Delay for generator voltage unbalance alarm Step 0 15 Range 0 60 0 s Gen f Shutdown level for generator over frequency Step 0 1 of Nominal frequency Range Gen gt Wrn 200 0 Gen f Wrn Warning level for generator over frequency Step 0 196 of Nominal frequency Range Gen f Wrn Gen V Gen f Shutdown level for generator under frequency Step 0 196 of Nominal frequency Range 0 0 Gen f Wrn Gen f Wrn Warning level for generator under frequency Step 0 196 of Nominal frequency Range Gen f Gen f Wrn Gen f del Delay for generator under frequency and over frequency alarm Step 0 15 Range 0 60 0 s Operation 4 9 Table 4 18 Sensor Spec Setpoints 12 AI3 alibrating constant to adjust the measured value of IL analog inputs Physical dimension of calibrating constant is corresponding to Analog input Step 1 Range 1000 to 1000 AnOut kW 20mA Conversion coefficient from gen set power to iG IOM or PTM analog output Step 1 Range 1 to 32000 Table 4 19 Module Setpoints niin 1 lev e level for 1 alarm detection Step 1 Range 100 to 10000 AnlInlIOM1 lev2 The level for IOM ANALOG INP
97. a start command is issued the controller issues a run and crank output signal The controller then monitors engine speed and when crank disconnect speed is reached the crank signal is terminated While the engine accelerates to normal speed the controller continuously monitors the engines speed signal Should the engine speed exceed the maximum predetermined setpoint the overspeed shutdown fault circuit will activate terminating the run signal In addition to overspeed shutdown the engine controller also monitors many other engine protection circuits and should they be activated the engine will be stopped and or alarm initiated The engine will automatically stop for any shutdown condition or when the remote and or local start signal is removed The engine controller operation includes time delay circuits for normal operating conditions such as start delays cool down and cranking periods Manual Start Stop To manually Start the Gen Set push the RUN push button The following happens 1 When the RUN push button is pressed an ENGINE START DELAY timer is initiated The start sequence will not be initiated if any shutdown fault condition is present 2 When the engine start delay time expires an engine RUN and CRANK output signal will be initiated The RUN output may be programmed to only energize when a start signal is initiated and an engine speed signal is detected 3 When the engine starts and begins to accelerate to nominal spe
98. abTime counter started Stop request READY TO LOAD off Cooling Rumi Cooling time timer started unning RPM 0 or any other shutdown condition READY TO LOAD off Shutdown FUEL SOLENOID off Loaded RPM 0 or any other shutdown condition FUEL SOLENOID off STOP SOLENOID Shutdown on READY TO LOAD off Cooling time elapsed FUEL SOLENOID off Stop STOP SOLENOID on Cooling RPM 0 or any other shutdown condition FUEL SOLENOID off Shutdown STOP SOLENOID on Start request READY LOAD on Running st RPM 0 Oil pressure not detected Vgen 10V Ready 60 sec Elapsed Stop Stop fail Some output conditions are optional and may require additional programming of field connection See appropriate wiring diagram Adjustment Menu The adjustment menu Figure 4 10 allows setting engine and generator values such as Passwords Pre Start Time Crank Time Cool Down Time Alarm Conditions and values Shutdown Conditions and values power transfer settings etc Figure 4 10 Adjustment Menu gt ENGINE BASIC Use A and W to move the cursor to the desired parameter ENGINE PROT Press ENTER to select the parameter group GEN BASIC Press PAGE to move to the next page of menu items GEN PROTECT Alarm List Shows the active alarms and warnings Press fault reset to clear the list ECU Alarm List Shows the active ECU engine control unit fault codes Press ENTER fault reset to clear the list MN2408
99. able Figure 4 19 Digital Fault Menu Loop Parameters Action y D S Shutdown O Open Delay Sec A Alarm C Close Low Oil Pressure 0 5 High ENG TEMP 1 0 Batt Chgr Input Fail 30 0 Low Fuel Level 0 1 Figure 4 20 Calibration Menu Loop Parameters Parameter etting Volts A B Zero XXX XXXVAC Volts A B Span XXX XXXVAC Volts B C Zero XXX XXXVAC Volts B C Span XXX XXXVAC Volts C A Zero XXX XXXVAC Volts C A Span XXX XXXVAC Volts A N Zero XXX XXXVAC Volts A N Zero XXX XXXVAC Volts B N Zero XXX XXXVAC Volts B N Zero XXX XXXVAC Volts C N Zero XXX XXXVAC Volts C N Zero XXX XXXVAC Current A Zero XXX XXXAAC Current A Span XXX XXXAAC Current B Zero XXX XXXAAC Current B Span XXX XXXAAC Current C Zero XXX Battery Voltage Span XXX XX X VDC Engine Temperature XXX XXX CIF Oil Pressure XXX XXXX PSI KPA 4 32 Operation MN2408 Figure 4 21 Engine Control Connections 12VDC 24VDC 5 104 GENERATOR o N p BANERY E Y5 V OUTPUT VOLTAGE 1A ES VB 9 0 N p 7 2 DELETE 74ASE VC FOR SINGLE PHASE GRD T VC 0 6 N o VC SYSTEMS CRANK VN N CRANK PILOT RELAY 24 IA 4
100. able and Towable products to qualify for any warranty consideration A start up inspection form warranty registration must be completed in its entirety and submitted to Baldor Generators within 30 days of start up to qualify for any warranty consideration excluding Portables Towables and Light Towers MN2408 General Information 2 1 2 2 General Information MN2408 Important Be sure you are completely familiar with all Safety Instructions detailed in Section 1 of this manual Do not proceed if you are unsure of any detail Contact your Baldor Distributor they are experienced and are happy to assist you and to answer your questions Installation Guidelines Site Planning Room Size MN2408 The procedures presented in this manual are suggestions and it is the responsibility of the Owner Operator to arrange for these procedures to be performed by licensed contractors according to all applicable codes including local codes for your Municipality City County and State In addition to these suggestions before installing your generator you should obtain the most up to date copies of the following documents from the National Electrical Code and other authorities National Electric Code Articles 230 250 445 517 700 e National Fire Protection Association No 30 Storage Handling and Use of Flammable Liquids No 37 Stationary Combustion Engines and Gas Turbines 99 Essential Electrical Systems for Health Care Facilitie
101. ad connections Check engine for malfunction or load for fluctuation Stabilize load The addition of a lamp load resistance load may compensate partially for load changes caused by intermittent motor operation Do not overload Verify all connections and terminal tighness Low output voltage Low engine speed Excessive load High resistance connections connections will be warm or hot Internal failure of Alternator Low power factor Verify engine RPM Check engine for malfunction or system for overload Reduce load Verify all connections and terminal tighness Return to factory for repair Reduce inductive motor load Some AC motors use about the same current regardless of load Do not use motors of greater horsepower rating than is necessary to move the mechanical load High output voltage Excessive speed fixed speed mode Check engine for malfunction Verify engine RPM Electrical shock when frame is touched Static charge Grounded armature or field coil Ground generator frame at local reference ground see Section 3 Return to factory for repair Mechanical noise Internal failure of Alternator Loose or misaligned coupling 5 2 Troubleshooting and Maintenance Return to factory for repair Tighten align coupling and alternator shaft to engine shaft MN2408 Table 5 2 Troubleshooting Guide Digital Controller Only Problem Controller does not power up even with correct DC power a
102. alog inputs values assignment Al1 Oil press AI2 Water temp Fuel level is fix It is possible to configure on each Analog input e Reading from IL Analog inputs or from Engine Control Unit via CAN bus J1939 Sensor characteristics from the list e Value dimension e g psi bars F C 96 1 Number of decimal points 0 1 2 Note Corresponding Analog input terminal is dead when reading is switched to ECU All values from ECU shall show but no alarm is displayed when CAN communication is interrupted Warning and shut down limits are adjusted in Engine protection group Table 4 13 Analog Inputs 11 Oil press Oil pressure analog input Default VDO sensor in range 0 to 145 psi Al2 Water temp Water temperature analog input Default VDO sensor in range 32 to 212 F Al3 Fuel level Fuel level analog input Default VDO sensor 0 180R 0 100 Table 4 14 Basic Setpoints nterPasswor assword 15 a four digit number assword enables change of relevant protected set points Use J keys to set and ENTER key to enter the password ChangePassword Use 1 or keys to set and ENTER key to change the password Gen set name User defined name used for InteliLite identification at remote phone or mobile connection Gen set name is max 14 characters long and have to be entered using LiteEdit software Nomin power 3ph Nominal power of the generator
103. ance of the Cranking Circuit 0 002 Ohms for 24 Voit Syste 0 0012 Ohms for 12 Volt Syster System 24 Volt Resistance of 6 Connections 0 00006 Ohms Resistance 100 of 1 0 00100 Ohms Total Resistance of Cranking Circuit 0 00106 Ohms a Ex EE 22 E E Va Ex z E Be ES m E a a m a 200 300 400 500 600 700 4 5 08 7 62 10 16 12 70 15 24 17 76 Length of Cable in Inches Meters General Information 2 13 2 14 General Information MN2408 Section 3 Receiving amp Installation Receiving amp Inspection When you receive your generator there are several things you should do immediately 1 Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered your system 2 Verify that the part number of the system you received is the same as the part number listed on your purchase order 3 Ifthe system is to be stored for several weeks before use be sure that it is stored in a location that conforms to published storage temperature and humidity specifications Lifting the Generator When lift or hoist equipment is used to lift the generator and move it to position be careful not to contact overhead wires or other obstacles Be sure lift or hoist equipment has appropriate ti
104. any nearby wall or structure Attention must also be given to exhaust noise in selecting placement of the exhaust system Multi Engine Installations Caution Do not connect multi engine exhaust systems together Each engine must have its own exhaust system for proper operation Exhaust gases from an operating engine will migrate back through a non operating engine and cause a hydraulic lock This may interfere with starting of the second engine The migrating gases will also tend to turn the turbos which are not being provided lubrication if the engine is not running The use of check valves in the exhaust system are discouraged due to their tendency to stick Exhaust Manifold There are two exhaust manifold types Dry type which is standard and the optional water cooled The dry type is simply exposed to the surrounding air and becomes very hot Shields insulating wraps or other types of guards can be used to limit operator contact with the hot surfaces This practice is common where engine room size is small creating cramped conditions Water cooled exhaust manifolds are not available on all engine models This type manifold has passages through which engine coolant is circulated to remove heat from the manifold surface It also will help protect the operator from contact with the hot manifold surface This will reduce the amount of heat that is radiated by the engine to the surrounding air by approximately 2096 In addition this type manifold si
105. as expired the LCD display will automatically change to either the next timing sequence countdown display or return to the original system status menu Apply Power and Main LCD Display Freq Reset faults 000 000 000 Show Operating Status screens ENGINE START Displays specific time delay function DELAY 45 SEC name and remaining time Other time delay functions are ENGINE START DELAY 45 SEC CRANK PERIOD REST PERIOD STARTER RE ENGAGE DELAY XX SEC BYPASS DELAY XX SEC COOLDOWN DELAY XXXX SEC WARMUP DELAY XX SEC RETURN DELAY XX SEC NEUTRAL DELAY XX SEC Note Countdown screens only appear if Utility Gen Ready To Load outputs are programmed 4 22 Operation MN2408 Generator Metering The controller is in the display mode at all times except when the programming mode The display screens and menus may be selected by pressing the Enter or Exit keys to access Operating Status Display Fault Display Timer Countdown Generator AC Metering or Programming Menus The LCD display shows the status of the generator output Generator Average Output Display 9 Freq 000 000 000 Average Voltage Displays the average generator voltage as follows 3 phase system AVERAGE LINE TO LINE VOLTAGE Phases 1 phase system LINE TO LINE VOLTAGE Phases A to B Average Current Displays the average generator current as follows 3 phase system AVERAGE LINE CURRENT Phases A B C 1 pha
106. ases 4 Adequate ventilation of the building when the engine shuts down MN2408 Receiving amp Installation 3 1 WARNING An open bottom stationary engine generator set must be installed over noncombustible materials and shall be located such that it prevents combustible materials from accumulating under the generator set Several other factors should be carefully evaluated when selecting a location for installation 1 For effective cooling and maintenance the system should be mounted on a flat smooth noncombustible level surface A concrete pad is ideal and provides a secure installation 2 Installation should prevent water levels from reaching the generator Drainage must be adequate to keep concrete pad free from standing water 3 Installation should prevent obstructions by buildup of leaves grass sand snow etc If these items pose a problem consider building a small fence or other break to protect the unit from accumulation of debris 4 Installation should place the generator as close as possible to the fuel supply and transfer switch 5 Atleast twenty four 24 inches clearance must be provided on all sides for air flow 6 Access must be provided to allow the enclosure covers to be opened or removed for service and maintenance 7 Maximum Ambient temperature is 122 F 50 C Figure 3 2 Generator Mounting Fuel Stub Up ___ GLC125 ONLY Large Exhaust Area For all models with enclosure
107. ault correction factor is 127 Increasing this will raise the displayed value conversely decreasing this value will decrease the displayed value Note Adjusting the ZERO function with voltage applied will result in non linear voltage readings With the correct voltage displayed press the ENTER push button to accept the correction factor number Record the correction factor number on the programming sheet for future reference Repeat this procedure for all remaining phases MN2408 Operation 4 27 Span Calibration Energize the generator supply voltage to the controller at nominal level Note It may be necessary to program the optional under and over voltage shutdowns as alarms to ensure the generator will continue to operate during calibration Caution must be taken to ensure the generator output voltage is set within nominal limits In the programming mode scroll to the desired generator supply voltage phases with the SPAN function selected Connect an external AC voltmeter of adequate voltage range and accuracy to the controller terminals associated with the voltage phases to be calibrated Use the INCREMENT or DECREMENT push buttons to adjust the correction factor number while observing the displayed voltage level Adjust the correction factor number to obtain an identical voltage reading as measured with the external AC voltmeter With the correct voltage displayed press the ENTER push button to accept the correction factor number Record the corr
108. be a minimum of 2 0 times the genset wet weight Figure 2 3 shows a method to calculate foundation thickness and the soil bearing load of the foundation and generator set The soil load bearing capacity under the foundation must equal or exceed the load from the foundation and genset If it does not then a footing as shown in Figure 2 4 must be added to spread the load over a larger area Figure 2 3 Calculate Soil Bearing Load SBL Capacity SBL TW WxL Where SBL soil bearing load Ibs per square foot kPa TW total weight of the engine generator the foundation and any other equipment that is supported on the foundation in pounds kg __ W foundation width in feet m add L foundation length in feet m Where T foundation depth in feet m W wet weight of genset in pounds kg 145 density of concrete in pounds per cubic foot 2322 kg m L foundation length in feet m W foundation width in feet m Figure 2 4 Typical Footing on Foundation in Soil With Low Soil Load Bearing Capacity Minimum 6 Foundation Meets NFPA 110 Expansion Joint and Sealant Material Floor Slab Gravel Fill Low Load Bearing Soil Footing Re Bar MN2408 General Information 2 7 Table 2 1 Approximate Load Bearing Capacities of Various Soil Types afe Bearing Capacity Soil Type Ib per ft kilo Pascals Ha
109. be located and fixed It is not an exhaustive how to for all types of problems Procedures that require in depth knowledge or skills like flashing the field should be referred to a qualified generator service center Table 5 1 General Troubleshooting Guide Problem Possible Cause Remedy Engine cranks but will not start No Tuel Check that fuel valves are ON Check fuel level in fuel tank Low Oil Level Low Oil Pressure Sutdown activated Replensih oil to full Restricted air flow Check replace air filter No spark Check replace spark plug s No engine speed during crank Check that engine switch is in Start position The magnetic pickup must be correctly adjusted and operating Engine will not crank electric start Dead battery Emergency Stop LED is ON Remove battery and trickle charge or replace with new battery Never Jump Start Reset controller after an Emergency Stop Engine starts but will not run smoothly Fuel or ignition problem Refer to engine manual Engine overheats Excessive load Debris or dirt buildup on engine Remove one or more electrical loads Remove debris Clean engine surfaces to allow cooling No output voltage Ciruit Breaker tripped or failed Internal failure of Alternator Reset circuit breaker or replace if required Return to factory for repair Output voltage varies Irregular speed fixed speed mode Fluctuating speed fixed speed mode Loose terminal or lo
110. de and ready to provide standby power Supplying Load green Generator is providing output voltage to load Table 4 8 Alarm amp Warning Conditions Em 3 High Coolant temperature Low Oil pressure Low Fuel level Generator Under Over Voltage Generator Under Over Frequency Generator Over Current Generator Overspeed Coolant temperature Low Starting battery Under Over Voltage X X X X X X X Immediately begins the crank cycle to start engine and produce power MAN mode only Start generator set operation MAN mode only Stops the Engine and generator set MAN mode only Displays setpoints adjustments Alarms and Warning conditions and Operating Mode selections Changes menu displayed Measurement Adjustment or History Allows selection of OFF MAN AUTO mode choices Deactivates the Horn output Reset Alarms and Warnings Selects the menu choice select the setpoint or select the menu or increase decrease the setpoint value Confirm and accept changed setpoint value Adjusts display contrast Enter Fault Reset Clears engine ECU faults MN2408 Operation 4 1 Digital Engine Controller Description EM0046A21 MRS17 Continued Operating Mode Display Menus Operating Modes and Horn amp Fault Reset MODE gt HORN FAULT RESET RESET 4 2 Operation Press Mode lt q or to scroll though the list of operating modes Off Manual and A
111. ection factor number on the programming sheet for future reference Note When the span calibration setting is complete re confirm the zero calibration points If the zero calibration setpoint needs further adjustment the span calibration point must also be re calibrated Current Sensing Calibration To accurately calibrate the current sensors an external test AC ammeter and current clamp is required with an accuracy of 0 5 or better CURRENT A ZERO 99 350A Displays the generator load current phase A B or C to be calibrated Displays the type of calibration function either ZERO or SPAN Displays the calibration correction factor number 0 255 used to obtain the correct current reading Note To correctly calibrate any of the current sensors the ZERO function must be calibrated before the SPAN function Displays the actual current measurement that will be the same value as shown on the MEC 2 display menus for generator supply This current reading may be calibrated higher or lower by changing the correction factor number Zero Calibration Connect an external AC ammeter with current clamp of adequate current range to the controller terminals associated with the current phases to be calibrated With the generator stopped confirm there is 0 current on the phases to be calibrated In the programming mode scroll to each of the desired generator supply current phases with the ZERO function selected Use the INCREMENT or DECREMENT push butto
112. ed the controllers speed sensor will terminate the CRANK output when engine speed reaches approximately 20 speed i e CRANK DISCONNECT speed setpoint Immediately upon reaching crank disconnect speed the controller will initiate the BYPASS DELAY time delay function After the BYPASS DELAY time period typically 10 seconds all fault circuits programmed as BYPASS DELAY YES are active All fault circuits programmed as BYPASS DELAY NO are continuously armed irrespective of any operation sequence To manually Stop the Gen Set push the OFF push button The controllers RUN output will be immediately terminated which will initiate the engine stop sequence Automatic Start Stop 4 14 Operation To setup the generator for automatic operation pressing the AUTO push button The following happens 1 The engine will automatically start upon activation of the remote start contact input The remote device initiates a start sequence upon contact closure 2 When the remote start signal is activated the engine will start as per the sequence of operation described for the manual start sequence 3 The automatic stop sequence will be initiated by removal of the remote start signal 4 When the start signal is removed a cool down delay function will be initiated MN2408 5 When the cool down time delay period expires typically 5 minutes the controllers RUN output will be immediately terminated which will initiate the engine to stop Aut
113. ensing wiring connections from current transformers CT s enter the calculated CT ratio e g when using a 600 5 CT enter a number of 120 Select the desired units for engine temperature display and analog setpoints Degrees Fahrenheit or Degrees Celsius Note Alarm setpoints do not automatically re configure when changing between Fahrenheit or degrees Celsius Select the desired units for engine pressure display and analog setpoints Pounds per square inch PSI or Kilopascals KPA Note Alarm setpoints do not automatically re configure when changing between PSI and KPA Select desired engine start delay time in seconds If engine start delay is not required set to zero Note If preheat and or prelube functions are used the engine start delay time should be set as required for these functions Select desired cranking time in seconds If cycle cranking is selected this time will be the crank time per attempt Select desired rest time between cranking attempts Only valid if multiple crank attempts are selected Note This value will be ignored if only one attempt has been programmed Starter Re Engage Duration This feature checks for a speed signal during cranking If no speed signal is sensed the controller assumes that the Number Of Crank Cycles Bypass Delay Cool down Time Nominal Engine RPM Flywheel Teeth Crank Disconnect Speed Overspeed engine starter is not turning the engine over and disengages it after the programmed ti
114. er the Warm Up timer expires the Utility Ready to Load output de energizes and the NEUTRAL Delay timer is initiated 5 After the NEUTRAL DELAY timer expires the Gen Ready to Load output energizes to signal the transfer switch to transfer to the generator supply Note The neutral delay function is only operative with an electrically held type transfer switch mechanism ie electrical contactor type Utility Power Restored 1 Remote Start input signal is removed and the Return Delay timer is initiated i e Utility Voltage returns to normal and the Utility voltage sensor contact opens 2 After the Return Delay timer expires the Generator Ready to Load output de energizes and the Neutral Delay timer is initiated 3 After the Neutral Delay timer expires the Utility Ready to Load output energizes to signal the transfer switch to transfer to the utility supply Note If the generator has a shutdown during the Return or Neutral Delay periods the timers are bypassed and the Utility Ready to Load output immediately energizes 4 The generator Cool down Timer starts after the Return Delay timer 5 The generator stops after the Cool down Timer Load Test Push button Operation 1 When the Load Test pushbutton is pressed the logic will internally simulate receiving remote start input 2 Engine starts after the Engine Start delay timer 3 After the engine has started and the generator output rises above the programmed voltage and frequency
115. erator set This operation is further defined in Table 4 9 AUT Mode No action if buttons START and STOP are pressed Engine Start Stop request is given by binary input REM Start Stop MN2408 Digital Engine Controller Description EM0046A21 MRS17 Continued Table 4 9 Manual Mode Sequence Description Menu tatus ondition of Transition Action 1 Next State Start request PRESTART on PRESTART Prestart time counter started Ready RPM gt 2 or Oil pressure detected or Stop Stop fail Gen voltage 10V OFF mode selected or Shut down alarm active Not Ready Not Ready RPM 2 Oil pressure not detected Vgen 10V Ready no shutdown alarm active other than OFF mode selected Prestart Prestart time elapsed STARTER on FUEL SOLENOID on Cranking MaxCrank time counter started RPM Start RPM STARTER off PRESTART off Starting D input activated or oil pressure detected or STARTER off PRESTART off Cranking Gen voltage gt 25 Vgnom Cranking MaxCrank time elapsed 1st attempt STARTER off FUEL SOLENOID off Crank pause STOP SOLENOID on CrankFail pause timer started TAS MaxCrank time elapsed last attempt STARTER off PRESTART off Shutdown Start fail ain Crank Pause CrankFail pause elapsed STARTER on FUEL SOLENOID on Cranking Measurement STOP SOLENOID off MaxCrank time counter started Starting 3096 Nominal speed reached READY TO LOAD on Running MaxSt
116. erature Engine Temperature Engine Temperature Oil Pressure Oil Pressure Battery Voltage Battery Voltage Battery Voltage Voltage AC Frequency Low Oil Pressure 2 Low Battery Voltage High Battery Voltage Weak Battery Undervoltage Under frequency An analog DC signal is provided from an engine mounted sender The low engine temperature fault is activated when engine temperature is below a pre determined setpoint for a specified time delay This fault is programmable for temperature setpoint level transient time delay settings and other functions An analog DC signal is provided from an engine mounted sender The high engine temperature fault is activated when engine temperature is above a pre determined setpoint for a specified time delay This fault is programmable for the level of temperature setpoint transient time delay settings and other functions An analog DC signal is provided from an engine mounted sender The high engine temperature fault is activated when the engine temperature rises above a pre determined setpoint for a specified time delay This fault is programmable for the level of temperature setpoint transient time delay settings and other functions An analog DC signal is provided from an engine mounted sender The low oil pressure alarm fault is activated when the oil pressure is below a pre determined setpoint for a specified time delay This fault is programmable for pressure setpoint le
117. es the IDLE NOMINAL output closes Binary output IDLE NOMINAL opens during Cooling period again Step 1 s Range 0 600 s Note If the IDLE function not supported on the governor set the Idle time nevertheless to minimum 5s to avoid Underspeed possibly caused by instability of the engine short after start GCB CloseDelay GCB can be closed earliest GCB CloseDelay after Stabil time when all electric values are in overunder voltage and over under frequency limits Step 1 s Range 0 300 s Stabil time Generator Nominal voltage is detected during genset start after starter is switched off and Idle time elapses Electric generator protections are active since detection Step 1 s Range 0 300 5 MinStpValvTime Binary output Stop solenoid closes when stop sequence begins and closes at least for MinStpValvTime Example MinStpValvTime 20 sec When engine stops RPM 0 in 10 seconds Binary output Stop solenoid still stays closed for 10 sec b When engine stops in 30 seconds Binary output Stop solenoid opens 10 seconds after RPM 0 and Vg 0 and Oil pressure 0 Those 10 sec is fix time for safe stop Step 1s Range 0 180 s Note Stop of engine is detected when all following conditions are met RPM 0 Oil pressure lt StartingPOil and Generator voltage 10 Stop fail is detected when is difference between those conditions e g and Generator voltage gt 10V Idle Function Stabil Time
118. ester Meds ea 2 13 Baltery Cables e b Le be die usen Lc dae ERO a GU eoe Se ete ane eae ER aoe 2 13 Section 3 Receiving amp 3 1 Receiving amp Inspection 3 1 MER BUTS RCTS TES OPE 3 1 Physical eI PR ______ 3 1 Secure the GenBralor 5 5 2 0 an odas e TRI e 3 3 Erigine Cooling c eee the ie e QUE aT i is 3 3 Hot Exha sp 6585565 52 00 ope De plc etie n E Rene A RO da 34 ccu 3 6 EUel Connections 2 2 ee unes ne OS HE 3 6 Electrical Connections teatro rhe e LA in ert 3 9 Battery Connections widen te ata UR DE EE Ea UR UE Yok ee 3 12 Recommended Engine Oil and Battery Type 3 13 Post is e Aea ne ade x Ran e C ORG Ue po 3 13 MN2408 Table of Contents i Section 4 Operation choc e e teet e ee te ena
119. et must be run at its proper speed to obtain the correct electrical power at its output All engines have a tendency to slow down when a load is applied to it The engine governor is designed to hold the operating speed as nearly constant as possible When the electrical load is increased the engine is more heavily loaded and engine speed drops slightly This slight decrease in engine speed results in a slight decrease in generator voltage and frequency output This voltage and frequency variation has no appreciable effect in the operation of motors lights and most appliances and tools However timing devices and clocks will not keep perfect time when used on this generator 1 Clean the generator set and remove any and all dust dirt or other foreign material 2 Inspect and clean the cooling air intake and exhaust louvers of the generator end Make sure they are clean Remove dirt or any buildup that may restrict the cooling air flow 3 Clean the generator set and its components with a damp cloth or sponge Never use a water hose or pressure washer as this may damage electrical componenis 4 Inspect and replace any control panel components that are broken or not working properly receptacles circuit breakers switches etc Troubleshooting and Maintenance 5 1 Problems and Solutions Some of the more common problems are listed in Table 5 1 This information is intended to be a check or verification that simple causes can
120. fuels are flammable and can cause fire explosions injury or death Keep generator at least three feet away from buildings and other structures Keep generator away from flammable or hazardous materials trash rags lubricants explosives paints etc and grass or leaf build up Keep a fire extinguisher near the generator while generator is in use An extinguisher rated ABC by the National Fire Protection Association is appropriate Parts of this generator are extremely hot during and after operation To prevent severe burns do not touch any part of the generator until you have first determined if the part is hot Wear protective clothing and after use allow sufficient time for parts to cool before touching any part of the generator Do not touch the hot exhaust parts or the high voltage spark plug or coil terminals of the engine Although spark plug voltages are not normally lethal a sudden involuntary jerk of the hand or body part caused by contact with high voltage or a hot surface can result in injury to yourself or others Engine coolant is under pressure and is near the boiling point of water when engine is hot Do not open the coolant system until the engine has completely cooled Hot coolant can cause severe burns and other injuries When engine is cool coolant level can be checked Continued on next page Product Safety Information 1 3 Warning Statements Continued Installation WARNING WARNING WARNING WARNIN
121. g gear teeth on the engine flywheel The magnetic pick up must be installed to sense the same teeth for speed sensing as programmed Set crank disconnect speed in percentage of nominal speed i e 3096 or 540 RPM on an 1800 RPM engine Set overspeed shutdown point in percentage of nominal speed i e 110 or 1980 RPM an 1800 RPM engine Overspeed Transient Delay Select desired overspeed transient delay time in seconds Time setting may be entered in tenths of seconds Run Output Fail safe MN2408 When enabled factory setting this feature inhibits the run output until the controller receives a speed sensing signal This prevents possible damage caused by starting the engine with no speed sensing for crank disconnect and overspeed If selected ensure that the speed signal is not less than 3 0VAC from the magnetic pick up while the engine is cranking If this feature is disabled no overspeed protection or crank disconnect will be provided if the speed signal fails If you disable this feature Baldor strongly recommends that backup crank disconnect protection and additional overspeed protection is provided Operation 4 25 Main Menu Loop Continued Loss Of Speed Signal Select the desired action i e alarm or shutdown when a loss of speed signal is detected during operation Note A loss of speed signal must be detected for longer than 2 seconds to initiate the desired action Common Fail For Not In Auto Function
122. glasses or goggles and protective clothing 2 Where electrolyte contacts the skin flush the area immediately with water and wash it off using soap and water 3 Where electrolyte contacts the eyes immediately flush the eye thoroughly with water and seek medical attention quickly 4 Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of one pound 500 grams bicarbonate of soda to one gallon four liters of water The bicarbonate solution is to be added until evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried A battery presents a risk of fire because they generate hydrogen gas Hydrogen gas is extremely explosive Never jump start a battery smoke in the area around the battery or cause any spark to occur in the area around the battery The following precautions are to be followed when working on batteries 1 Do not smoke when near batteries 2 Do not cause flame or spark in battery area 3 Discharge static electricity from body before touching batteries by first touching a grounded metal surface Continued on next page Product Safety Information 1 5 Warning Statements Continued Maintenance WARNING WARNING WARNING WARNING WARNING WARNING Before cleaning inspecting repairing or performing any maintenance to the generator set always be sure the engine has stopped and that all
123. gnificantly increases the amount of heat the cooling system must dissipate Marine and Mining Safety Administration MSA codes may require water cooled manifolds in all genset installations If you are in doubt on your particular application consult your Baldor Distributor Exhaust Gas Restriction The maximum allowable back pressure or system restriction is 3 inches of mercury If this back pressure is exceeded the air fuel ratio is reduced due to incomplete scavenging of the cylinders fuel economy and power output is reduced engine life is reduced and exhaust temperatures and smoke levels increase Any restriction of the exhaust gas reduces horsepower Take every precaution to reduce restriction Proper design and installation will provide safe genset operation It is essential that all engine exhaust systems by designed with the least possible restriction to exhaust gas flow This can be calculated through the use of Figure 2 6 or in the case of simple exhaust systems the nomograph in Figure 2 6 may be used MN2408 General Information 2 9 Figure 2 6 Exhaust System Calculations d inches r3 Q cim LxSxQ _ 10000 5184 x 0 S 8000 mm inches Hg Per Foot 1 0 95 E E F 0 05 P kPa L x S x Q x 10 000 kea 0 0027787 x D 70905 6000 inches x 25 4 mm Hg P Backpressure psi kPa psi 0 4912 x inches Hg kPa 0 1333 x mm Hg L Length of pipe ft m NM Q Exhaust ga
124. h 76mm iron pipe sleeves should be placed around the bolts in the foundation to allow for any mislocation of the bolts after the foundation hardens J or L type bolts are recommended for the foundation bolts e After the foundation is cured and the genset is located the sleeves are filled with grout Figure 2 5 shows a typical foundation installation Figure 2 5 Typical Foundation Installation Grout as required to fill voids between sub base and concrete finish 1 max t Bolts size quantity amp localion as required by genset Sub base 12 300mm il TESI See ee a TT i ES Foundation Subsoil 8 200mm of Sand or Gravel Concrete 3000 psi 20 600 kPa Ye 10mm Expansion Joint 8 Sealant Material 9 2 8 General Information MN2408 Exhaust System Exhaust Checklist A Exhaust outlets are not located upwind or near any building air intakes B Flexible piping section is used at engine exhaust outlet C Exhaust piping material is adequate for expected service D Exhaust piping sizing is adequate to prevent back pressure E Exhaust piping components are insulated as necessary to preven
125. h current devices that exceed the 10 resistive rating The run output control logic provides an Energize To Run Signal i e the run contact closes when a run condition is activated For energize to stop control logic refer to the programmable output control function The Crank output contact is a Form A dry contact and is used to control an external crank pilot relay that directly controls the engine starter motor An external crank pilot relay is required to energize the high current starter motor pinion solenoid that exceeds the 10A resistive crank output contact rating The crank output contact closes when a crank condition is activated and the contact will automatically open when crank disconnect speed is obtained and or the generators output AC voltage exceeds 1096 of nominal level The generators output AC voltage is utilized for back up crank disconnect protection should the speed sensor fail Four 4 standard programmable output contacts are provided 1 2 3 and 4 Each programmable output is a Form dry contact that is programmable for any of the following conditions The output relay will energize when a stop signal has been activated The output will remain energized for 10 seconds after the engine has come to a complete stop then de energizes The output relay will energize when the controller s operation mode switch is not in the auto position The output relay will energize when the controller s mode switch is in the auto m
126. has remote testing circuitry When pushed a signal is issued to the remote transfer switch to permit an automatic engine start and load transfer Once initiated the engine will receive a start signal from the transfer switch and upon the generator reaching nominal voltage and frequency levels a load transfer will be initiated The generator set will remain running at load until a different operating mode is selected or the generator set develops an alarm or shutdown fault condition On when the load test of the generator set is active Special Function Switches Silence Horn Silence Press both Exit and Decrement at the same time Voltage Adjust This will silence the audible alarm horn without resetting the fail condition Lamp Test Press both Decrement and Increment at the same time Causes the LED s and LCD display to illuminate for approximately 2 seconds then return to their original status Note The emergency stop LED is not affected by this test Reset Fault Reset Press both Increment and Enter at the same time Resets the controller when in a shutdown mode Note reset after a fault the engine must come to a complete stop and the controller s OFF switch must be pressed Increase or Decrease the Generator output voltage displayed on VOLTAGE meter Operating Procedures engine generator controller is designed to start and stop an engine from either local Manual or remote Automatic modes When
127. he gaseous fuel supply please refer to the pipe chart in Tables 3 5 and 3 6 to be sure you are using piping of significantly large size to deliver the necessary amount of fuel 7 If copper tubing is used it should be or L having a minimum wall thickness of 0 032 inches Black Iron Pipe is recommended but follow building codes for your area The following pamphlets are available from National Fire Protection Association NFPA P O Box 9101 Quincy MA 02269 No 37 Combustion Engines No 54 Gaseous Appliances and piping No 58 Storage and handling LPV MN2408 Example Determining Pipe Size for Natural Gas A generator has a 16Hp engine 60 feet from the supply Determine the supply pipe size for Natural Gas fuel 16 x 10 000 160 000 BTU s per hour for proper operation 160 000 1 096 From Table 3 6 a 60 foot run requires a minimum 1 pipe at full engine load 146 cubic feet per hour Natural Gas Connections The incoming pressure must be 11 inches water column 6 oz pressure Table 3 5 Natural Gas Flow Rate Cubic Feet per Hour per Pipe Length Iron Pipe Size 1 1 3 2 1 5 1174 2386 3704 818 1712 2646 673 1419 2213 587 1241 1924 524 1077 1684 433 962 1501 885 1376 404 827 1289 366 750 1174 337 693 1077 308 635 991 289 596 933 274 558 875 260 524 827 Note Almost all operation problems are related to t
128. he installation techniques used Do Not guess be sure pipe size is adequate for required flow rate 1 Connect the proper size gas pipe at the Inlet Connection to the Fuel Lock Solenoid Connect the Natural Gas pipe line shown in Figure 3 3 using the correct size pipe for the required flow rate and length of pipe Refer to Table 3 5 for pipe size Be certain that all connections are sealed and no leaks are present The installer must ensure that all gas connections comply with all building codes 2 Verify Fuel Supply Pressure Prior to initial operation of generator verify that fuel system pressure is 11 Water Column 6 oz pressure and fuel pipe sizes comply with Table 3 5 3 Proceed to Electrical Connections Figure 3 3 Gas Line Connections Air Cleaner Carburetor External Supply Piping by installer Solenoid Fuel Lock U L requires a second shutoff valve and regulator to be installed in the supply piping to control the gas supply to the generator Inlet Connection Inlet SS N Supply Piping Connection Mounting Bracket Additional Regulator _ Additional Valve 11 14 water column pressure Safety Shutoff Valve MN2408 Receiving amp Installation 3 7 Example Determining Pipe Size LPV A generator has a 16Hp engine 60 feet from the supply Determine the supply pi
129. ible coupling 3 Itis extremely important that you do not allow the hot exhaust gases to re circulate into the engine s cooling air intake 4 Water is one by product of combustion and is present in the exhaust pipes or muffler This water must be kept from draining back into the engine This can be done by slanting the horizontal section of the exhaust system piping downward slightly away from the engine A water trap consisting of a tee extension with a drain cock should also be provided This water trap should be located between the flex coupling and the muffler but as close to the engine as possible on a horizontal section of the exhaust piping 5 It is also recommended that an exhaust rain be used whenever it is possible that rain could get into the system This will help to prevent corrosion and damage to the exhaust system and engine 6 The exhaust system is subject to the engine s vibration and it must therefore be solidly secured to reduce mechanical stress and the potential for breakage 7 engine s exhaust system is the hottest component of the installation and extreme care and considerations must be given to it 3 4 Receiving amp Installation MN2408 WARNING WARNING MN2408 8 Asmuch ofthe exhaust piping as possible should be located near the power ventilation exhaust This will reduce the radiant exhaust heat inside the building 9 Keep all fuel and its associated piping away from all components of the
130. ical arrangement of two gensets in parallel with transfer switches for loads that have different levels of priority A typical multiple genset installation is shown for 110 Level 1 and Level 2 emergency power circuits and a priority control to select the appropriate transfer switch Wattmeters should be installed on each genset so load sharing can be checked The control system should include an automatic paralleling control Paralleling identical gensets is not difficult but paralleling dissimilar sets can cause load sharing problems When designing an installation that includes the paralleling of dissimilar generators contact your nearby Baldor Distributor Transfer Switch Location The transfer switch location is important and key considerations are 1 Locate the transfer switch as close to the emergency load as practical to avoid interruptions of the emergency power system due to natural or man made disasters or to equipment failures Consider several small transfer switches instead of one large one to increase reliability 2 Locate the transfer switch in a clean dry well ventilated location away from excessive heat When the ambient air is above 104 F 40 C fuses and circuit breakers must be derated Allow adequate working space around the transfer switch 3 circuit breaker or fuses should be installed in the line between the generator and the transfer switch Baldor Gensets are available with properly sized circuit brea
131. il Pressure Sender p n 003654 Thompson p n Manufacturer Datcon p n 102227 Datcon Sender must be used with MEC software version 1 81 or greater previous software versions cannot be used MN2408 Operation 4 29 Figure 4 16 Configuration Data Sheet WORK ORDER REV REV DATE INITIATED BY CUSTOMER DEFAULT PROGRAM DATE PROJECT NAME TPS VER ENGINE GEN SYSTEM INPUTS SYSTEM AC VOLTS PHASES FREQUENCY DC VOLTAGE DIGITAL DISPLAY FEATURES LI AC VOLTAGE Li AC CURRENT BATTERY VOLTAGE 6 ENGINE TEMPERATURE PRESSURE FREQUENCY HOURMETER DIGITAL FAULT CIRCUITS 15 ANALOG FAULT CIRCUITS FAULT NAME INPUT NAME FAULT NAME INPUT NAME 771 Gs 0 5 STANDARD OUTPUT CONTACTS OUTPUT NAME OUTPUT TYPE PROGRAMMABLE CONTACTS OUTPUT NAME OUTPUT TYPE ATS Test Std Default or Custom Programmable 1 Form C Common Alarm Std Default or Custom Programmable 2 Form C Common Shutdown Std Default or Custom Programmable 3 Form C Engine Running Std Default or Custom Programmable 4 Form C EPS Supplying Load Engine Running Std Default or Custom Programmable 5 Form A B 110 MEC 2 Exp Group 1 Only Disabled Std Default or Custom Programmable 6 Form A B EAP 110 2 Exp Group 2 Only 4 30 Operation MN2408
132. in three phases connection Step 1 kW Range 1 3000 kW Nomin power 1ph Nominal power of the generator in single phase connection Step 1 kW Range 1 3000 kW CT Ratio Gen set phases current transformers ratio Step 1 A Range 1 5000A 5A PT ratio Gen set potential transformers ratio Step 0 1 V V Range 0 1 500 0 V V Nominal freq Nominal generator frequency usually 50 or 60 Hz Step 1Hz Range 45 65 Hz Gear teeth Number of teeth on the engine gear for the pick up Set to zero if no pick up is used Engine speed is counted from the generator frequency Step 1 Range 0 500 Note Generator frequency can be used only when generator voltage min 5V is present before reaching of the firing speed Starting RPM after start Nominal RPM Nominal engine speed Step 1RPM Range 100 4000 RPM FLTRESGOTOMAN DISABLED Controller stays in AUT mode after Fault reset ENABLED Automatic switch from AUT or TEST to MAN mode after Fault reset to avoid automatic engine start This function is active for Shut down protection only DispBackLightTO Timeout after which the display backlight is switched off Step 1 min Range 0 60 min Default value 0 the display lights all the time Mode IL OFF MAN AUT Equivalent to Controller mode changes by or buttons Note Controller Mode change can be separately password protected RS232 mode Communication protocol switch S
133. ing iiu mira RR FERRE RAE 2 3 ROOM Size A a Pet Fede ice dont Partt abe UNE e E SCA 2 3 Room Location tae me ett Se eec Ee Bede tta ee FD a Rea Cade ode iex 2 4 Foundation IEEE e S EVER e 2 5 Exhaust System euer ED A E LN 2 9 dd Roe cde te ecd redet t 2 9 System Placement SEE M 2 9 Multi Engine Installations 2 2 9 ExhaustManifold evt dave ue Ia pst e 2 9 Exhaust Gas Restriction sce ctr a Naw date inde da ced Lr c 2 9 Exhaust Pipini s see acti ru RUM E dre wae ee NU eee E dh 2 10 RE 2 10 Transfer D esee b p dtr 2 11 Battery Starting System 2 12 Battery Locatiofi iE RI ec QUEE MAU I Edge E Rd 2 12 Battery p KL Vaden Ral eee ae Dagens ede 2 12 Battery Charger 2 E
134. ion Often a separate building located on the site away from the main building is the most simple and cost effective Major considerations when housing the genset in a separate building are 2 4 General Information Maintain the building at a satisfactory temperature year round to meet applicable codes Assure the genset is not located so far from the emergency loads that reliability is compromised The floor s load carrying capacity must be checked and must exceed the weight of the genset and its associated equipment Engine Cooling System A genset with an engine mounted radiator is the least costly to install however the room must be located in a place where sufficient radiator cooling air can be brought into and exhausted from the room Exhaust System The exhaust system must minimize exhaust restriction Exhaust restriction must be limited to 3 in Hg 76 mm Hg maximum to ensure proper engine operation The exhaust system should be as short and have as few bends as possible Room Air If the genset is cooled with an engine mounted radiator and sufficient air is brought into and exhausted from the room to satisfy the radiator cooling requirements and the combustion air requirements the room will not overheat when the genset is running If a remote mounted radiator or a heat exchanger is used and adequate air is circulated through the room to keep it at a reasonable temperature there will be adequate air for combustion Fuel
135. ion Sheet The wet weight includes the fluids coolant and oil Figure 2 2 can be used to design the foundation except in critical situations Figure 2 2 Approximate Weight vs kW Output 28000 12701 26000 11794 24000 HERD 10886 EET 22000 9979 H 5 20000 1 Hd 9072 50 Hz 18000 8165 16000 m 7258 H mi 14000 6350 12000 5443 10000 4536 8000 3629 L 6000 2722 4000 Li 1814 2000 907 1 4 Approx Genset Wet Weight with Accessories Ibs kgs 0 200 400 600 800 1000 1200 1400 kW Output 2 6 General Information MN2408 Designing An Isolated Foundation If the genset cannot be mounted directly on a floor slab or if it is desirable to isolate it from the floor slab then a separate foundation slab must be designed A massive concrete foundation is not required Outside dimensions of the foundation should exceed the outside genset dimensions by 12in 300mm For single genset installation the foundation weight should be a minimum of 1 50 times the genset wet weight For multiple genset installation the foundation weight should
136. is completely assembled tested and adjusted at the factory before it is shipped to you The procedures presented in this manual are suggestions and it is the responsibility of the Owner Operator to arrange for these procedures to be performed by licensed contractors according to all applicable codes including local codes for your Municipality City County and State External connections required at the time of installation are 1 Fuel System 2 Electrical Connections power wiring optional transfer switch and control wiring 3 Battery not included 4 Ground Connection After installation the post installation checks must be performed prior to starting the engine After these checks have been performed and the system operation is verified to be good refer to Section 5 Maintenance for periodic checks that must be performed at scheduled intervals to ensure continued operation with minimal problems Fuel Connections Fuel selection is Natural Gas or LPV Liquid Propane Vapor If natural gas supply is used follow the Natural Gas Connections procedure If LPV supply is used follow the LP Vapor Connections procedure Table 3 4 defines the flow rate required for each fuel type Table 3 4 Fuel Consumption Natural and LPV Model Fuel Consumption at 100 6 load Model Fuel Consumption at 100 load cubic ft Hr cubic m Hr cubic ft Hr cubic m Hr Natural Gas LP Vapor Natural Gas LP Vapor GLC10 34
137. is plentiful Exhaust gases contain carbon monoxide a colorless odorless and extremely dangerous gas that can cause unconsciousness or death Symptoms of carbon monoxide poisoning include dizziness nausea headaches sleepiness vomiting or incoherence If you or anyone else experiences these symptoms get out into fresh air immediately Stop the engine and do not restart the engine until it has been inspected and if necessary repaired or reinstalled in a well ventilated area Hot exhaust gasses must never be directed toward anything that may catch fire or explode This generator must not be used on or near any forest covered brush covered or grass covered land unless the engine s exhaust system is equipped with a spark arrestor The spark arrestor must be maintained in effective working order by the operator Some parts of this generator rotate during operation Rotating parts can present extreme danger if clothing or body extremities are caught by the rotating part and can cause serious or fatal injury Never touch a part of the generator until the engine has been stopped and all rotating parts are completely stopped Also disconnect the spark plug wires and battery connection to prevent accidental engine rotation during servicing Never move a generator set that is running Loads should be connected and position secure before starting the engine Hazards are caused by moving a generator set that is running Continued on next page 1 2 Prod
138. it to be set for Open to Fail or Close to Fail sensing contacts Bypass On Start Delay Allows the alarm or shutdown fault to be disabled until after the bypass timer has expired Faults that are not delayed are enabled at all times i e engine running or stopped Transient Delay Times Allows the selected fault to be disabled until the delay period has expired Delay times 0 0 to 999 9 seconds Idle Control Digital Input Programming When a digital input is set to Idle function these settings must be programmed to ensure correct operation Action Alarm Alarm Latch No Polarity Close Bypass On Start No Transient Time 0 1 Note The corresponding digital output must also be programmed for IDLE to enable correct operation No Load Test Control Digital Input Programming The No Load Test digital input feature is typically used in an AMF application where it is required to do an automatic timed No Load Test of the engine generator set A contact from an external exercise clock timer is required to be connected to the digital input circuit which is programmed for No Load Test When a digital input is programmed as Load Test these settings must be programmed to ensure correct operation Action Alarm Alarm Latch No Polarity Close Or Open dependent on external circuit used Bypass On Start No Transient Time 0 1 Calibration Menu Loop AC Voltage AC current and battery voltage analog circuits are factory calibrated and should not req
139. itch connections Verify with a voltmeter Verify that the engine starting battery is disconnected so accidental starting is not possible Verify that the generator is securely mounted and anchored to its cement pad Verify that proper clearance exists on all sides and top of enclosure Verify that generator power is properly connected to the transfer switch Verify that generator and transfer switch are properly grounded Assure that generator is a safe distance from any flammable or combustible material Verify that the generator and transfer switch load are voltage compatible O Verify that no load is connected to the circuit breaker and or transfer switch 1 Inspect the engine and generator and verify that there are no loose wires or components Tighten if necessary 2 Verify that the ground conductor is of correct wire size and properly connected 3 Verify engine oil level is full Refer to engine manual if necessary 4 Verify engine coolant level is full Refer to engine manual if necessary 5 Verify exhaust system to assure it is in properly connected and pointing away from combustible materials 6 Verify that the Master Control Switch is still in the Stop position Connect the engine starting battery to the starter Verify it is installed correctly 7 the fuel source 15 ON and the pressure and flow rate are correct 8 Remove all tools rags etc from inside the generator enclosure Close all enclosure doo
140. ituation which if not avoided could result in injury or death Indicates a potentially hazardous situation which if not avoided could result in damage to property Additional information that is not critical to the installation or operation IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for the generator that should be followed during installation operation and maintenance of the generator and battery batteries For ease of reading the Warning statements are divided into four categories Operation Burn Installation and Maintenance Operation WARNING WARNING WARNING WARNING WARNING WARNING WARNING Never operate this generator in a manner other than as described in this manual Operation in any manner not described in this manual should be considered unsafe and should not be attempted Never start the engine unless you have first verified that the installation and operation of the generator are as described in this manual Be sure that you are completely familiar with the safe operation of this equipment This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment Improper use can cause serious or fatal injury Exhaust fumes gases are extremely dangerous and can cause severe illness or death Never breath exhaust fumes produced by a running engine Only run the engine outdoors where ventilation
141. ker built into the generator control through 1200 amp breakers The circuit breaker can be separately mounted In the case of very large circuit breakers a separate floor mounted circuit breaker is easier to wire up than a wall mounted breaker 4 Install power and control wires in separate solid conduit with flexible sections at the genset The flexible sections prevent vibration from damaging the conduit All power conduits from the genset must contain all three phases 5 Never install control wires in the same conduit as power conductors MN2408 General Information 2 11 6 Conduit wire circuit protective device sizes insulation etc must conform to applicable local and national codes and regulations 7 certain to seal around conduits that penetrate the walls of the genset room to reduce the amount of noise that is transmitted to the surrounding areas of the building and maintain site fire code rating Battery Starting System This section describes the battery starting system nominal 12 volt rating of the battery supply for the engine battery charger and precautions to take if the ambient temperature is expected to be below 70 F 20 C WARNING If batteries are not mounted in the battery rack supplied with the genset protect batteries from vibration and do not locate them near a source of flame or spark A battery presents a risk of fire and explosion because they generate hydrogen gas Hydrogen gas is extremely e
142. l energize when the engine RUN i e FUEL energizes prior to the engine starting The output will remain on until the engine has reached a stop or shutdown command The output relay will energize when the engine s speed exceeds the overspeed setpoint level The output will remain energized until the engine s speed drops below the low speed setpoint typically 5 of rated speed Note An external pilot relay is required if the main air flap solenoid current rating exceeds the contact rating This feature is only operative if the remote transfer switch is interconnected with remote testing capability The output relay will energize when a load test operating mode is selected by the Load Test keypad push button After initiated the engine will receive a start signal from the transfer switch and when the generator reaches nominal voltage and frequency levels a load transfer will be initiated The generator set will remain running on load until a different operating mode is selected or the generator set develops an alarm or shutdown condition Note 1 When the Utility Ready to Load and Generator Ready to Load outputs are programmed the Load Test programmable output is not required as the engine starting logic is internally initiated Note 2 When both Utility Ready to Load and Generator Ready to Load outputs are programmed for an AMF control configuration the ATS Output is not used i e engine start signal
143. limits a Warm Up timer is initiated 4 After the Warm Up timer expires the Utility Ready to Load output de energizes and the Neutral Delay timer is initiated 5 After the Neutral Timer expires the Gen Ready To Load output energizes to signal the transfer switch to transfer to the generator supply Note If a generator shutdown occurs during a Load Test Operation the Load Test mode will be de activated When Auto Mode is restored after Load Test Operation the following occurs 1 Simulated Remote Start input signal is removed 2 Gen Ready To Load output de energizes and Neutral Delay timer is initiated 3 After the Neutral Delay timer expires The Utility Ready To Load output energizes to signal the transfer switch to transfer to the utility supply 4 The generator Cool down timer starts timing following the transfer to the utility supply 5 The generator stops after the Cool down timer MN2408 Standard Faults Internal Faults Overspeed Shutdown Loss of Speed Alarm Shutdown Overcrank Shutdown Switch not in AUTO Digital Input Faults Digital Inputs N O or N C MN2408 No Load Test To allow a timed No Load Test of the engine generator set while using the AMF control application a digital input contact from an external timer must be programmed for NO LOAD Test The sequence of operation for a No Load Test condition is as follows 1 With the utility supply normal and the generator stopped a no load test seq
144. me delay and re engages it again This process will repeat until a speed signal is sensed or cranking time expires whichever occurs first If a speed signal is sensed cranking continues until the engine starts or an overcrank condition occurs Set time in seconds as desired i e a setting of 5 seconds will attempt cranking for 5 seconds after which time if no speed signal is detected the crank output will be removed for a preset 1 second delay before re engaging Note This action is more than a cycle cranking function and is independent of the number of attempts selected Therefore the crank time should be considered To disable this feature set to zero Set to the number of cranking cycles required Zero will default to one This setting is the time period that Alarm or Shutdown faults will be ignored after crank disconnect allowing the engine to settle into its normal operating mode i e proper oil pressure etc Typically 10 seconds Set to desired cool down time in seconds Up to 9999 seconds of cool down time may be programmed Set to zero if not required Vote If the controller is used in an AMF application it is recommended to set the cool down timer to a minimum of 10 seconds to allow the generator to transfer Off Load before enabling the cool down time Ensures the load is transferred off of generator prior to stopping the engine Set to the nominal engine speed in revolutions per minute RPM Set to the number of rin
145. me in seconds The Neutral Delay timer is typically set for 3 seconds The Neutral Delay feature is only effective when an electrically held contactor type transfer switch is connected Contact Baldor for further application information on use with other types of transfer switch mechanisms The Return Delay menu appears when the Utility Ready To Load output is selected typically for AMF application The Return Delay is initiated when the remote start signal is removed signaling utility power is available After the Return Delay timer expires the Generator Ready To Load output is removed and the Utility Ready To Load output energizes to signal transfer the load back to the utility supply The purpose of the Return Delay timer is to ensure that the utility power has returned to a steady state for the selected time period before the load is transferred back to the utility supply The Return Delay timer is typically set for 120 seconds Caution The Programmable Output Contacts selection must agree with the external control wiring prior to energizing the controller Failure to do so may cause severe equipment damage Programmable Output Contacts Select the desired function that will activate the programmable relay output contact Reset Run Hours One of the following functions may be selected Energize To Stop Gen Ready To Load Air Eps Supplying Load Utility Ready To Load Oil Bypass Timer Complete Common Fail Digital Faults 1 104 Switch
146. mmodate dynamic loads e The actual mounting arrangement ie surface area in contact with the floor will determine the compressive strength required genset should be securely fastened to the floor slab with expansion anchors that fit the mounting holes shown on the genset installation diagram For installations not expected to be permanent elastomer pad with non slip surface placed between the base and the floor will also prevent movement e floor slab surface should be as flat as possible to prevent sub base deflection Vibration Isolators e Mounting to the pad will result in overall reduced motion on other parts of the genset The trade off is that slightly more vibration is transmitted to the structure common practice when mounting to a concrete pad is to use vibration isolators The two most common types of vibration isolators are steel spring and elastomer pad The primary purpose of vibration isolators is to reduce the noise and vibration which would be transmitted from the genset to the foundation or supporting structure e A simple and effective method of mounting and applying pad type isolators is to place non skidding type isolation pads directly between the sub base and floor The number of pads required will be determined by the load bearing capability of the pads and the genset s weight Figure 2 1 Typical Installation of Spring Type Isolator Genset Sub base Spring Type isolator
147. n of a generator to any electrical circuit normally powered by means of an electric utility must be connected by means of approved transfer switch equipment to isolate the electrical circuit from the utility distribution system when the generator is operating Failure to isolate the electrical circuits by such means may result in injury or death to utility power workers due to backfeed of electrical energy onto the utility lines Incorrect installation of this generator set could result in property damage injury or death Connection of the generator to its fuel source must be done by a qualified professional technician or contractor Be sure the system is properly grounded before applying power Do not apply AC power before you ensure that grounds are connected Electrical shock can cause serious or fatal injury NEC requires that the frame and exposed conductive surfaces metal parts be connected to an approved earth ground Local codes may also require proper grounding of generator systems Intended Use The intended purpose of this generator set is to provide emergency power when the main utility power supply is interrupted Therefore it is important that all the wiring that connects the generator set with your house transfer switch distribution box battery charger etc be properly installed Circuit Protection Circuit protection is not provided within the generator Circuit Breaker protection is an option Wire Size If purchased with your
148. ngine temperature or oil pressure displays 9999 OR Engine alarms are ON for high engine temperature or low oil pressure when engine is operating properly Sending unit is disconnected open circuit Defective sending unit Wrong Temp or pressure calibration Verify the sending units wiring to controller terminals 37 amp 38 i e wiring is not open or shorted Verify the engine mounted senders have correct resistance values for corresponding input temperature or pressure Verify calibration Keypad Buttons switches do not operate MN2408 Keypad not connected to controller Verify the interconnecting ribbon cable between the lexan faceplate and main printed circuit board is correctly connected Replace controller if failed Troubleshooting and Maintenance 5 3 Note See Engine Controller manual for additional information Table 5 3 Troubleshooting Guide Analog Controller Only Problem Possible Cause Remedy Controller cannot be Reset Engine not stopped Verify the engine is at a complete stop before trying to reset Controller not in OFF mode Set the controller to the OFF mode before trying to reset Engine alarms are ON for high engine Sending unit is disconnected open Verify the sending units wiring to controller terminals is not open or temperature or low oil pressure when circuit shorted engine is operating properly Defective sending unit Verify the engine mounted senders have correct resistance values
149. ns to adjust the correction factor number while observing the displayed current level Adjust the correction factor until 0 amps is displayed With the correct current displayed press the ENTER push button to accept the correction factor number Record the correction factor number on the programming sheet for future reference Repeat for each phase Span Calibration Apply 50 100 load to the generator set It is recommended to load the generator set to 100 rated load for calibration purposes to obtain good accuracy throughout the full span of operation Do not exceed the current rating of the CT Non linear output of the CT will result when the secondary current exceeds 5 amps and will similarly effect the displayed values In the programming mode scroll to the desired generator supply current phases with the SPAN function selected Connect an external AC ammeter and current clamp of adequate current range to the controller terminals associated with the current phases to be calibrated Use the INCREMENT or DECREMENT push buttons to adjust the correction factor number while observing the displayed current value Adjust the correction factor number to obtain an identical current reading as measured with the external AC ammeter With the correct current displayed press the ENTER push button to accept the correction factor number Record the correction factor number on the programming sheet for future reference Repeat for each phase Note When the
150. ode and no shutdown or alarm conditions are present The output relay will energize during the start delay timer period and cranking period until the engine starts and reaches crank disconnect speed The preheat output is typically used for an engine starting aid such as glow plugs Note An external pilot relay is required to switch the high current glow plug load The output relay will energize when the generators output voltage and frequency exceeds predetermined setpoints e g voltage 90 nominal frequency 95 nominal as user programmed and a warm up time delay period expires After the output has energized it will remain on regardless of voltage frequency levels until the controller either has a stop shutdown signal or the engine s speed drops below crank disconnect level The voltage frequency and time delay levels are programmable This output is typically used in an Auto Mains Failure AMF application The output relay will energize when the remote start input has not been activated i e contact on terminals 16 amp 17 not closed and the Return Delay amp Neutral Delays have expired if programmed The output will de energize when the remote start input has been activated and the Engine Start Delay amp Warm Up Delays have expired if programmed This output is typically used for Auto Mains Failure AMF applications The output relay will energize when the engine has started and has reached crank disconnect speed The output relay wil
151. of the building or compartment in the open air Keep the thermometer out of direct sunlight or any other heat sources 3 Run the engine under maximum load for an extended period of time at least one hour 4 temperature difference between the two should not exceed 15 degrees F Note that opening any door window or other opening can upset the air flow pattern and result in a significant reduction in the cooling air flow across the generator set This may result in overheating fire or explosion Receiving amp Installation 3 3 Hot Exhaust Gasses WARNING Exhaust fumes gases are extremely dangerous and can cause severe illness or death Never breath exhaust fumes produced by a running engine Only run the engine outdoors where ventilation is plentiful Exhaust gases contain carbon monoxide a colorless odorless and extremely dangerous gas that can cause unconsciousness or death Symptoms of carbon monoxide poisoning include dizziness nausea headaches sleepiness vomiting or incoherence If you or anyone else experiences these symptoms get out into fresh air immediately Stop the engine and do not restart the engine until it has been inspected and if necessary repaired or reinstalled in a well ventilated area WARNING Hot exhaust gasses must never be directed toward anything that may catch fire or explode It is extremely important to discharge engine exhaust gasses away from the engine and out of the building If these gasses
152. omatic Fault Shutdown When a fault circuit is programmed as a SHUTDOWN the engine will immediately stop when the fault is activated specific shutdown fault can be programmed with a definite time transient delay period that must expire before the shutdown is activated The stop sequence will cause the controllers RUN output to be immediately terminated which will cause the engine to stop This will prevent subsequent operation of the generator set The Run Stop Auto selector switch on the operator control panel must be momentarily placed in the Stop position to reset the fault Automatic Mains Failure AMF Figure 4 14 Auto Mains Failure AMF Connections UTILITY MAINS NV o __ _ __ __ __ __ __ __ __ 22013807 2 0 V wo l Transfer UTILITY MAINS Switch MAINS CONTROL FAILURE FUSES 5 V RELAY 16 eu 5 U U O PROGRAMMABLE LLL OUTPUT 3 Y OU G AUX b UTILITY MAINS N57 36 A CONTACTOR W a Y id MANUAL OVERRIDE w LOAD SWITCH OPTIONAL N NENNEN Vy GRTL 20 0 lt 4 lt 0 ig PROGRAMMABLE zi GENERATOR OUTPUT 4 U AUX b CONTACTOR Y E VAO VBO VCO O y GENERATOR SUPPLY CONTROL FUSES 5A N Ww NOTES 220 380V N CONTACTS RATED 10A 240VAC RESISTIVE 57 MAINS FAILURE CONTACT CLOSES WHEN VOLTAGE DROPS BELOW SETPOINT PROG
153. onpoo oois ud eui jou seop 3 uon2euuo2 api oJd pup uo pesoq 401D49u85 55 9 641 94A 9 N QO313TivHVd 53 Z NI 53 31003 ueo eun 0 O0 4oip nbes 576101110016 8 49 S 1 310N 0000 9 Series GLC B 5 MN2408 Figure B 15 Single Phase Two Breaker Connection Diagram 49 5 z 3SVHd L WVMOVIQ NNOO N39 219 CPVDODONESSISH 2 YAL 002 90 01 61 66 71 35 38 YLT 38 9 OINLOHJTA NWOGCIVH 0 8 2 136034 834 2530 AJY oro 0 N3MISDOL 7 S3NIM 31105 du unus pedinbe jou s pun D j euj au Ul peanoes 0 0 dui yunus jpuondo saaxypauq di junus UMOS sy LZEXS ZvXS S oip nba
154. ousing unit located in front of the engine radiator Figure A 10 Generator Lifting Silencer Enclosure O y v X Weather Proof Enclosure Li Sound Attenuated Enclosure GLC10 25 H1 36 0 GLC10 25 L1 11 75 GLC30 45 H1 52 1 H2 66 6 GLC30 45 L1 30 H2 52 0 GLC60 90 H1 64 2 2 76 8 GLC60 90 L1 30 H2 64 2 GLC100 105 H1 64 2 2 87 6 GLC100 105 L1 30 H2 64 2 MN2408 Options amp Accessories A 9 10 Series GLC MN2408 Appendix Series GLC Information amp Wiring Diagrams GLC Circuit Breaker amp Electrical Data Circuit Breaker Size Qty per Phase Min Wire Gauge OSH Plant Ampacity 0125C 5 90 20 TR EPDMIPERPHASE 90 30 90 40 90 50 90 60 1 m r mePPRSE 0 70 1 90 80 90 90 tS EPDWIPER PHASE 1 700 1 C 6EPWPERPHRE _ 1 40 1 6 C6EPWPERPHRE _______5 105 Eripe c coo AREE ARS 150 1 4 EPDM PER PHASE 170 175 265 200 rrr 265 225 1 1 1 265 250 a roar 35 300 1 460 EPDM PER PHASE 355 350 40 400 PT RI EPDWIPER PASE 250 2 0 ID EPDM PER PHASE 670 500 P02 EPOM PER PRASE 60 500 2 3 PDM PER PFA 770 700 POM PER PFA 520 500 a 7 HSEPDTPERPHRSE om 500 20 S
155. pe size for Natural Gas fuel LP Vapor Connections vapor withdrawal only 16 x 10 000 160 000 BTU s per hour for proper operation 160 000 2 516 From Table 3 6 a 60 foot run requires a minimum 1 pipe at full engine load 63 5 cubic feet per hour The LPV connections should only be made if your generator is setup to run on LPV If it is setup to run on Natural Gas contact your Baldor representative and do not continue with installation The incoming pressure must be 11 inches water column 6 oz pressure Table 3 6 LP Vapor Flow Rate Cubic Feet per Hour per Pipe Length Pipe Iron Pipe Size pron 1 5 3 4 1 1 1 4 1 1 3 2 2 1 3 3 4 6 8 15 48 109 218 475 772 1570 2437 4115 8786 24497 50007 30 33 76 153 339 538 1127 1741 2975 6140 17325 35353 45 27 63 126 275 443 934 1456 2469 5001 14781 28865 60 24 54 110 241 386 817 1266 2184 4304 12236 25004 75 49 98 218 345 709 1108 1899 3798 10957 22345 90 44 89 196 310 633 987 1709 3482 10001 20414 105 41 83 180 285 582 905 1551 3228 9254 18895 120 76 171 266 544 848 1456 3038 8659 17673 150 69 153 241 494 772 1323 2754 7748 15825 180 63 142 222 456 709 1234 2532 7064 14432 210 58 130 202 418 652 1127 2342 6439 13356 240 120 190 393 614 1063 2209 6077 12405 270 113 180 367 576 1000 2057 5697 11780 300 108 171 345 544 943 1899 5381 11179 3 8 Receiving amp Installation Note Almos
156. peration of this equipment 5 It is the responsibility of the owner operator of this generator to ensure that it is properly maintained and safety inspected at regular scheduled intervals 6 Itis the responsibility of the owner operator of this generator to ensure that any person who has not been trained on the safe use of this equipment does not have access to this equipment Read This Manual Thoroughly MN2408 If you do not understand any concept any procedure any safety warning statement any safety caution statement or any portion of this manual contact Baldor or your nearest authorized Baldor representative We are happy to make sure you understand the information in this manual so that you can safely enjoy the full use of this generator Product Safety Information 1 1 Symbols This symbol is shown throughout the manual to indicate a connection to ground reference point IN Indicates a potentially hazardous situation which if not avoided could result in injury or death Indicates a potentially hazardous situation which if not avoided could result in injury or death Precaution Statements Used In This Manual WARNING Caution Note There are three classifications of precautionary statements used in this manual The most critical is a WARNING statement then the Caution statement and the least critical is the Note statement The usage of each statement is as follows Indicates a potentially hazardous s
157. pesoq poe JoyoJeues pajou sse un dIX 256 9JIM IN ALON uag aury 3AV33 SISSVHO MOIVJ3N39 AYAI v a ZH 2 e y 9 A AN ILOL 6 8 9 v xog 5 g 3 i 4 Boman P 06 09 69V0000M9 MN2408 B 8 Series GLC 35 319 5 80 NOILO3NNOO 3OLVH3N39 279 6LVOD00MO ue D 00562 lt 01 0 8 038 3H 8 417 A34 0 OITWLOJTM SOGIVG 20530 79 SSIGNNG TWOLLNAG 31dlL INW SY a3sn Suv S3MIM FIdILINW 3l H3H13901 SIYM 31708 dayoasg du junus pedinbe you s jun D y jo DY D vgQ 0 dui junus puodo eun sjexybejq di JUNYS uwous sy LZEXS LZvXS siojojnDa 5 9 uid aboman eu uo eq jou eBoweu 9 ejdnjnu eumbe suogmalddo OMY 1edcud 2009 1009 0 710002 71001 Seam 40 ouo W43 995 jo skyd jomjoo y jou sop i epioJd uwous suona uueo ebbyoA
158. pplied Possible Cause Wiring Mistake Overload Condition Remedy Check that there are no wiring errors short circuits connected to the controller The MEC 20 contains an electronic fuse that trips when an overload condition exists and does not reset until the supply voltage is removed and reapplied after the overload condition is corrected LCD Display cannot be viewed Microprocessor failure Improper Supply Voltage Improper contrast adjustment Check that the controller s microprocessor is running by observing a red flashing watchdog LED on the rear of the PCB Replace controller if failed Check DC supply voltage at terminals amp B 10 30VDC ani LCD contrast potentiometer R115 on rear of PCB for best isplay Controller cannot be Reset Engine not stopped Controller not in OFF mode Verify the engine is at a complete stop before trying to reset Set the controller to the OFF mode before trying to reset No RUN output signal Shutdown Faults not reset Engine speed not detected at cranking Run Contact not closing terminals 18 amp 19 All shutdown faults must reset red shutdown LED must be off Engine speed signal must be detected speed signal green LED on during cranking if the run output fail safe feature is enabled Verify correct magnetic pickup signal at cranking 2 0VAC min during cranking Check that the RUN output LED on the rear of the PCB is on If yes ve
159. rd Rock Granite etc 50 000 200 000 2 395 9 576 Medium Rock Shale etc 20 000 30 000 958 1 436 Hardpan 16 000 20 000 766 958 Soft Rock 10 000 20 000 479 958 Compacted Sand and Gravel 10 000 12 000 479 575 Hard Clay 8 000 10 000 383 479 Gravel and Coarse Sand 8 000 10 000 383 479 Loose Medium and Coarse Sand 8 000 10 000 383 479 Compacted Fine Sand 6 000 8 000 287 383 Medium Clay 4 000 8 000 192 383 Loose Fine Sand 2 000 4 000 96 192 Soft Clay 2 000 96 Table 2 1 shows approximate load bearing capacities for various types of soil if the actual load bearing capacity of the soil under the foundation is not known Caution Check the local building codes for load bearing capacity requirements Caution If the soil is subject to freezing and thawing the foundation must be extended below the frost line Check the local building codes Reinforce the foundation with No 8 gauge steel wire mesh placed horizontally on 6in 150mm centers As an alternative use No 6 re bars on 12in 300mm centers horizontally Minimum cover over the bars should be 3in 76mm e Suggested concrete mixture by volume is 1 part cement 2 parts sand and 3 parts aggregate Maximum slump of 4in 100mm and a 28 day compressive strength of 3000 psi 20 600 kPa e size of the bolts holding the sub base to the foundation should be sized to fit the mounting holes shown on the Installation Diagram e Three inc
160. re 8 Intelilite Remote Annunciator AB X CANADDRESS JUMPERS AS Goma e DC power 4 supply CAN bus Connection 200m Maximum Only one 1208 resistor can be connected to the CAN bus If it is the last device on the network termination MN2408 Options amp Accessories A 7 Radiator Duct Flange A 8 Series GLC Optional Radiator Duct Flange Top View Frame Frame Figure A 9 C Optional Radiator Duct Flange Radiator Fan Assembly Frame Side View Table A 1 Mounting Dimensions GLC10 25 GLC30 60 GLC80 100 Radiator Fan Assembly Radiator Duct Flange for Open Skid Mount Provides easy connection to air ducting to carry away hot air from engine radiator Duct flange mounts to front of engine radiator Add 3 to length MN2408 Enclosures Weather Resistant Enclosure Heavy duty 12 gauge hot rolled steel with welded corners and baked powder coat finish Fasteners are zinc chromate plated and the locking latches are chrome plated on the lift off access doors Silencer is mounted on top of reinforced pitched roof Sound Attenuated Enclosure Heavy duty 12 gauge hot rolled steel with welded corners and baked powder coat finish includes sound deadening insulation for 15 dB of attenuation Fasteners are zinc chromate plated and the locking latches are chrome plated on the lift off access doors Silencer is internally mounted in end h
161. red as protection Table 4 11 Binary Inputs Alarm Alarm type Warning or Alarm active All the time or Engine running only Rem start stop External request for engine run AUT mode only Emergency stop If the input is opened shut down is immediately activated Input is inverted normally closed Rem start stop External request for engine run AUT mode only Table 4 12 Binary outputs tarter relay output The closed relay energizes the starter motor The relay opens if The firing speed is reached or Maximum time of cranking is exceeded or Request to stop occurs Fuel solenoid relay output Closed output opens the fuel solenoid and enables the engine start The output opens if Emergency stop occurs or Cooled gen set is stopped or In pause between repeated starts Prestart Output is closed prior to the engine start Prestart and opens when START RPM speed is reached During repeated crank attempts the output is closed too The output could be used for pre glow pre heat or prelubrication Common Sd MN2408 Output closes when any shut down alarm appears The output opens if alarm is not active and FAULT RESET is pressed Used for shunt trip Operation 4 5 Analog Inputs Set points 4 6 Operation Three analog inputs for resistive sensor 0 to 2400 ohms measuring are available on IL controller Use LiteEdit software to modify configuration The An
162. remain in the cylinder poor performance or eventual engine damage may result This condition results from excessive back pressure which could be caused by any one or a combination of the following conditions 1 Exhaust pipe too long or the diameter is too small 2 Excessive number of sharp bends in the exhaust system 3 Obstruction in the exhaust system Backpressure must not exceed 20 of water column The direction of the discharged hot air and hot exhaust gases is important as they have the potential to create brown spots on the lawn or adjacent structures In extreme cases this extremely hot air could cause dried grass or other debris to ignite Exhaust lines should be as short and straight as possible Long pipe lengths and elbows tend to resist the flow of gases and accumulate carbon deposits Each pipe fitting and elbow will further restrict the exhaust flow Guidelines for Exhaust System 1 Ifyou are using a remote muffler it should be mounted as close to the engine as possible since it will clog with carbon if it s operating temperature is too low 2 Ifyou are using a remote muffler a flexible coupling of 12 or more must be installed between the exhaust line and the manifold to absorb the engine s vibration However a short solid section of pipe between 6 and 8 long should be placed between the connection of the manifold and the flexible coupling This nipple will reduce the possibility of the hot gases burning up the flex
163. res for the terrain to avoid becoming stuck or tipping over If the shipping pallet is intact use a fork lift to move the generator If the shipping pallet has been removed use two steel pipes through the Lift Point holes to lift the generator See Figure 3 1 Figure 3 1 Generator Lifting To lift the generator always use spreader bars chains eyehooks and other hardware that is of sufficient strength to lift at least three times the Lift weight of the generator Point NSNNSNSNNSNNSNSNSNNNSNNNNSNSNSNNNSSNNSSNSSSSNSSSSS SS 277777777777777777777777777777777777777777777747 AAA 4 Width Lift Point Physical Location The mounting location of the system is important It should be installed in an area that is protected from direct harmful gases or liquids dust metallic particles shock and vibration It should be installed in an outdoor location so the exhaust fumes are vented to the atmosphere When the Generator is installed outdoors The factory installed enclosure is designed to keep out undesirable weather elements while providing cooling and ventilation When the Generator is installed in a building it is essential to provide 1 Adequate control and exhausting of the heated air 2 Anadequate and constant supply of incoming cooling air 3 Adequate control and discharge of the engine s hot exhaust g
164. rify relay contact operation on terminals 18 4 19 Replace controller if failed Overspeed shutdown occurs at normal speed Controller programmed values are wrong or controller has failed Verify the controller programmed values are correct for the number of flywheel teeth nominal RPM and overspeed setpoint percentage Replace controller if failed Voltage or current metering is incorrect Controller programmed values are wrong Ground is missing Analog input needs to be calibrated Voltage sensing wiring mistake Verify the controller programmed values are correct for the voltage sensing PT ratio and or current sensing CT ratio Verify that the battery supply DC negative conductor is properly grounded to the engine block i e to a common ground point Verify that the controller s analog input is properly calibrated Verify the voltage sensing wiring connection to the MEC 20 matches power distribution type Note standard direct voltage connection requires that the generators neutral is solidly grounded Engine temperature or oil pressure display is incorrect Analog input needs to be calibrated Failed engine sensor Ground is missing Verify that the controller s analog input is properly calibrated Verify engine sensors Note engine sensors must be factory supplied units only Verify that the battery supply DC negative conductor is properly grounded to the engine block i e to a common ground point E
165. rotating parts have also stopped After stopping certain components are still extremely hot so be careful not to get burned Before servicing the generator set be sure to disconnect the spark plug wires and the battery terminals to prevent accidental engine rotation or starting Engine coolant is under pressure and is near the boiling point of water when engine is hot Do not open the coolant system until the engine has completely cooled Hot coolant can cause severe burns and other injuries When engine is cool coolant level can be checked Before servicing the generator set be sure to disconnect the spark plug wires and the battery terminals to prevent accidental engine rotation or starting Inspect all wiring frequently and replace any damaged broken or frayed wiring or wires with damaged insulation immediately Electrical shock can cause serious or fatal injury Disconnect all electrical wires and load devices from generator power outlets before servicing the generator Electrical shock can cause serious or fatal injury Always treat electrical circuits as if they are energized Check all fuel supply piping and their connections monthly for fuel leaks LPG and natural gas fuels are flammable and can cause fire explosions injury or death If a leak is found replace only with approved pipe or components Caution Statements Caution Caution Caution Caution Caution Caution Caution Avoid installing the generator
166. rough the generator mounting frame Engine Cooling A sufficient flow of clean cool air is required for combustion and to dissipate the heat produced MN2408 by the engine Approximately 60 of the heat value of the fuel used is given off as heat cooling air and exhaust The air that will cool the engine must be brought in from outside the building A sufficient air flow of rate Cubic Feet per Minute CFM will allow the incoming fresh air to cool the engine This requires a power ventilation system of sufficient CFM to be located at the highest possible point of the building to exhaust hot air and draw in cool fresh air Note The exhaust fan must not be located where it could easily become blocked by leaves snow water debris etc It is recommended that the cool air intake have at least three 3 times the cross sectional area of the power ventilation system It is also recommended that the cool air intake be located as close as possible to the top of the generator set The exhaust fan must be connected to the AC power terminals of the generator set so that when the generator set starts it will provide immediate cooling air flow The fan will operate until the generator set stops To test the ventilation system do the following Ventilation Test 1 Place a thermometer as close to the cool air intake of the engine s blower housing as you can without allowing the thermometer to touch any material surface 2 Place another thermometer outside
167. rounded before applying power Do not apply AC power before you ensure that grounds are connected Electrical shock can cause serious or fatal injury NEC requires that the frame and exposed conductive surfaces metal parts be connected to an approved earth ground Local codes may also require proper grounding of generator systems Place protective covers over all rotating parts such as drive shaft pulley belt etc Rotating parts cause extremely dangerous situations because they can catch loose clothing or extremities and cause serious or fatal injury Unauthorized modification of a generator set may make the unit unsafe for operation or may impair the operation of the unit Never start a generator set that has been modified or tampered with Be sure that all covers and guards are properly installed and that the unit is safe before starting the engine If you are unsure contact Baldor before starting the engine When moving the generator use reasonable caution Be careful where you place fingers and toes to prevent injury Pinch Points Never try to lift a generator without a hoist or lift means because they are heavy and bodily injury may result Never connect this generator to the electrical system of any building unless a licensed electrician has installed an approved transfer switch The national electrical code NEC requires that connection of a generator to any electrical circuit normally powered by means of an electric utility must be connected
168. rs and be sure no hands are inside the generator enclosure when it starts 9 Verify all loads are disconnected 0 Start the generator Refer to Section 4 Operation for details 1 The engine should begin to crank and start when the fuel moves through the pipe to the carburetor If the engine fails to start refer to Section 5 Troubleshooting 3 14 Receiving amp Installation MN2408 Post Installation Checks Continued 22 With the engine running several checks must be made a d e Verify there are no fuel leaks If a fuel leak is detected stop the engine immediately move the Master Control Switch to the Stop position and repair the leak before proceeding Verify there are no coolant or oil leaks If a leak is detected stop the engine immediately and repair the leak before proceeding Verify that operation is smooth If belt squeals vibrations or other sources of noise exist stop the engine immediately and repair before proceeding Verify that the correct voltage exists line to line and line to neutral at the generator and at the transfer switch Minor adjustment of the output voltage is made using the Voltage Adjust potentiometer on the control panel WARNING Engine coolant is under pressure and is near the boiling point of water when engine is hot Do not open the coolant system until the engine has completely cooled Hot coolant can cause severe burns and other injuries When engine is cool coolant level
169. ry charger outside you must protect it from the environment and the elements 4 not mount the battery charger where flammable liquids or vapors are present General Wiring Considerations 1 When routing the interface wiring do not route it up against anything that could cut or chafe the wiring do not route the wire up against any hot or potentially hot object 2 Make sure that all the electrical components generator set transfer switch battery charger etc share a common hard wired ground 3 Check with your local building inspector to determine what you must do to comply with the local regulations for grounding of this type of permanent installation 3 12 Receiving amp Installation MN2408 Battery Connections The generator may be shipped with no battery installed Procedure The correct type battery must be installed in the battery compartment provided see Table 3 7 Installation and servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions Keep unauthorized personnel away from batteries 1 Open access doors and locate battery tray 2 Place the correct battery see Table 3 7 on the tray 3 Install the Battery Hold Down Bar and Rods as shown in Figure 3 7 a Place the bent end of the Battery Hold Down Rod through the hole in the Battery Tray b Place the threaded end of the Battery Hold Down Rod through the hole in the Battery Hold Down Bar and secure with
170. s No 101 Life Safety Code No Systems No 110 1985 Emergency and Standby Power Systems e NEMA MG1 e Local Codes applicable to Genset Installation See your local building inspector NFPA National Fire Protection Association 617 770 3000 includes NEC 1 Batterymarch Park Quincy MA 02169 7471 USA NEMA National Electrical Manufacturers Association 703 841 3200 1300 N 17th Street Suite 1847 Rosslyn VA 22209 USA Open frame generators must be protected from the environment while having good ventilation and cooling Here are some considerations for planning a generator room or enclosure e Never use the Genset room for storage as well The room must be large enough to contain the genset and all the accessories such as batteries and their charging system transfer switch and other controls and elements of the cooling and fuel systems e A minimum of 2 feet preferably 4 feet must be allowed on the two sides of the engine for service access On generator end of the engine allow space equal to the length of the generator generator length only not the entire genset Atthe front of the engine 4 feet of clearance is preferable Allow clearance between hot parts of the system exhaust and structural members of the building e Certain safety and building codes may require the genset room not to be used to house any other mechanical or electrical equipment General Information 2 3 Room Locat
171. s 2144 2538 GENER ATOR CURRENT VOLTAGE 0 5 3 230 400 V BOOT JUMPER 802 FUEL T pe X START 2 RI 5 Gd BINARY INP UTS BI NA RY OUTPUTS mma BO6 SISSS SS NSS 2 74 STARTER FUEL SOLENOI 4 12 Operation BINARY OUTPUTS TO BATTERY MN2408 Operator Control Panel MICROPROCESSOR Engine Controller Only The Operator Control Panel is shown in Figure 4 13 WARNING Never connect this generator to any buildings electrical system unless a licensed electrician has installed an approved transfer switch The National Electrical Code NEC requires that connection of a generator to any electrical circuit normally powered by means of an electric utility must be connected by means of approved transfer switch equipment so as to isolate the electrical circuit from the utility distribution system when the generator is operating Failure to isolate the electrical circuits by such means may result in injury or death to utility power workers due to backfeed of electrical energy onto the utility lines Figure 4 13 Digital Operator Control Panel MICROPROCESSOR ENGINE CONTROLLER ALARM O Aavg Freq READY SHUTDOWN O 000 000 000 SPEED SIGNAL
172. s flow cfm m min 222 090 77 x 2500 4 ium lt gt 0 0067 inches Hg 5000 etm x 0 472 Us 4500 4 4000 Inside diameter of pipe mm 3000 4 inches Hg x 25 4 S Specific weight of gas Ib ft kg m 39 6 mn S Ib ft 9 be Exhaust Temperature 460 Mis A 9n H o o01 1500 Use 2X Equivalent of f 0 0005 L 9 5 kg m 35205 0 Straight Pipe Exhaust Temperature 273 16 C BLOWS ete i Lg 90 Elbow 16 x Dia in inches 1000 46 Elbow 9 x Dia in inches 99001 To obtain equivalent length of straight pipe for each long radius 909 bend 2 800 L ft 15 x D L m 15 x D cm US L in 15x D L mm 15 x D 12 1000 EXAMPLE 2000 Through 6 Dia 909 Elbow 16 x 6 Dia 96 Length Equivalent 8 ot B Dia Pipe The radius of 90 bends with radii 1 times dod ME the pipe diameter help to lower resistance Exhaust Piping Caution The weight of the exhaust system must never be imposed on the turbo charger outlet Damage to the turbo charger and other components may result An exhaust system must withstand the vibration and thermal expansion that they are subjected to yet supported well enough to remain independent of the engine The most common method of providing flexibility is with the use of bellows type flexible piping This piping component allows lateral and linear movement of the piping system without subjecting fixed components
173. s for a period of time as set forth in the Warranty Period chart below Baldor products requiring warranty service shall be transported or shipped freight pre paid to a Baldor Generator repair facility Notification of the defect or problem a description of the manner in which the Baldor generator is used and the name address and telephone number of the customer requiring warranty service must be included Baldor is not responsible for removal and shipment of the Baldor product to the service center or for the reinstallation of the Baldor product upon its return to the customer or any incidental or consequential damages resulting from the defect removal reinstallation shipment or otherwise Problems with Baldor products can be due to improper maintenance faulty installation non Baldor additions or modifications or other problems not due to defects in Baldor workmanship or materials If a Baldor Generator repair facility determines that the problem with a Baldor product is not due to defects in Baldor workmanship or materials then the customer will be responsible for the cost of any necessary repairs Genset engines are covered under the engine manufacturers warranty Proper engine maintenance is required Any request for engine warranty or repair should be made directly with the engine manufacturers warranty center See engine manufacturers data for applicable engine warranty periods and location of repair centers This Limited Warranty and Service
174. s manual for specific engine maintenance instructions for your generator set Any maintenance instructions or recommendations in the engine owner s manual take precedence over any of the following general recommendations General 1 Inspect the fuel system for leaks Replace all defective components immediately Inspect and replace any fuel line that shows signs of deterioration Inspect all the fuel clamps to ensure they are tight Inspect and clean the battery posts and the associated battery cable terminals Inspect the external wire cables and connectors used with the generator set for cuts fraying or loose connections Repair or replace any problems prior to using the unit Engine 1 Clean and or replace any fuel oil and or air filters per the engine manufacturers guidelines 2 Check oil level regularly at least every 5 to 8 operating hours Maintain the proper oil level 3 Change the oil as is recommended in the engine manufacturer s owner s manual 4 Replace the spark plug s as is recommended by the engine manufacturer 5 Clean the cooling fins on the engine to keep the engine s heat dissipation potential at its maximum 6 Inspect and clean all governor and carburetor linkages so they operate properly 7 Inspect the recoil starting rope for any damage and replace it if necessary if applicable 8 Clean the trash screen around the recoil starter or other cooling air intake Alternator also called Generator End This generator s
175. se system AVERAGE LINE CURRENT Phases Frequency Displays generator frequency in hertz HZ The frequency is displayed with a resolution of 1 10 of a hertz Generator KVA Display KVA 632 23 KVA Displays the generator s total power output in kilo voltamperes KVA Generator Phase Voltage Display Vbc Vca Line to Line 600 600 600 Vab Displays the generator s output voltage 3 phase system LINE TO LINE VOLTAGE Phases A to B 1 phase system LINE TO LINE VOLTAGE Phases A to B Vbc Displays the generator s output voltage 3 phase system LINE TO LINE VOLTAGE Phases B to C 1 phase system LINE TO NEUTRAL VOLTAGE Phases Vca Displays the generator s output voltage 3 phase system LINE TO LINE VOLTAGE Phases C to A 1 phase system LINE TO NEUTRAL VOLTAGE Phases B N Generator Phase Neutral Voltage Display Van X Vbn Vcn Line to Neutral 347 347 347 Note The generator s neutral must be connected to controller terminal TB1 VN and the neutral connected prompt in the main program menu must be selected as Yes Van Displays generator voltage Phase A to Neutral Vbn Displays generator voltage Phase B to Neutral Vcn Displays generator voltage Phase C to Neutral Generator Phase Current Display Amps a b 408 451 415 Amps Displays generator load current as follows 3 phase system PHASE A CURRENT 1 phase system PHASE A CURRENT Amps b Displays generator load current as follows 3 phase system PHASE B CUR
176. shutdown fault circuit is programmable for the percentage of nominal engine speed i e overspeed setpoint and for the transient time delay period The programming prompts for overspeed are located in the main menu programming loop Loss Of Speed is initiated when the engine s speed sensing circuit does not detect a speed signal for a period more than 2 seconds following a run signal The loss of speed fault may be user programmed as a latching shutdown fault or alarm only The programming prompts for loss of speed are located in the main menu programming loop Overcrank Shutdown is initiated when the engine fails to start after the selected crank time or number of crank cycles The overcrank fault circuit is internally programmed as a latching shutdown fault and is not user programmable Switch not in AUTO is initiated when the controller s operating mode switch is changed from the auto position to any other position ON the keypad This fault is internally programmed as a non latching alarm In the main programming loop this alarm may be user programmed to initiate the common fail output relay Four digital faults are provided and these are user programmable Each digital fault input circuit is activated by a remote sensing contact that is external to the controller Each digital fault input circuit may be programmed with a unique fault label description as stored in the controller s non volatile memory Factory settings have four standard digital faul
177. st leaks can occur MN2408 Fuel Strainers amp Fuel Lines A fuel strainer and flexible fule line can be installed at the fuel pressure regulator to make connection to the fuel main shutoff valve easier Either 1 1 4 or 2 fittings may be specified Figure A 5 Fuel Strainer and Flex Fuel Line Connections n Fuel Regulator GLCFFL1 3 4 NPT Female fittings 12 long GLCFFL2 1 1 4 NPT Female fittings 18 long GLCFFL3 2 NPT Female fittings 12 long GLCFFS1 3 4 NPT Fuel Strainer female Inlet male outlet GLCFFLS3 2 NPT Fuel Strainer female Inlet male outlet 4 X Frame A Fuel Strainer Fuel Flex Line Installation Use appropriate thread sealer as required by plumbing codes Thread Fuel strainer onto NPT close pipe nipple Install NPT close pipe nipple to Fuel strainer input Thread Flex Fuel Line onto NPT close pipe nipple Connect other end of Flex Fuel Line to site fuel supply pipe as required by plumbing codes MN2408 Options amp Accessories A 5 E Stop E Stop Switch Kit Mounts to Baldor supplied Enclosure to provide easy access to shut down engine with the press of a button Connects to Remote Run Terminals on genset Must be adapted for remote mounting when used with open skid mount units Figure A 6 4 13 le osse BW0052D ne hae zie 7045 u zl 3 75 00520 is an optional jumper that is installed t po
178. t This setpoint should be used only for Volvo and Scania engines ECU Speed Adjust This setpoint should be used only for Volvo and Scania engines WTBF Accept RPM The WtBfAcceptRPM delay setpoint will start to count down since cranking Controller waits before communicating with the ECU for this time This is because the JD engine passes some erroneous RPM signals during the first 500ms Step 0 1s Range 0 3s Eng prot del During the start of the gen set some engine protections have to be blocked e g Oil pressure The protections are unblocked after the Protection del time The time starts after reaching Start RPM Step 1s Range 0 300 s Horn timeout Max time limit of horn sounding Set to zero if you want to leave the output HORN open Step 1s Range 0 600 s Overspeed Threshold for over speed protection Step 196 of nominal RPM Range 100 150 Wrn Oil press Warning threshold level for ANALOG INPUT 1 Step 1 psi Range Sd Oil press 10000 Sd Oil press Shutdown threshold level for ANALOG INPUT 1 Step 1 psi Range 100 Wrn press Oil press del Delay for ANALOG INPUT 1 Step 1 s Range 0 180 Sd Water temp Warning threshold level for ANALOG INPUT 2 Step 1 C Range Wtemp 10000 Wrn Water temp Warning threshold level for ANALOG INPUT 2 Step 1 F Range Wtemp low Sd Water temp Wrn Wtemp low Warning threshold level for low value on A
179. t all operation problems are related to the installation techniques used Do Not guess be sure pipe size is adequate for required flow rate Connect the proper size gas pipe at the input to the LP Vapor regulator Connect the LPV pipe line shown in Figure 3 3 using the correct size pipe for the required flow rate and length of pipe Refer to Table 3 6 for pipe size Be certain that all connections are sealed and no leaks are present The installer must ensure that all gas connections comply with all building codes Verify Fuel Supply Pressure Prior to initial operation of generator verify that fuel system pressure is 11 Water 1 Column 6 oz pressure and fuel pipe sizes comply with Table 3 6 Proceed to Electrical Connections MN2408 Electrical Connections Class 1 wiring methods must be used for field wiring connections to terminals of a class Warning Warning WARNING 2 circuit It is the responsibility of the owner operator to arrange for these procedures to be performed by a licensed electrical contractor and ensure conformance to all applicable codes including local codes peculiar to your municipality city county and state Wire size and insulation type should be as required by NEC National Electrical Code and local codes Never connect this generator to the electrical system of any building unless a licensed electrician has installed an approved transfer switch The national electrical code NEC requires that connectio
180. t be located close to battery heater Figure A 2 Battery Heating Pad Installation M B gt lt gt BTHTR81 Heater 1 Carefully disconnect the Negative battery terminal from the battery Carefully disconnect the Positive battery terminal from the battery Remove battery hold down bracket Remove battery Install Heating Pad in battery tray refer to Figure A 2 The A and B dimesions should match the battery tray Install battery on top of Heating Pad Install battery hold down bracket Carefully install the Positive battery terminal to the battery Carefully install the Negative battery terminal to the battery 0 Connect the AC power cord to shore power outlet akon ONO A 2 Series GLC MN2408 Engine Block Heater Installation Considerations Shore power must be available 120VAC or 240VAC to power the block heater and other components that may be installed Shore power outlets or wiring must be located close to block heater Figure A 3 OUTLET HOSEBARB 625 1 0 i T SIF 48 16 3 Catalog G10A Block Heater refer to block heater manual for specific details 1 Mount the block heater refer to Figure A 3 to determine suggested location 2 Connect the inlet hose to the inlet hose bib on the block heater 3 Connect the outlet hose to the outlet hose bib on the block heater 4 Connect the AC power cord to shore power outlet
181. t operator burns and reduce pipe radiant heat losses F Pipe sleeves or fire proof materials are used where exhaust pipe passes through building materials as per local and state codes G Exhaust pipe includes rain cap or is horizontal The purpose of the exhaust system is to safely discharge the engine combustion products into the atmosphere outside the building A silencer should be installed in the exhaust system to reduce noise levels Compliance with local noise codes is always required Level Of Attenuation In general manufacturers offer three grades of silencers industrial residential and critical In most cases these grades are comparable from make to make However attenuation curves for the silencer should be checked to assure the desired level of silencing is met System Placement By this time the general genset placement within the room or building has been decided The routing of the exhaust system should be as direct as possible to the building exterior WARNING Never allow the exhaust outlet to be positioned so that the exhaust gases are directed towards any openings or air entry routes doors windows vents etc of an occupied building When discharging the hot exhaust gases out of the building do not direct them towards anything that could catch fire or explode For aesthetic reasons consider exhaust placement in relation to the building Over a period of time exhaust gas carbon deposits will tend to accumulate on
182. tall and operate your generator set During the preparation of this manual every effort was made to ensure the accuracy of its contents This manual describes only very basic engine information A separate owner s manual for the engine is supplied with this unit for your use Please refer to the engine manual for information relative to engine operation maintenance recommendations and additional safety warnings Copyright Baldor 2008 All rights reserved This manual is copyrighted and all rights are reserved This document may not in whole or in part be copied or reproduced in any form without the prior written consent of Baldor Electric Company Inc Baldor Generators have earned the reputation of being high quality and dependable We take pride in this fact and continue to keep our quality standards high on our list of priorities We are also constantly researching new technological ideas to determine if they could be used to make our generator sets even better Baldor makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied warranties of fitness for any particular purpose The information in this document is subject to change without notice Baldor assumes no responsibility for any errors that may appear in this document Limited Warranty Baldor will replace or repair free of charge any part or parts of the generator of their manufacture that are defective in workmanship and material
183. tandard Modbus Standard LiteEdit communication protocol Modbus Modbus protocol Note For detail description see chapter Modbus protocol Num rings AA Number of rings prior to open modem connection Step 1 Range 1 30 Note NumberRings AA change is not activated immediately It is activated after controller is switched on or when modem is connected to controller MN2408 2408 Table 4 15 Engine Setpoints tart RPM Firing speed when iL controller stops cranking starter goes OFF Step 196 of nominal RPM Range 5 50 Starting When reached controller stops cranking starter goes OFF Step 0 1 psi Range 100 10000 Note There are three conditions for stop cranking Starting RPM StartingPOil and D when enabled Starter goes off when any of these conditions is valid Prestart time Time of closing of the PRE START output prior to the engine start Set to zero if you want to leave the output PRE START open Step 1s Range 0 600 s MaxCrank time Maximum time limit of cranking Step 1s Range 1 60s CrnkFail pause Pause between crank attempts Step 1s Range 5 60s Crank attemps Max number of crank attempts Step 1 Range 1 10 Idle time Idle time delay starts when RPM exceeds Start RPM Start fail is detected when during Idle state RPM decreases below 2 During the Idle time timer running the binary output IDLE NOMINAL is opened when it elaps
184. to excessive stress A minimum of 12 inches of flexible connection must be provided at the engine exhaust manifold to allow for thermal expansion and vibration If the engine is to be mounted on spring type vibration isolators increase the length to 24 inches This component can be specified to be provided by your Baldor distributor Flexible pipe should never be used for pipe bends or to cure misalignment problems Exhaust piping systems may be supported by a wide variety of methods to long as the system remains flexible and capable of withstanding thermal expansion The material most commonly used for straight runs and elbows in exhaust systems is Schedule 40 black iron If hanging weight is a problem other materials may be used Galvanized piping should never be used in exhaust system Where exhaust piping passes through combustible material exhaust thimbles must be used See Figure 2 7 Figure 2 7 Exhaust Pipe Thimble Installation e installation 9 229 mm Through Roof Minimum p 9 229 mm Minimum Holes in End of 1 Si prb Installation Through Flashing Wall or Partition Holes in End of Roof Inner Sleeve 8 229 mm Minimum Wali or Partition 9 229 mm Minimum Exhaust Pipe Dia plus 12 305 mm minimum Rain Protection Moisture entering the engine through an exhaust system can cause extensive damage Exhaust outlets must have a rain cap or be horizontal to prevent such damage See Figure
185. tor may cause injury or death Never operate the generator unless all guards covers shields and other safety items are properly installed Do not put hands feet tools clothing or other objects near rotating parts such as drive shaft pulley belt etc Rotating parts cause extremely dangerous situations because they can catch loose clothing or extremities and cause serious or fatal injury When operating this generator remain alert at all times Never operate machinery when physically or mentally fatigued or while under the influence of alcohol drugs or medication Never operate the engine when the air cleaner is removed An engine backfire can cause serious burns Never jump start a generator to start the engine If the battery charge is insufficient to start the engine charge or replace the battery and try to restart Jump starting a battery can cause the battery to explode and cause severe injury or death to anyone in the area High voltage is present whenever engine is running Electrical shock can cause serious or fatal injury Never operate electrical equipment while standing in water on wet ground or with wet hands feet or shoes or while barefoot High voltage is present whenever the engine is running Electrical shock can cause serious or fatal injury Always stop engine before connecting or disconnecting power cords or external devices Do not smoke near generator during operation or when close to fuel source LPG and natural gas
186. ts as follows Fault Fault Digital Inputs Name Action Terminal Low Oil Pressure Shutdown Shutdown Alarm Alarm High Engine Temperature Battery Charger Input Fail Low Fuel Level The following is a list of all digital faults High Bearing Temp Failed To Sync Reverse Power Bat Charger Input Fail High Cooler Vibration Low Fuel Press Fail To Sync Bat Chrg Trouble High Engine Temp Low Engine Temp Vent Damper Fail Bat Charger Fail High Engine Vibration Low Oil Pressure Gen Breaker Open DC Fail High Fuel Level Low Fuel Level Ground Fault Breaker Tripped High Oil Level Low Oil Level No Load Test Basin Rupture High Oil Temp Fuel Leak ATS In Bypass High Winding Temp Low Fuel Press Remote Emerg Stop Highintkmanftemp Low Coolant Level Air Damper Tripped Blank i e no text for unused inputs Operation 4 17 Figure 4 15 Engine Controller Inputs amp Outputs FEATURE STANDARD FAULTS OUTPUT CONTACTS MAGNETIC OVERSPEED PICKUP N SHUTDOWN LOSS OF SPEED ALARM SHUTDOWN U OVERCRANK SHUTDOWN SWITCH NOT IN AUTO ALARM LOW ENGINE TEMP ALARM HIGH ENGINE TEMP ALARM HIGH ENGINE TEMP SHUTDOWN ENGINE TEMPERATURE SENDER TEMP DISPLAY ENGINE OIL PRESSURE SENDER LOW OIL PRESSURE PRESS ALARM DISPLAY LOW OIL PRESSURE SHUTDOWN LOW BATTERY VOLTAGE ALARM BATTERY EB VOLTAGE DC HIGH BATTERY E SQUE VOLTAGE ALARM WEAK BATTERY ALARM 3 PHASE
187. uct Safety Information MN2408 Operation Warning Statements Continued WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING Burn WARNING WARNING WARNING MN2408 Never connect or disconnect loads during operation Always connect load circuits before starting the engine and use external branch disconnects etc to switch loads On Off Be sure that you understand how to stop the engine quickly in case of an emergency situation Become familiar with the controls and safety systems provided with this generator set Always wear safety glasses with side shields and hearing protection when working near the generator Improper operation may cause violent motion of connected equipment Be certain that unexpected movement will not cause injury to personnel or damage to equipment Never operate the generator set indoors or in a poorly ventilated area such as a tunnel or cave Exhaust fumes are extremely dangerous to all personnel that are in or in contact with that area Never permit anyone to operate the generator without proper instructions Be sure to keep a copy of this manual with the generator so that all users can be properly informed of its safe operation Never allow children or pets to be in the area where the generator is running The generator and the equipment being powered by the genera
188. uence may be initiated by closing an external exercise timer contact to the programmed digital input for No Load Test 2 After the external exercise timer contact closes the engine will start and come up to normal operating speed and voltage The controller will issue an alarm of a No Load Test condition The connected transfer switch will remain on the utility and the generator will not transfer on load Note should the utility supply fail the generator will automatically transfer on load 3 The engine will continue to run as long as the external exercise timer contact remains closed 4 After the external exercise timer contact opens the engine will continue to run for its cool down time as programmed then it will automatically stop When a fault occurs information about the fault is displayed The engine controller has many analog and digital inputs for monitoring and control operations Three types of faults are used 1 Faults are derived from a combination of digital and analog inputs 2 Digital Input Faults are initiated from external contact inputs 3 Analog Input Faults are initiated from external analog signal inputs Figure 4 15 shows how the controller inputs and outputs are organized A description of each is provided Overspeed Shutdown is initiated when the engine s speed has increased above the overspeed setpoint The overspeed fault circuit is internally programmed as a latching shutdown fault The overspeed
189. uire field calibration If field calibration is required refer to the calibration procedure Voltage Sensing Calibration Phase To Phase or Phase To Neutral VOLTS AB ZERO 99 600V Displays the generator phase voltages to be calibrated Displays the type of calibration function either ZERO or SPAN Displays the calibration correction factor number 0 255 used to obtain the correct voltage reading Note To correctly calibrate any of the voltage sensors the ZERO function must be calibrated before the SPAN function Displays the actual voltage measurement that will be the same value as shown on the MEC 2 display menus for generator supply This voltage reading may be calibrated higher or lower by changing the correction factor number Voltage Calibration Procedure Note Zero Calibration must be completed before Span Calibration Zero Calibration Connect an external AC voltmeter of adequate voltage range and accuracy to the MEC 2 controller terminals associated with the voltage phases to be calibrated With the generator stopped confirm there is Zero volts on the phases to be calibrated In the programming mode scroll to each of the desired generator supply voltage phases i e phase to phase or phase to neutral with the ZERO function selected Use the INCREMENT or DECREMENT push buttons to adjust the correction factor number to obtain zero volts on the right hand side of the display as confirmed with the external voltmeter The factory def
190. ure Calibration To accurately calibrate the controller s temperature sensor an external temporary engine mounted temperature gauge is required The external temperature gauge should be connected as close as possible to the temperature sender To accurately calibrate the controller s pressure sensor an external temporary engine mounted pressure gauge is required The external pressure gauge should be connected as close as possible to the pressure sender ENGINE TEMP 127 95 C Displays the type of calibration function Displays the calibration correction factor number 0 255 used to obtain the correct Temperature or Pressure reading Displays the actual temperature or pressure measurement shown on the display menus This reading may be calibrated higher or lower by changing the correction factor number Engine Temperature engine temperature analog circuit must be calibrated with the engine temperature sender mounted on the engine Connect a temporary engine mounted temperature gauge of suitable accuracy and start the engine After the engine reaches normal operating temperature enter the programming mode and scroll to the Engine Temperature Offset calibration point Use the INCREMENT or DECREMENT push buttons to adjust the correction factor number while observing the displayed temperature Adjust the correction factor number to obtain the identical temperature reading as measured with the external temperature gauge With the correct temperat
191. ure displayed press the Enter push button to accept the correction factor number Record the correction factor on the programming sheet for future reference Oil Pressure Connect a temporary engine mounted pressure gauge of suitable accuracy and start the engine After the engine reaches normal operating pressure and temperature enter the programming mode and scroll to the Engine Pressure Offset calibration point Use the INCREMENT or DECREMENT push buttons to adjust the correction factor number while observing the displayed pressure Adjust the correction factor number to obtain the identical pressure reading as measured with the external pressure gauge With the correct pressure displayed press the Enter push button to accept the correction factor Record the correction factor on the programming sheet for future reference Engine ender il ender Temperature Resistance Pressure Resistance c Ohms KPA PSI Ohms 392 200 20 1034 150 38 374 190 24 965 140 42 356 180 28 896 130 48 338 170 33 827 120 54 320 160 39 758 110 62 302 150 46 689 100 70 284 140 55 621 90 79 266 130 65 552 80 89 248 120 76 483 70 101 230 110 90 414 60 114 212 100 106 345 50 127 194 90 147 276 40 142 176 80 197 207 30 160 150 70 290 138 20 183 140 60 426 69 10 206 122 50 622 104 40 952 86 30 1486 68 20 2322 50 10 3644 32 0 6284 Note Sender resistance data shown are for O
192. utomatic The control mode is shown in the highlighted area at the top of the display Figure 4 9 When the desired Control Mode is highlighted press Start to begin operation Press Stop to terminate operation OFF Generator set operation is not allowed MAN Press Start to manually start the generator set immediately Press Stop to stop the generator set immediately AUT Start and Stop buttons are ignored The binary input terminal conditions start and stop the generator set Three display menus are available Measurement Adjustment and history Press the Page button repeatedly to display each menu Use A V and Enter keys to change and accept setpoint values or press the Page button to cancel changes Measurement Menu The measurement menu shown in Figure 4 9 displays the operating mode and operating parameters such as kW engine RPM etc Figure 4 9 Measurement Menu Control Mode OFF MAN AUT Control operating mode highlighted OFF MAN AUT Alarm indication is active Ready Ready Status PF 0 00 kW Active power produced by generator RPM 0 PF Power Factor 0 kW Timer 0 RPM Engine speed in revolutions per minute Timer Event counting time e g prestart cooling etc OFF Mode Starting of the generator set is not possible Outputs STARTER BO1 and FUEL SOLENOID BO2 are not energized No action if buttons START and STOP are pressed MAN Mode START button starts the generator set STOP stops the gen
193. vel transient time delay settings and other functions An analog DC signal is provided from an engine mounted sender The low oil pressure shutdown fault is activated when the oil pressure is below a pre determined setpoint for a specified time delay This fault is programmable for pressure setpoint level transient time delay settings and other functions The low battery voltage alarm fault is activated when the battery voltage drops below a pre determined setpoint for a specified time delay This fault is programmable for the voltage setpoint level transient time delay settings and other functions The high battery voltage alarm fault is activated when the battery voltage rises above a pre determined setpoint for a specified time delay This fault is programmable for voltage setpoint level transient time delay settings and other functions The weak battery alarm fault is activated when the battery voltage drops below a pre determined setpoint for a specified time delay The weak battery alarm detects a low capacity i e weak battery condition during the cranking cycle The weak battery alarm is programmed for a lower battery voltage setpoint and shorter time delay than the low battery alarm function This fault is programmable for voltage setpoint level transient time delay settings and other functions All 3 phases of the generator output are monitored for an undervoltage condition The undervoltage sensor is programmable for type of fault action
194. xplosive Never jump start a battery smoke in the area around the battery or cause any spark to occur in the area around the battery Battery Location Battery Size Locate batteries as close as possible to the genset to minimize starting circuit resistance see Figure 2 9 High starting circuit resistance substantially reduces starting cranking ability Mount batteries on a level rack away from dirt and liquids Allow space for servicing checking water level and level of charge Cold ambient temperature at the battery location substantially reduces the battery output Figure 2 9 Battery Starting System The ability to start the engine depends upon battery capacity ambient temperature and coolant and oil temperatures The Engine Generator Set Data Sheet lists minimum recommended battery capacity Battery capacities decrease as ambient temperatures decrease so it is important to specify batteries with the appropriate CCA rating at a temperature no higher than the minimum ambient temperature for the application 2 12 General Information MN2408 Battery Cables 00400 00380 00360 00340 00320 00309 00280 00260 00240 00220 00200 00180 00160 00140 00120 Resistance of Ohms at 77 F 25 C 00100 00080 00060 00040 00020 MN2408 An engine mounted alternator charges the batteries during engine operation Standby gensets should include a solid state battery charger that

Baldor GLC105 Portable Generator User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents