Home

Baldor GLC10 Owner`s manual

Contents

1. GW0000B57 ROTATING RECTIFIER 1 gt ALTERNATOR 2 AAA EXCITER ROTOR 3 4 5 ININ YY MAIN STATOR EXCITER STATOR L1 EE VO 6 YY A A A H 3 T2 7 amp 2 YY 8 T4 12 1K OHM REMOVE JUMPER Mie QM Sok 10 RHEOSTAT RHEOSTAT IS INSTALLED 4 4 11 2 z d 15 9 2 8 13 0 8 9 fep 4 3 2 5 SE350 e m CONTROL PANEL VOLTAGE REGULATOR 6 8 5 o p 292 mom PES 47 INTELILITE NT OM E S 9 a gt N 12 PET gt 15 vi 12 12 12 5 2 19 8 is gt 1 3 SE 5 a 20 N gt i N iz zi ci ul gt 5 8 8 518 22 ees 12 TIO lt oo 55 25 c3 c3 23 5 13 gt 1 7 2 24 6 00 gt gt 25 CONTROL PANEL 26 5 5 5 x 9 8 27 UNLESS OTHERWISE STATED ALL CONTROL WIRING IS 16AWG z 2 e AWG SEE BREAKER WIRE SIZE CHART BWO707D 9 g d LINES INDICATE OPTIONAL ACCESSORIES NEUTRAL GROUND 8 BOND CUSTOMER e CONNEC
2. t ALTERNATOR 2 AAA EXCITER ROTOR 3 4 MAIN ROTOR 5 V MAN STATOR EXCITER STATOR U1 T1 Li lt 02 12 7 2 5 13 8 TA 12 1K OHM REMOVE JUMPER 5 ADJUSTING VOLTAGE ADJUST JI 10 RHEOSTAT RHEOSTAT IS INSTALLED 7 74 73 2 FUSE Air mimi lt lt 1 11 n ium 9 8 z d E a Ce 7 8 m gi 8 s N AS480 UL CONTROL PANEL VOLTAGE 15 REGULATOR EIE E alg 2 i T p SM 17 INTELILITE NT L1 u 5 18 L2 S 99 X lt lt amp S d gt v2 12 12 5 19 855 15 5 20 now z 9 21 Li 813 22 lt ul lt un c2 c2 23 Hoo 24 699 25 8 CONTROL PANEL 26 a gt lt 24 F BO ORG 27 UNLESS OTHERWISE STATED ALL CONTROL WIRING IS 16AWG z AWG SEE BREAKER WIRE SIZE CHART BWO707D 245 28 LINES INDICATE OPTIONAL ACCESSORIES NEUTRAL GROUND BOND CUSTOMER CONNECTION 5 29 GCB z GND L2 um T 31 if 1
3. Series GLC B 7 MN2408 1N ASN LSNW B 8 Series GLC Figure B 15 DC Schematic for 35 130kW CONTROL BOX WIRING 1 ENGINE OPTIONAL ACCESSORY WIRING BWO708D m ms 42e ME 2 BATTERY CHARGER 3 FS FUEL SOLENOD ou n bx Q 5 g 1 TENCE 2 couo 74 men l Q vem mow y 4 P 2 mo 29 am p 2s m ud OF p A T NAM is aam yy pum uc LOCKOFF PROPANE VAPOR 2 of om yt cowecrnesons E 15 6 K H FS FUEL SELECT T ut 5 n PR RUN RELAY n MA n E 19 t 4 mwen J 4
4. 91570 8 139 HS NOILYTIYLSNI 43015 OHHorod 8 0102 22 20 80 25 20 035 138 10ZN91000NVSdN 31l3 066ZS000000 10 NOISH3A CHL A38 3lvOdn 0S30 3SVHd JIONIS NO IVNIWN3L L 3LON 3SVHd 3I9NIS NO LON IVNIWS3L 1 ILON Ni a7 oos i e sze i e szel 522 sze NI 81 oziNi 81 NI 81 092 IWON 009 TINO 06 INO 009 066 0 1 071 INOW 005 ON NI 81 21 300501 2 9 1 NNOO omy 9 owv vif 9Mv vi NNOO EM zi zz 39NVu NNOO MIYOS M3HOS 13M00S 30 M3MOS 80103NNOO MIYOS M3NOS 13MO0S M3MOS 2 al 80193NN02 no no no SwolonaNoo 1 SYOLONGNOD 206 206 206 206 3518 dW3L 206 206 206 206 3 dW3L 005 27815713 3005 3000 21919313 1 201 3ZIS A1IOVdAV 7 201 3ZIS ALIOVdNV WNOLLWN 1 201 3ZIS ALIOVdNV zai NouvouuNaat lano 3SvHd QvO1 QNO avol saam 3SvHd
5. Note Almost all operation problems are related to the 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 Genset verify that fuel system pressure is 11 Water Column 6 oz pressure and fuel pipe sizes comply with Table 3 5 3 NG fuel install jumper terminals 12 and NG 4 Proceed to Electrical Connections Example Determining Pipe Size for LPV A Genset has a 16Hp engine 60 feet from the supply An engine needs 10 000 BTU s per hp to run efficiently For LP fuel there are 2 650 BTU ft Determine the supply pipe size for LP fuel 16hp x 10 000BTU Hr hp 160 000 BTU s per hour for proper operation 160 000 2 650 From Table 3 6 a 60 foot run requires a minimum 1 pipe at full engine load 60 4 cubic feet per hour 3 8 Receiving amp Installation MN2408 Figure 3 3 Gas Line Connections Air Cleaner
6. 75202 22 00 311 n UONVTTAH A a M3N 0530 T o PNE TNR S i 3015 1337 AGIA 1 8 4 ASIA 3015 LASTS 830914 370 DLW SZ 2 H 3S 8g8 8g nS 30 ASIA NV d MJA MJA NV Td 6 6 II 9 X SE 2101 9 X S3 DH DLW 2 0 9389 dn gnis 1303 AW 7 0 1 501 2101 62 X 57 S4 SE 2101 v2 X 4 5 7991819373 Z 2 5 J IHVADUWJ3S aral L TANVd 8339338 LINIJI 70819409 0212791 0213791 009 00 84 00 8 ev 89 32 0 M2 ena T T 02 010 92 6 210 000 9S ev 22 8652 DI 192 SS3 191 00 9 SOT 58 5101 n92 Sr319I 0078 00 85 8r 46 52 662191 92 5 2191 AW IW qH H A S310H I S31DH 31 1H9I3H HION31 00221 ONTLNAOW COOH T1V83AD 1T1V33AU O I SOT 803 08 6 6 IDI 303 59 SE 2101 03 AH V3elv 5 7304 JHL 8320034 5 3514 9 9 419135 S DlvN331l NV 79214 1 JAY NADHS SLHDI3A v T SNUII2VMJ 652 XX SIWWIDAT 31310345 3SIA233H1L 5537 S3ONV3J UL 37925 OL ONIMVAC
7. 37 LM SA Ai ws 1 T x we utt 8 DT st GROUT BREAKER SHUNT B 2 BATERY cwo FAL see oust SR swen FUB sm me 2 L mo ulot ul et 46 44 4 d gt muon E 2 mo in 34 be 14 4 ot 4 COMMUNICATION MODULE H RS232 SERAL NULL MODEM CABLE 5232 SERIAL NULL MODEM CABLE RS232 SERIAL MODEM CABLE rex 12 zi y2 1 E ES meme ye EZ p Beer 1 6 5 4 PB LA ot Ji EM o fed O44 DB9 RS232 SERIAL NULL MODEM CABLE WIRING 45 R R 7 ene alg FEMALE FEMALE st Tm B e ela DN p 7 7 S44 47 aa 8 49 K n BELDON 8304 4 PAIR 22 AWG COMMUNICATION CABLE m ALL WIRE 15 16 AWG UNLESS NOTED ms Ed la 51 NOTE 1 FOR LP VAPOR APPLICATIONS CONNECT THIS JUMPER ACCROSS TERMINAL 12 AND TERMINAL FS TB1 rs G LINES INDICATE WIRING FOR OPTIONAL ACCESSORIES PB TW NFPA 110 OPTION INCLUDES REMOTE ANNUNCIATOR REMOTE 5 4 AN
8. s gt gt plete 15 208 B gt Pi euv 16 12 i wmumw 27 3 57 05 k Pe 4 vas tow 2 45 gt lt Q8 st BREAKER Su s AN BATERY FAL sPED sumer FIR FUEL souon RELAY sm RELAY EE dz nl et 416 44 4 a 295 2 muon of das wu m GREEN PE zs vl g fe 14 4544 4 e z MODEM GABLE SEMAL MAL MODEM CABLE EISE slg x 12 2 6 re i 1 re E ror reme j RE pts Len j BREAKER 1 8 ot 4 514 LA ot E S o fed 44 209 B H DB9 RS232 SERIAL NULL MODEM CABLE WIRING s 45 R NRECT R i UY em alg FEMALE FEMALE st Tm H 3 3 oll i j 7 7 S44 47 gt J3 6 4 2 8 LM ecd PIP 4 BELDON 8304 4 PAIR 22 AWG COMMUNICATION CABLE L ALL WIRE 15 16 AWG UNLESS NOTED ms la 51 s NOTE 1 FOR LP VAPOR APPLICATIONS CONNECT THIS JUMPER ge ACCROSS TERMINAL 12 AND TERMINAL FS ON TB1
9. 0 002 Ohms 24V Systems the cranking 0 0012 Ohms 12V Systems System Voltage 24V Resistance of 6 connections 0 00006 Ohms Resistance of 100 of 1 Cable 0 00100 Ohms Total resistance of cranking circuit 0 00106 Ohms 100 200 300 400 500 600 700 2 54 5 08 762 1016 1270 1524 17 78 Cable Length inches meters General Information 2 11 Formulas Single Phase Electric Three Phase Electric Length Area Pressure Temperature Torque Velocity Volume Miscellaneous Single Phase Power Factor is typically 1 0 1 kW 1 kilo Watt 1 000 Watts Watts Watts Volts x Power Factor Amps Volts x Amps x Power Factor Three Phase Power Factor is typically 0 8 1 kW 1 kilo Watt 1 000 Watts Watts Watts Apa Volts x Power Factor x 1 732 inches x 25 40 mm feet x 0 305 m yard 0 914 inches2 x 6 451 feet x 0 0929 pounds ft x 0 006944 pounds in psi x 6 8948 kPa psi 0 4912 inches Hg F 32 x 0 55555 oz in x 0 007062 Nm Ib in x 0 11296 Nm lb ft 1 356 Nm ft sec x 0 3048 m sec miles hr x 1 6093 km hr miles hr x 0 44704 m sec inches x 16 388 mm feet x 0 0283 m3 gallons x 3 785 liter gallons x 0 13337 ft3 Watt 0 00134 or 746 watts
10. NOLVOLJLLN3QI N 5 5 1 7 1 N 9 5 ION 1 1 diMIS TWNINMAL diMIS TWNINYAL LINDID diMIS TWNINMAL T3NVd JTOBLN02 SNOLLO3NNOO 9 1 1 0 TW SLINN 3SVHd JIONIS NO LON ILON 3SVHd 319NIS LON IVNIWH3L L 3LON sze i e szel 1 05 3nowol 81 60 NI 81 ozilNi 81 NI 81 05 005 OSE TINO OG WO 005 0 O 1 SMV 0 1 0 2 0 2 0 3oNvH omy pif ouv ___ NNOO M3NOS 11005 MIYOS 134005 MO 4OLO3NNOO 5 5 z xnv 1 xnv MOLVIONDNNY SINGH E LON 906 906 905 206 su 9 906 908 906 u ss 3005 21815313 3005 219313 1 201 3ZIS ALIOVdAV VNOILVN 7 201 3ZIS ALIOVdhv e 21 21 2121 e e e eo e 2121 2218
11. 11 GV L o 26 Bug 120 2 27 55 15 2gx 1 ae gt 1 vo 28 N N 28 29 9 30 31 2592 32 5 5 lt 5 56 2 8 88 ap es 34 9 hj o2 co m 35 2 g 36 CONTROL PANEL E Tu x 25 s L UNLESS OTHERWISE STATED ALL CONTROL WIRING IS 16AWG z 38 SEE BREAKER WIRE SIZE CHART BWO707D fi g LINES INDICATE OPTIONAL ACCESSORIES NEUTRAL GROUND o dd BOND CUSTOMER E CONNECTION JP 40 1 2 41 GND L z als g HASE 4 WIRE 98000049 GW0000B61 LINK BOARD CONNECTIONS SERIES STAR 4 VOLTAGE 480 277 416 240 600 347 OUTPUT TERMINALS LINK BOARD CONNECTIONS PARALLEL STAR 44 VOLTAGE 208 120 240 139 OUTPUT TERMINALS u2 v2 ve 2 w e eH L3 V v5 1 U us u1 LINK BOARD CONNECTIONS SERIES DELTA 3PH 4W VOLTAGE 240 120 OUTPUT TERMINALS 9 N GCB GENERATOR CIRCUIT BREAKER B 12 Series GLC MN2408 MN2408 Figure B 20 ROTATING RECTIFIER GW0000B62
12. 21 Mounting Bracket Typical piping as shown Solenoid Fuel Lock U L requires a second shutoff valve and regulator to be installed in the supply piping to z Supply Pipi G To inet Pring Carburetor External Supply Piping by installer control the gas supply to the Genset Inlet Connection Connection lt H Tr Additional Regulator A Additional Valve 11 14 water column pressure Safety Shutoff Valve LP Vapor Connections vapor withdrawal only connections should only be made if your Genset is setup to run If it is setup to run on Natural Gas contact your Baldor representative and do not continue with installation To run on LP Vapor fuel remove the jumper on TB1 terminals 12 and FS 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 Iron Pipe Size 2 2 2 _ 1 1570 2437 1127 1741 934 1456 817 1266 709 1108 633 987 582 905 544 848 494 772 456 709 418 652 393 614 367 576 345 544 Note Almost all operati
13. B 37 z z aL UNLESS OTHERWISE STATED ALL CONTROL WIRING IS 16AWG z cu 38 XXX AWG SEE BREAKER WIRE SIZE CHART BWO707D n 9 g LINES INDICATE OPTIONAL ACCESSORIES NEUTRAL GROUND N BOND CUSTOMER CONNECTION zm 40 1 5 43 GND L ic IB 4 3 PHASE 4 WIRE 980000M9 GW0000B63 LINK BOARD CONNECTIONS SERIES STAR 4W VOLTAGE 480 277 416 240 600 347 OUTPUT TERMINALS LINK BOARD CONNECTIONS PARALLEL STAR 44 VOLTAGE 208 120 240 139 OUTPUT TERMINALS U V W N 1 2 v N 2 W lt 6 VS vi US u1 LINK BOARD 5 SERIES DELTA 3PH 4 VOLTAGE 240 120 OUTPUT TERMINALS U V W N GCB GENERATOR CIRCUIT 14 Series GLC MN2408 Figure B 22 LD6205B31 HS SNIMV23Q 0919110 W9 30V3831NI SS3NuVH 0102 0 20 0 1 20 035 138 996N 1000NVSdN 374 667464000000 13401 O NOISH3A 2 WI A38 MSONVTTSH ALON 3215 0530 NOILYONddY JHL ATEVLINS 303839 TIM 190G023d 5 001 8 SNININ3313Q 3O4 318ISNOdS33 SI YSWOLSNO 9 SI 10 1 02 TIY 31916 3SIMH3
14. 3TDH DLW 52 1 3799 o 70 S Nn d NI SLHOIJA 119 Y PT S3HONI NI SNDISN3WIQ 119 5 135 N39 DL 33438 SNOLLVONSWWOD3S 19717915 1 X04 S133HS 0345 14004 796 33438 Vivd Lonadodd 903 S310N O8I Sr 2701 0191 131100 1SnvHx3 TANT AIA NV ld AIA 8938 AJIA 219I 9 X 061 607 SE 0191 9 X v3sv dn 8nis 7303 370 DLW 2 2 081 801 2191 62 X SL SE 2101 ve X 57 m 4 15 101312313 m TANNVHO 3718 VADW3M lt 3 7031 05 0582 92 0612191 n52 0 1970I 192 9937 05 84 He s er 92 9019791 N92 S010791 NOLLVTIV ISNI 0 me m m 22 6427BI 9191 000 2 S2 H ev 92 669 151 92 8623 191 su gt w N e 2651 00 9 00 0T 78 2191 572791 OvEI 00 0085 61 81 vi 9 9 9 52 562191 5 63701 SE ab AW 2 IH3 H 1 d SSH v HIGIA 53 0 S31DH IHDI3H 1HDI3H HICIMA HION31 7300W 0022 In 13 ONTLNAOW ONILNOON 3302 3402 3402 11933AD 360 0 1 S 219l S1S MN2408 Hot Exhaust Gasses WARNING Exhaust fumes gases are extremely dangerous
15. 9 229 mm Minimum Exhaust Pipe Dia plus 12 805 mm minimum Wind Barrier Wind blowing against air exhaust or intake openings of the Genset room must be considered especially where the radiator and fan are located on the engine Wind blowing against an exhaust opening creates restriction to the fan Wind blowing against intake openings can blow open gravity louvers causing low temperature and moisture problems in bad weather A turning vane may be required to prevent exhaust air recirculation between the exhaust louvers and the barrier surface This will route the exhaust upward into the atmosphere 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 2 4 2 8 General Information MN2408 Transfer Switch Transfer Switch Checklist Main Disconnect Branch Protection 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 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
16. 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 ECUFreqSelect 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 D terminal is not used Note Magnetization current is independent of this setpoint value Table 4 9 Engine Protect Setpoints This setpoint should be used only for Volvo and Scania engines ECU Speed Adjust Adjusts engine speed using CAN bus Nominal speed 50 WTBF Accept RPM The 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 15 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 300s Horn timeout Max time limi
17. avo7 lano 3SvHd 3svHd zoz ioz ooz 212 912 1 12 2121 ziz 0126021802 Zoz 9oz 612 212 zt voz coz 5 21 N 9 9 G aoN N 9 9 G aoN z1 n Qoo oloeioloeioleoioileloloieo eileleie eieileileieieloeleoilo elo diMIS M3xv3H8 LINDYIO diMIS TWNINYAL M3xv3H8 LINDYIO 00S9 19W LINDYIO SNOLLOANNOD 5 212000 0012000 YAWN LINDYIO SNOLLOANNOD 5 T M3TIOMINOO 1 01 30078 5 1 1 310N MADEL MOL SNOLLO3NN0O 3SVHd NO G3SN LON 71 3LON YINOLSNO SNOILO3NNOO M3Wolsno NET DUI LLL 33050 exo NI 81 NI 81 OZINI 81 0ZL 8 St 319301 z xnv i xnv YOLVIONNNNY 0 1 071 Zf AVI3H 0 4015 3 AYASI LOWY Luvis gt rut omy l omy vif MY 1 mE NOW a siya 1 M3MOS M3NOS 134005 YO MIYOS MO193NNOO no no no SwolonaNoo Q oo oooo 20 0 N 9 9 206 206 206 206 20
18. NI 5 779 S3HONI NI SNOISNAWIC TV TYNNYW 135 39 OL 3 3433 1911918 1 504 513398 2348 aod va 43434 9190 10 40 4 303 S31DN SYOLVAANAD O TOI NOLLVTIV ISNI StiO LYti SN 38 O eIOCI Ivg 360 0 1 6 9191 715 MN2408 3 4 Receiving amp Installation inued 35 130kW Cont Receiving amp Installation 3 5 Imensions Table 3 3 Mounting D 4 Z HS LN ul 360 0 1 S 219I S1S Osnodod 6002 81 21 12 25 80 03SIA33 9 1N91000Nv9eN 31H o NYI an SXOCI IWE 5672615000000 00 NOISH3A TAH 053 OEI SOT 3791 D3 08 5 5 2791 9 03 SE 9791 D3 A8 4 15 7309 8120034 ASNIVALS h vi 3514 8 3103135 SBDILVNSEGI IV ASIA 3015 1331 SIA INUSd 3015 JANTONI NV TWOIdAL 349 NADHS SLHOISA SNOLLOVS4 XX 51901030 Q3L4I23dS 1 37 32 53704 930914
19. Prestart time elapsed STARTER on FUEL SOLENOID on MaxCrank time counter started Cranking Cranking RPM gt Start RPM STARTER off PRESTART off Starting D input activated or oil pressure detected or Gen voltage gt 25 Vgnom STARTER off PRESTART off Cranking MaxCrank time elapsed 1st attempt STARTER off FUEL SOLENOID off STOP SOLENOID on CrankFail pause timer started Crank pause MaxCrank time elapsed last attempt STARTER off PRESTART off Shutdown Start fail Crank Pause CrankFail pause elapsed STARTER on FUEL SOLENOID on STOP SOLENOID off MaxCrank time counter started Cranking Starting 30 Nominal speed reached READY TO LOAD on MaxStabTime counter started Running Running Stop request READY TO LOAD off Cooling time timer started Cooling RPM 0 or any other shutdown condition READY TO LOAD off FUEL SOLENOID off Shutdown Loaded RPM 0 or any other shutdown condition FUEL SOLENOID off STOP SOLENOID on READY TO LOAD off Shutdown Cooling Cooling time elapsed FUEL SOLENOID off STOP SOLENOID on Stop RPM 0 or any other shutdown condition FUEL SOLENOID off STOP SOLENOID on Shutdown Start request READY TO LOAD on Running Stop 1 RPM 0 Oil pressure not detected Vgen lt 10V Ready 60 sec Elapsed Adjustment Menu The adjustment menu Figu
20. Table 4 3 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 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 MN2408 Inputs and Outputs Any Binary input or output can be configured to any controller terminal Inputs are BI7 Outputs are BO1 BO7 or changed to different function LiteEdit software There is fixed 1 sec delay when any binary input is configured as protection Table 4 4 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 5 Binary outputs tarter relay output The closed relay energizes the starter motor The relay opens if The firing speed is reached Maximum time of cranking is exceeded Request to stop occurs Fuel solenoid relay output Closed output opens the fuel solenoid and enables the en
21. ber etos pma bon be 3 2 Engine c os cto eo cree dev Og E FR DIOE E ee eee us T aa 3 2 3 6 Installations eh ca nd ed bs Cose CHEN bal as 3 7 Fuel Son oris su auda deka RU Ld te bc But at 3 7 Electrical Connections 3 10 Single Phase Power 5 3 11 Battery Connections igi any Ra Be NUS wank US 3 14 Recommended Engine Coolant 3 15 Recommended Engine Oil and Battery Type 3 15 Post Installation Checks che ih tes Piven Meee 3 15 MN2408 Table of Contents i Section 4 Operation Digital Engine Controller Description 4 1 DICH u bays pusa 4 4 Inputs ard OUIDU IS ebbe Subs Died 4 5 Analog MPU exe SU uh Q beta a a 4 6 a h 4 6 Section 5 Troubleshooting and Maintenance 5 1 Maintenance a RE u eal ku 5 1 Problems S
22. BTU hr x 0 293 Watts BTU hr x 0 0003929 hp Approximate fuel Higher Heating Values HHV Natural Gas 1015 BTU ft8 Liquid Propane 2650 3 Effect of engine efficiency on fuel consumption 2 12 General Information hp x 2545 BTU hr per hp _ 0 25 efficiency Volts x Amps x Power Factor x 1 732 mm x 0 03937 inches m x 3 280 feet m x 1 094 yard cm x 0 394 inches m x 10 764 feet pounds in x 144 pounds ft kPa x 0 1450 psi kPa 0 1333 x inches Hg F C x 1 8 32 Nm x 141 6029 oz in Nm x 8 8495 Ib in Nm x 0 7376 Ib ft m sec x 3 2808 ft sec km hr x 0 6214 miles hr m sec x 3 2808 ft sec m sec x 2 2369 miles hr cm x 0 06102 inches m x 35 315 feet liter x 0 2642 gallon Watts x 3 4122 BTU hr hp x 2 545 BTU hr 10 180BTU hr MN2408 Section 3 Receiving amp Installation Receiving amp Inspection When you receive your Genset 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 If the system is to be stored for several weeks before use be sure that it is stored a location that conforms to published storage temperature and humidity specifications Lifting the Genset When lift or
23. NORTH AFRICA VSE INTERNATIONAL CORP BOX 5618 BUFFALO GROVE IL 60089 5618 PHONE 847 590 5547 FAX 847 590 5587 PANAMA AVE RICARDO J ALFARO EDIFICIO SUN TOWERS MALL PISO 2 LOCAL 55 CIUDAD DE PANAMA PANAMA PHONE 507 236 5155 507 236 0591 SINGAPORE 18 KAKI BUKIT ROAD 3 03 09 ENTREPRENEUR BUSINESS CENTRE SINGAPORE 415978 PH0NE 65 6744 2572 FAX 65 6747 1708 SWITZERLAND POSTFACH 73 SCHUTZENSTRASSE 59 CH 8245 FEUERTHALEN SWITZERLAND 41 52 647 4700 FAX 41 52 659 2394 TAIWAN 1F 126 WENSHAN 3RD STREET NANTUN DISTRICT TAICHUNG CITY 408 TAIWAN R 0 C PHONE 886 4 238 04235 FAX 886 4 238 04463 UNITED KINGDOM 6 BRISTOL DISTRIBUTION PARK HAWKLEY DRIVE BRISTOL BS32 OBF U K PHONE 44 1454 850000 FAX 44 1454 859001 VENEZUELA AV ROMA QTA EL MILAGRO URB CALIFORNIA NORTE CARACAS 1070 VENEZUELA PHONE FAX 58 212 272 7343 MOBILE 58 414 114 8623 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 World Headquarters P O Box 2400 Fort Smith 72902 2400 USA Ph 1 479 646 4711 Fax 1 479 648 5792
24. Stop Menu Group LED Indicators Note The operator control panel is equipped 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 mode and ready to provide standby power Supplying Load green Generator is providing output voltage to load Table 4 1 Alarm amp Warning Conditions Warning X High Coolant temperature Low Oil pressure Generator Under Over Voltage Generator Under Over Frequency Generator Over Current Generator Overspeed Coolant temperature Low Starting battery Under Over Voltage 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 Alarm
25. Warning level for generator overvoltage All three phases are checked Maximum out of three is used Step 1 of Nominal voltage Range Gen lt V Wrn Gen gt V Gen lt V Wrn Warning level for generator under voltage All three phases are checked Minimum out of three is used Step 1 of Nominal voltage Range lt V Gen gt V Wrn Gen lt V Shutdown level for generator under voltage All three phases are checked Minimum out of three is used Step 1 of Nominal voltage Range 0 Gen lt V Wrn Gen V del Delay for generator under voltage and over voltage alarm Step 0 1s Range 0 60 s 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 1s Range 0 60 0 s Gen gt f Shutdown level for generator over frequency Step 0 1 of Nominal frequency Range Gen gt Wrn 200 0 Gen gt f Wrn Warning level for generator over frequency Step 0 1 of Nominal frequency Range Gen lt f Wrn Gen gt V Gen lt f Shutdown level for generator under frequency Step 0 1 of Nominal frequency Range 0 0 lt f Wrn Gen f Wrn Warning level for generator under frequency Step 0 1 of Nominal frequency Range Gen f Gen gt f Wrn Gen f del Delay for generator under frequency and over frequency alarm Step 0 15 Ran
26. www baldor com All Rights Reserved Printed in USA Baldor Electric Company 1 10 MN2408
27. 1 1 1 09 lt 03193NNOD SN N3dO 193136 1303 H 54 2 3NvdOHd 4404901 3 ran A Syd NW IP WYNLYN g 4 Y MSN 2 3309 z BAJ zm 447002 5101 308 Te L gt 5 a z L wale zi M 5 7303 253 H Xx X78 30123NNOO TENVd TOMINOD 959 282 GIONSIOS Tani 153 e 4 9 1 MN2408 B 16 Series GLC UNITED STATES ARIZONA PHOENIX 4211 S 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 FAX 303 595 3772 CONNECTICUT WALLINGFORD 65 SOUTH TURNPIKE ROAD WALLINGFORD CT 06492 PHONE 203 269 1354 FAX 203 269 5485 FLORIDA TAMPA PUERTO RICO VIRGIN ISLANDS 3906 EAST 11TH AVENUE TAMPA FL 33605 PHONE 813 248 5078 FAX 813 247 2984 GEORGIA ATLANTA 62 TECHNOLOGY DR ALPHARETTA GA 30005 PHONE 770 772 7000 FAX 770 772 7200 ILLINOIS CHICAGO 4 SAMMONS COURT BOLINGBROOK IL 60440 PHONE 630 296 1400 FAX
28. 39850 19N3 YSHSVM 3007 4 34250 19N3 1 134 335 Vlad 335 ldW3x3 33v 300 55 3578 OL T3NVd 75 01 3004 ST3NVd OL 4354 STANVd QN3 01 343 3004 T3NVd 01 FIGGIN LONG TANVd OL 53015 LONG S3IdAVX3 I3Nvd 330SO15N3 NV OL SALVW SV IN3NOdWOO JYNSO TONS Yad M3HSVM HLOOL TVN331X3 Z 51 OS 7235 00046 AJSUuVS OL 5135 39 0066 11 8404 0357035 N3HSVM HLOOL L 03110345 ASIMYSHLO 554110 S31ON 1 19130 335 c 335 19130 415 T 19134 335 100 000 21 5 2408 2 Series GLC BW0451D Series GLC B 3 Figure B 10 Customer Interface Connection Diagram
29. ALL CONTROL WIRING IS 16AWG z 4 AWG SEE BREAKER WIRE SIZE CHART BW0707D s Oo Ad umm 2 g 28 LINES INDICATE OPTIONAL ACCESSORIES NEUTRAL GROUND 45106 BOND CUSTOMER CONNECTION E 29 GCB GENERATOR 2 g 30 GND 12 3 31 4 1 PHASE 3 WIRE 0980000 5 Series GLC 11 Figure B 19 ROTATING RECTIFIER 2 ALTERNATOR EXCITER ROTOR 3 4 MAIN 5 SS EXCITER STATOR MAIN STATOR SYN 92 T4 P 05 17 6 T10 12 v2 15 1 vs 18 SEE APPROPRIATE 4 ve 111 LINK BOARD CONNECTION DIAGRAM m 1 gt zx gt mim Ph 22 w2 C6 ox m 17 5 19 5 gt 8 Ol aa we T12 28 2 19 1 OHM VPE eum 20 RHEOSTAT RHEOSTAT IS INSTALLED 7 7 lt 8 5 z 21 212191 2 gt 1 sia F2 F1 7 8 SEE APPROPRIATE wy 2 52 LINK BOARD fal 3 AS440 UL CONNECTION DIAGRAM S CONTROL PANEL VOLTAGE g 24 REGULATOR 112153 S 25 MI gt 5 9
30. ALL CONTROL WIRING IS 16AWG z 5 15 50 38 XXX SEE BREAKER WIRE SIZE CHART BWO707D 2 LINES INDICATE OPTIONAL ACCESSORIES WEURAJGROUND Fle 3s BOND CUSTOMER CONNECTION 3 GCB GENERATOR CIRCUIT BREAKER 3 x GND c gt i 3 PHASE 4 WIRE 980000M9 MN2408 Series GLC B 5 1N ASN LSNW B 6 Series GLC Figure B 13 DC Schematic for 10 25kW CONTROL BOX WIRING ENGINE OPTIONAL ACCESSORY WIRING BWO710D Ae CONTROL E Meet qua gt s gt t ez lieg ud 2086 BATTERY CHARGER 3 FS FUEL SOLENOD 4 Fh om Q 5 1 MENACE COMECTOR 1762 iy gt gt START COMMAND 74 hs te Us s gt e 8 yeuow W 2 2 204 N orem PENES am p m 10 gt m nd unl y MOURA 13 gt 1 LOCKOFF PROPANE VAPOR
31. 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 active No action if buttons START and STOP are pressed MAN Mode START button starts the generator set STOP stops the generator set This operation is further defined in Table 4 2 AUT Mode No action if Start button is pressed The controller can be programmed so the Stop Button is either active or inactive when controller is in the AUT mode Engine Start Stop request is given by binary input REM Start Stop MN2408 Digital Engine Controller Description EM0046A45 MRS19 Continued Table 4 2 Manual Mode Sequence Description ondition of Transition Action 1 Main Measurement Start request PRESTART on Prestart time counter started PRESTART RPM gt 2 or Oil pressure detected or Gen voltage gt 10V Stop Stop fail OFF mode selected or Shut down alarm active Not Ready Not Ready RPM lt 2 Oil pressure not detected Vgen lt 10V no shutdown alarm active other than OFF mode selected Ready Prestart
32. 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 Reinforce the foundation with No 8 gauge steel wire mesh placed horizontally on 150mm centers As an alternative use No 6 re bars 12in 300mm centers horizontally Minimum cover over the bars should be 3in 76mm 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 The size of the bolts holding the sub base to the foundation should be sized to fit the mounting holes shown on the installation diagram Three inch 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 L type bolts are recommended for the foundation bolts After the foundation is cured and the Genset is located the sleeves are filled with grout Exhaust System Exhaust Checklist moom gt Exhaust outlets are not located upwind or near any building air intakes Flexible piping section is used at engine exhaust outlet Exhaust piping material is adequate for expected service Exhaust piping sizing is adequate to prevent back pressure Exhaust piping components are insulated as necessary t
33. 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 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 d
34. hoist equipment is used to lift the Genset and move it to position be careful not to contact overhead wires or other obstacles sure lift or hoist equipment has appropriate tires for the terrain to avoid becoming stuck or tipping over If the shipping pallet is intact use a fork lift to move the Genset If the shipping pallet has been removed use two steel pipes through the Lift Point holes to lift the Genset See Figure 3 1 Figure 3 1 Genset Lifting 0 To lift the Genset always use spreader bars A chains eyehooks and other hardware that is of 9 e sufficient strength to lift at least three times the weight of the Genset Width n d e Height Spreader Bar Method Maximum Lift angle 30 lt Lift li M Point Lift 1 1 Point k H i 2 Point Lift Method WARNING An open bottom stationary engine Genset must be installed over noncombustible materials and shall be located such that it prevents combustible materials from accumulating under the Genset 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 Genset is ins
35. 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 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 Alternator also called Generator End This generator set 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 f
36. larger area Check the local building codes for load bearing capacity requirements If the soil is subject to freezing and thawing the foundation must be extended below the frost line Check the local building codes Figure 2 2 Calculate Soil Bearing Load SBL Capacity T Wi Foundation IW 145 xW T WxL Where K Where Foundation depth in feet m Cx SBL Soil bearing load in W Wet weight of Geneset Ibs kg L Ibs ft kPa 145 Density of concrete in Ibs ft TEL Ww TW Total weight foundation load kg m Genset wet and all other L Foundation length in feet m equipment to be supported W Foundation width in feet m in Ibs kg L Foundation length in feet m W Foundation width in feet m 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 MN2408 General Information 2 5 Table 2 1 Approximate Load Bearing Capacities of Various Soil Types afe Bearing Capacity Ib per ft2 kilo Pascals Soil Type Hard 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
37. 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 Maximum distance from the controller is 656ft 200m For GLC all CAN Address jumpers are removed to select address 1 Figure A 7 Intelilite Remote Annunciator AB CAN ADDRESS JUMPERS DC power 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 5 Radiator Duct Flange 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 Frame Frame Optional Radiator Duct Flange Figure A 8 Radiator Fan As IGLC45 75 IGLC105 IGLC130 A 6 Series GLC Optional Radiator Duct Flange MN2408 Appendix B Series GLC Information amp Wiring Diagrams GLC Circuit Breaker Wire Size Line Side Circuit Breaker Size Wire Size AWG or kcmil Qty Phase Type of Conductor Ampacity 600VAC 20 10 1 THHN THWN XHHW 40 30 10 1 THHN THWN XHHW 40 40 8 1 THHN THWN XHH
38. 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 10096 Table 4 7 Basic Setpoints EnterPassword Password is a four digit number Password enables change of relevant protected set points Use or keys to set and ENTER key to enter the password ChangePassword Use U keys to set and ENTER key to change the password Gen set name User defined name used for 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 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 5000 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 pre
39. 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 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 General Information 2 3 Utility Power During periods when the generator is not running utility power must be provided to power critical components Battery chargers block heaters space heaters and other devices mus
40. 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 Engine 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 and 2 wiring is not open or 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
41. switch The national electrical code NEC requires that connection of a Genset 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 Genset 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 Warning Incorrect installation of this Genset could result in property damage injury or death Connection of the Genset to its fuel source must be done by a qualified professional technician or contractor WARNING 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 Genset systems Intended Use The intended purpose this Genset is to provide emergency power when the main utility power supply is interrupted Therefore it is important that all the wiring that connects the Genset with your house transfer switch distribution box battery charger etc be properly installed Circuit Protection Circuit Breaker protection is provided within the Genset The breaker box is mount
42. to full nameplate voltage If this precaution is not taken serious damage to the Genset can result Caution Do not apply high voltage to windings do not start the Genset in a moisture saturated condition Moisture can cause insulation breakdown making it necessary to return the Genset for repair Note 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 2 Verify that the transfer switch is in Utility Power mode No power must be present at the Genset or transfer switch connections Verify with a voltmeter 3 Verify that the engine starting battery is disconnected so accidental starting is not possible 4 Verify that the Genset is securely mounted and anchored to its cement pad MN2408 Receiving amp Installation 3 15 Post Installation Checks 16 17 18 19 20 21 22 23 Continued Verify that proper clearance exists on all sides and top of enclosure Verify that Genset power is properly connected to the transfer switch Verify that Genset and transfer switch are properly grounded Assure that Genset is a safe distance from any flammable or combustible material Verify that the Genset and transfer switch load are voltage compatible Verify that no load is connected to the circuit breaker and or transfer switch Inspect the engine and Genset and verify that there ar
43. 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 E This symbol is shown throughout the manual to indicate a connection to ground reference point AN Indicates a potentially hazardous situation which if not avoided could result in injury or death AN 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 a potentially hazardous situation which if not avoided could result in injury eath 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
44. 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 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 precaut
45. we U1 12 2 us 13 v 3 7030 we 5 D w2 W5 02 05 w V2 L3 V6 V5 V2 12 G NO LEAD H NO LEAD Series WYE PT Lead NOUT 277 480 VOLT u Ul 240 416 VOLT 12 13 wi ue ve E U2 05 2 F v2 V5 3 5 2 W5 7050 H 3 12 Receiving amp Installation MN2408 Frame Ground Connection It is important for safety reasons that the Genset transfer switch and battery charger share a common Ground and neutral The NEC requires that the frame and exposed metal surfaces be at local ground reference potential to avoid electrical shock hazard A local ground reference may require a driven earth ground conductor at the Genset installation site Make the ground connection as shown in Figure 3 7 Use the appropriate size wire as required by NEC and local codes Figure 3 7 Frame Ground Connection Nut Washer Ground Wire Lug Washer Stud Frame 1 Determine ground stud location and connect the ground wire to the earth ground terminal shown in Figure 3 7 This ground is the local reference ground to ground the Genset frame only Battery Charger Considerations 1 Mount the battery charger on the Genset as close to the Genset as possible 2 Ifyou mount the battery charger inside the building mount it near the main breaker box or disconnect box 3 Ifyou mount the battery charger outside you must protect it from the environment and t
46. with battery racks already installed Cold ambient temperature at the battery location substantially reduces the battery output Figure 2 6 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 at various ambient temperatures The recommended battery capacities are listed in the Electric Systems section of the Engine Data Sheet cold cranking amps CCA at 0 F 18 C 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 Battery Charger An engine mounted alternator to charge the batteries during operation is an available option Standby Gensets require a solid state battery charger that 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 emergency circuit The batteries on prime power Gensets are charged by the engine mounted alternator if equipped Harmonic wave forms from solid state battery charges and belt driven alternators can cause the electronic governor on the engine to act erratically To avoid this the output of the battery charger or the belt driven alternator must be connected directly to the battery or to t
47. 05 FAX 204 956 4251 AUSTRALIA UNIT 3 6 STANTON ROAD SEVEN HILLS NSW 2147 AUSTRALIA PHONE 61 2 9674 5455 FAX 61 2 9674 2495 UNIT 8 5 5 ROAD ROWVILLE VICTORIA 3178 AUSTRALIA PHONE 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 2 816 9900 CHINA 160 SONG SHENG ROAD SONGJIANG INDUSTRY ZONE SHANGHAI 201613 CHINA PHONE 86 21 5760 5335 FAX 86 21 5760 5336 DIESELSTRASSE 22 D 85551 KIRCHHEIM MUNICH GERMANY PHONE 49 89 90 5080 FAX 49 89 90 50 8492 14 COMMERCE AVENUE MAHAGANESH COLONY PAUD ROAD PUNE 411038 MAHARASHTRA INDIA PHONE 91 20 25 45 27 17 18 FAX 91 20 25 45 27 19 TALAVERA OFFICE PARK 28TH FLOOR SUITE M18 JI T B SIMATUPANG KAV 22 26 JAKARTA 12430 INDONESIA PHONE 62 21 7599 9879 FAX 62 21 7599 9878 ITALY BALDOR ASR AG SUCCURSALE DI MENDRISIO VIA BORROMINI 20A CH 6850 MENDRISIO SWITZERLAND PHONE 0041 91 640 99 50 FAX 0041 91 630 26 33 JAPAN DIA BLDG 802 2 21 1 TSURUYA CHO KANAGAWA KU 221 0835 JAPAN 81 45 412 4506 FAX 81 45 412 4507 MEXICO LEON GUANAJUATO KM 2 0 BLVD AEROPUERTO LEON 37545 GUANAJUATO MEXICO PHONE 52 477 761 2030 FAX 52 477 761 2010 MIDDLE EAST amp
48. 1 295 8 4 GLC30M240LS IGLC35 2GU 430 12 2 175 5 0 GLC73M208MS IGLC75 2GU 790 22 4 330 9 3 GLC43M240LS IGLC45 2GU 585 16 5 246 7 0 GLC105M208MS IGLC105 2GU 1164 33 0 511 14 5 GLC55M240LS IGLC55 2GU 744 21 1 295 8 4 GLC128M208MS IGLC130 2GU 1650 46 7 580 16 4 MN2408 Receiving amp Installation 3 7 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 Example Determining Pipe Size for Natural Gas A Genset has a 16Hp engine 60 feet from the supply An engine needs 10 000 BTU hr per hp to run efficiently For Natural Gas fuel there are 1015 BTU ft3 Determine the supply pipe size for Natural Gas fuel 16hp x 10 000 BTU Hr per hp 160 000 per hour for proper operation 160 000 1 015 From Table 3 5 a 60 foot run requires a minimum 1 pipe at full engine load 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 158 cubic feet per hour Iron Pipe Size 1 1 gt 2 2 1 1174 2386 3704 818 1712 2646 673 1419 2213 587 1241 1924 524 1077 1684 433 962 1501 415 885 1376 404 827 1289 366 750 1174 337 693 1077 308 635 991 289 596 933 274 558 875 260 524 827
49. 2102 002 12 912 12 212 212 v zi soz vozcoz v 3909 IMET elelelelelelelelelelelelelelelelelelelelelelele o o e QvO1 jano avo1 aN5 avol 3SvHd zal ena ua9 eur1 ue9 euri N 9 MTIOMINOO WNINYAL NOLOANNOD ura o1Sno n deS TVNINHSL LINOYIO SNOLLOANNOD YINOLSNO MN2408 Figure B 11 Single Phase Diagram ROTATING RECTIFIER GW0000B62 1 lt lt GENERATOR 2 EXCITER ROTOR 3 e 4 MAIN ROTOR 5 INNAN S STATOR EXCITER STATOR ut T1 OO 0 7 k 02 T2 8 12 9 US T 16 NESS 11 Us 14 12 15 1K OHM 5122 REMOVE JUMPER VOLTAGE FROM 1 TO 2 nime ADJUSTING VOLTAGE ADJUST 7 2 RHEOSTAT IS INSTALLED
50. 3715 4 lt 924000000 YAL ZO NOISH3A 8 A34 I SIONVTTSE ALON Q3SIA3N LE NOILON3LX3 3dld 15 22530 A33 z 5 09 4 1 d S3HONI NI SNDISN3WIQ TW 2 xua e o 11 WHO DUC VS 19 aava 1 Eco 3402 135 N39 335 1102812 SNDILLVINGNWWDIO 32 xog DH uu NDILVTTIVISNI NU 71 1031 30Nv14 1204 0191498 02 40 399 WOLLOd 3598 3AUSV 3anl 137100 15 9 9 1119515 3 1051405 380915 9349 dn gnis 19218412313 8 X 29 AIVA 839NVH2 A3311v8 99 MLE Lv 5 41553229 X GDN 2 gt ND 9 N 5 SI NDILO3NNUO 1303 9349 8115 1203 X Receiving amp Installation 3 3 MN2408 35 130kW Imensions Table 3 2 Mounting D 210 HS LN 60 0 1 9 0191 515 0510094 6002 81 21 80 22 80 03SIA33 9Z1 91000 WOd TTA
51. 630 226 9420 INDIANA INDIANAPOLIS 5525 W MINNESOTA STREET INDIANAPOLIS IN 46241 PHONE 317 246 5100 FAX 317 246 5110 IOWA DES MOINES 1800 DIXON STREET SUITE C DES MOINES IA 50316 PHONE 515 263 6929 FAX 515 263 6515 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 5993 PROGRESS DRIVE STERLING HEIGHTS MI 48312 PHONE 586 978 9800 FAX 586 978 9969 MINNESOTA 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 AUBURN ONE ELLIS DRIVE AUBURN NY 13021 PHONE 315 255 3403 FAX 315 253 9923 NORTH CAROLINA GREENSBORO 1220 ROTHERWOOD ROAD GREENSBORO NC 27406 PHONE 336 272 6104 FAX 336 273 6628 OHIO CINCINNATI 2929 CRESCENTVILLE ROAD WEST CHESTER OH 45069 PHONE 513 771 2600 FAX 513 772 2219 CLEVELAND 8929 FREEWAY DRIVE MACEDONIA OH 44056 PHONE 330 468 4777 FAX 330 468 4778 OKLAHOMA TULSA 7170 S BRADEN SUITE 140 TULSA OK 74136 PHONE 918 366 9320 FAX 918 366 9338 OREGON PORTLAND 20393 SW AVERY COURT TUALATIN OR 97062 PHONE 503 691 9010
52. 8 208 120 3 44 55 153 41 51 142 GLC54M208MS IGLC55 2GU UCI24E 311 208 208 120 3 54 67 5 187 52 65 180 GLC73M208MS IGLC75 2GU UCI224G 311 208 208 120 3 73 91 253 67 84 232 GLC105M208MS IGLC105 2GU UCI274D 311 208 208 120 3 105 131 364 99 124 344 GLC128M208MS IGLC130 2GU UCI274E 311 208 208 120 3 114 142 5 396 128 160 444 3 10 Receiving amp Installation MN2408 Transfer Switch Considerations The following are general considerations for the safe use of a transfer switch 1 transfer switch should be located inside the building near the main breaker box the disconnect box 2 transfer switch must be kept away from any location that might allow water to get on it 3 If the transfer switch is mounted outside it must be protected from the environment and its elements Do not mount the transfer switch on the Genset 5 Do not mount the transfer switch where flammable liquids or vapors are present Figure 3 4 Basic Power Transfer System Utility Power Genset Power Remote Start penu pum z L1 12 N L1 L2 N Ground b 9 Fuses Main Panel Circuit Circuit Breakers Breakers 1 L Brace 777 i Earth Transfer p y Switch Mechanical 4 Interlock e lt Ground e L1 L2 N Power To Load R
53. BALDOR GENERATORS GLC Generator Gaseous Liquid Cooled GLC10 15 20 25 35 45 55 75 105 and 130 Installation amp Operating Manual 1 10 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 Safety NONCE die a s o 1 1 Responsibilily gs ue quan guy mbi 1 1 IMPORTANT SAFETY INSTRUCTIONS be ee ees Se ee end 1 2 Caution Statements a dal CA ee EI Ga chee ee UR E Oe s 1 6 Section 2 General Information Limited ma E soto 2 1 installation Guidelines s ce cr eee oes whe uda 2 2 Site Planning s Dae 2 2 HOON SIZE m 2 2 ROOM Locations een mer ER S 2 3 Utilty POWEr ant cet mus ama 2 4 F
54. D LOW COOLANT LEVEL INDICATOR ALARM IS CONNECTED wi E IF BATTERY CHARGER OPTION IS SELECTED mo 080048 MN2408 Figure B 16 DC Schematic for 35 130kW Continued BWO708D 1 1 20 0102 60 20 5 DEUM 535565359 WiUD SNT TOS 56 531 055300 TVNOlLdO 3LV9IQNI SINI 02 SGISNI LAOAVI TANVd aLVTdg ova AMISNI sssi 70 1 05 40 TIVA MOVA ACISNI OOOO asnray isnray 03385 39v110 vor oNu isin O pr OLW N BAE Series GLC 9 MN2408 Figure B 17
55. FAX 503 691 9012 PENNSYLVANIA PHILADELPHIA 1035 THOMAS BUSCH MEMORIAL HIGHWAY PENNSAUKEN NJ 08110 PHONE 856 661 1442 FAX 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 DALLAS 3040 QUEBEC DALLAS TX 75247 PHONE 214 634 7271 FAX 214 634 8874 HOUSTON 10355 W LITTLE YORK RD SUITE 300 HOUSTON TX 77041 PHONE 281 977 6500 FAX 281 977 6510 UTAH SALT LAKE CITY 2230 SOUTH MAIN STREET SALT LAKE CITY UT 84115 PHONE 801 832 0127 FAX 801 832 8911 WISCONSIN MILWAUKEE 1960 S CALHOUN ROAD NEW BERLIN WI 53151 PHONE 262 784 5940 FAX 262 784 1215 INTERNATIONAL SALES FORT SMITH AR BOX 2400 FORT SMITH AR 72902 PHONE 479 646 4711 FAX 479 648 5895 CANADA EDMONTON ALBERTA 4053 92 STREET EDMONTON ALBERTA T6E 6R8 PHONE 780 434 4900 FAX 780 438 2600 TORONTO OAKVILLE ONTARIO 2750 COVENTRY ROAD OAKVILLE ONTARIO L6H 681 PHONE 905 829 3301 FAX 905 829 3302 Baldor District Offices MONTREAL QUEBEC 5155 J A BOMBARDIER ST HUBERT QUEBEC CANADA J3Z 164 PHONE 514 933 2711 FAX 514 933 8639 VANCOUVER BRITISH COLUMBIA 1538 KEBET WAY PORT COQUITLAM BRITISH COLUMBIA V3C 5 5 PHONE 604 421 2822 FAX 604 421 3113 WINNIPEG MANITOBA 54 PRINCESS STREET WINNIPEG MANITOBA R3B 1K2 PHONE 204 942 52
56. HIO 5531 S Hd NN T 3 02 02 MOTISA 02 P 302 902 E ZH0S 03193NNO9 ZHO9 N3dO 1 6 1409 IA09 109 9N N3d0 8 193136 7303 Sd 54 2 440901 8321 bis Svo wainuvN 440x201 wu e MS v m m 15915 4 7 7 98 HOLMS T3A31 su 1NV1000 5101 TL X18 z tbe aay 7 2 zi 21 Sw l AE QION310S 734 253 veli 9 QION3IOS 1304 183 A S y e 4 9 169804901 Series GLC 15 MN2408 Figure B 23 LD6205B35 130 HS LW 55 0102 70 20 85 70 60 03534 8O8NFLO00NVSdN 3113 27126000000 301 80 NOISH3A H Hl 3215 2530 9 SI 1 11 9349 ASIMYSHLO SSJINN 202 4 d SoZ 359 502 N N 02 NOTA mz 7H0S Q3193NNOO ZH09 N3dO
57. 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 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 generator 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
58. PHASE 3 WIRE ug 298000049 Series GLC B 13 Figure B 21 ROTATING RECTIFIER 2 ALTERNATOR EXCITER ROTOR 3 amp 4 nov LL MAIN ROTOR 5 Y EX ITER STATOR MAIN STATOR 2 YN v2 05 17 5 6 T10 5 SYN ME v2 15 SEE APPROPRIATE ve 111 LINK BOARD CONNECTION DIAGRAM A 1 mz x mim w2 C6 1558 33 ws 19 S 8 we 112 28 2 S 7 19 suuper HREM tol 2 20 RHEOSTAT RHEOSTAT IS INSTALLED 7A z UL FUSE BA aa ASSY 8 895 9 Z 2 gt 21413 1 sia E NEL a AS480 UL DIAGRAM CONTROL PANELI VOLTAGE S E 5 REGULATOR S 19 L1L2 L3 s eR 5 3 WEEN 1 M TA B 26 Sud 0 2 27 55 rS 15 E GS 13 9 28 e N N 28 29 9 ot 9 30 31 12952 32 5 lt 2 gt 5 Goo 13 34 9 o9 PA 35 Hie 2 36 CONTROL PANEL gt E 2
59. ROTATING RECTIFIER 1 2 EXCITER r 3 LINK BOARD CONNECTIONS SERIES STAR 3PH 4W VOLTAGE 480 277 416 240 600 347 4 OUTPUT TERMINALS W N MAIN 5 STATOR E eee MAIN STATOR e u1 5 1 1 92 8 u5 T7 A 96 T10 8 10 1 2 11 v2 15 vs LINK BOARD CONNECTIONS SEE APPROPRIATE ve 11 PARALLEL STAR SPH 40 CONNECTION feruna s 139 DIAGRAM W N t N mim 25122 w2 16 Q3 2718 v L3 9 we 112 V 5 PA E 1K OHM REMOVE JUMPER 7 7 Jolas RHEOSTAT RHEOSTAT IS INSTALLED 7 7 H IP 2m a 5 5 gZ 22 218 1 51 LINK BOARD CONNECTIONS F2 F1 7 8 SEE APPROPRIATE 8 23 2 2 LINK BOARD SERIES DELTA 4 A5440 UL CONNECTION VOLTAGE 2407120 a CONTROL PANELI VOLTAGE DIAGRAM TERNAS 24 REGULATOR 5 111213 25 5 V ix Li 26 120 2 EIE 2 55 m 5 ao L3 vo oo 28 7 N N Slo N 113 29 c m N in 8 9 30 i298 c2 32 x 555 52 5 Boo 13 o9 Q m 929 35 a 36 CONTROL PANEL x ix ix iz iE TZ x oix iX iX i 37 5 gt gt gt gt 4 UNLESS OTHERWISE STATED
60. 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 WARNING 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 WARNING 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 accidentally touches the positive battery terminal or wire The risk of such shock is reduced when the ground lead is removed during installation and maintenance Procedure The correct type battery must be installed in the battery compartment provided see Table 3 8 Installation and servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions Keep unauthori
61. TIES OF FITNESS FOR PARTICULAR PURPOSE AND MERCHANTABILITY Warranty Period 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 portable 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 I
62. TION 55 GENERATOR E Bien GND d 31 5 1 3 WIRE x 188000049 B 10 Series GLC MN2408 MN2408 Figure B 18 GW0000B60 ROTATING RECTIFIER 1 2 5 TE IS ALTERNATOR 2 AAA EXCITER ROTOR 3 y ON NN 4 e MAIN 5 w EXCITER STATOR MAIN STATOR U1 1 L1 6 CY XY YN 8 111 02 2 05 3 b ONY YN 5 ue 14 12 1K OHM JUMPER ADJUSTING Wen 019 amp ADJUST WHEN Jl 10 RHEOSTAT RHEOSTAT IS INSTALLED 7 2 1 1 13 8 gt 1 00 sic 2 78 5 AS440 UL amp iz CONTROL PANEL VOLTAGE 15 REGULATOR o sgg r m c veg 17 NT M 518 2 1 1 E a 5 18 Sua L2 N gt 55 N m E v2 2 as 2 13 1 z 3 a gt 8118 20 14 219 21 38 58 22 g L2 915 2 c2 5 25 L3 o 2 24 69 M 25 o 5 CONTROL PANEL 8 26 x x x x x x z 27 UNLESS OTHERWISE STATED
63. Table 4 10 Generator Protect Setpoints Threshold for generator overload in of Nominal power Step 1 of Nominal power Range 0 200 Overload Wrn Threshold for generator overload warning in of Nominal power Step 1 of Nominal power Range 0 200 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 of Nominal current Range 100 500 96 21 IDMT curve shape selection 21 del is Reaction time of IDMT protection for 200 overcurrent 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 2Inom del Nomin current Reaction Time Igen Nomin current Curr unbal Threshold for generator current asymmetry unbalance Step 196 of Nominal current Range 1 100 of Nominal current Curr unbal del Delay for generator current asymmetry Step 0 1 s Range 0 60 0 s Gen gt V Shutdown level for generator overvoltage All three phases are checked Maximum out of three is used Step 1 of Nominal voltage Range Gen gt V Wrn 200 Gen gt V Wrn
64. W 55 50 8 1 THHN THWN XHHW 55 60 6 1 THHN THWN XHHW 75 70 6 1 THHN THWN XHHW 75 80 4 1 THHN THWN XHHW 95 90 4 1 THHN THWN XHHW 95 100 2 1 THHN THWN XHHW 130 110 2 1 THHN THWN XHHW 130 125 1 1 THHN THWN XHHW 150 150 1 1 THHN THWN XHHW 150 175 2 0 1 THHN THWN XHHW 195 200 40 1 THHN THWN XHHW 260 225 40 1 THHN THWN XHHW 260 250 40 1 THHN THWN XHHW 260 300 300 1 THHN THWN XHHW 320 350 400 1 THHN THWN XHHW 380 400 500 1 THHN THWN XHHW 430 450 40 2 THHN THWN XHHW 520 500 40 2 THHN THWN XHHW 520 600 300 2 THHN THWN XHHW 640 700 400 2 THHN THWN XHHW 760 800 500 2 THHN THWN XHHW 860 Wiring Diagrams Wiring diagrams for these generators are contained on the following pages of this appendix MN2408 Series GLC B 1 Figure B 9 Enclosure Grounding 5 124 000 001 5135 39 002210 30 3B SOTON3 303 NOLLVOI3O3dS S002 1 0L 67 19 51 0361134 6SINZ0000NV9dN 3114 127445000000 10 NOISH3A V ALT 09 HOGIVd L 40 ONJ OL 51 0300 0530 c Vl 3 1708 LAN LAJSNI LANGISM J 3HSVA 3a sm IoN3 3007 11145 S3HSVA 8007 S3HSVA 1973 38850 IONS LE ALS AN LAN LASSNI LONG IA 8001 11145 3HSVA 1913
65. activated Replensih oil to full Restricted air flow Check replace air filter No spark Check replace spark plug s Check that engine switch Is in Start position Engine will not crank electric start Dead battery Remove battery and trickle charge or replace with new battery Never Jump Start Emergency Stop LED is ON Reset controller after an Emergency Stop Engine starts but will not run smoothly Fuel or ignition problem Refer to engine manual Verify fuel selection jumper setting Engine overheats Excessive load Remove one or more electrical loads Debris or dirt buildup on engine Remove debris Clean engine surfaces to allow cooling No output voltage Ciruit Breaker tripped or failed Reset circuit breaker or replace if required Internal failure of Alternator Contact service Output voltage varies Irregular speed fixed speed mode Check engine for malfunction or load for fluctuation Fluctuating speed fixed speed mode Stabilize load The addition of a lamp load resistance load may compensate partially for load changes caused by intermittent motor operation Do not overload Loose terminal or load connections Verify all connections and terminal tighness Low output voltage Low engine speed Verify engine RPM Excessive load Check engine for malfunction or system for overload Reduce load High resistance connections Verify all connections and terminal tighness connections will be warm or hot Internal failure of Alternator Contact se
66. cks 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 A fuel selection jumper is located at customer terminal block TB1 The jumper must be correctly set for the type of fuel being used by the genset IGLC 10KW 130KW 26 FUEL SELECT TERMINAL BLOCK TB1 12 1288 rs LP 12 6 NG 124146 1304 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 Fuel Consumption at 100 load Fuel Consumption at 100 load Catalog Number Model Number cubic ft Hr cubic m Hr Catalog Number Model Number cubic ft Hr cubic m Hr Natural Gas LP Vapor Natural Gas LP Vapor GLC10M240LS IGLC25 2GU 203 5 8 86 2 4 GLC72M240LS IGLC75 2GU 790 22 4 330 9 3 GLC15M240LS IGLC25 2GU 247 7 0 108 3 1 GLC32M208MS IGLC35 2GU 430 12 2 175 5 0 GLC20M240LS IGLC25 2GU 300 8 5 131 3 7 GLC44M208MS IGLC45 2GU 584 16 5 246 7 0 GLC25M240LS IGLC25 2GU 365 10 3 154 4 4 GLC54M208MS IGLC55 2GU 744 21
67. d 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 leak is found replace only with approved pipe or components Caution Statements Caution Caution Caution Caution Caution Caution Caution Avoid installing the generator 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 sta
68. d is removed during installation and maintenance Recommended Engine Coolant Refer to the Engine manual for coolant type Normally a 50 50 mix of coolant and water is required Coolant system capacity is shown in Table 3 8 Recommended Engine Oil and Battery Type When replacing batteries use only the recommended battery for your Genset see Table 3 8 Table 3 8 MODEL ITY SUMMER WINTER OIL OIL RECOMMENDED AMPS COLD OIL less than 0 F CAPACITY BATTERY CRANKING IGLC25 2G 20 0 18 9 SAE 15W40 5 30 5 0 015 Group 24 675 635 206 20 0 18 9 SAE 154 40 5 30 5 0 015 Group 24 675 IGLC45 2G 20 8 19 7 SAE 15W40 5 30 5 0 015 Group 31 925 IGLC55 2G 21 2 20 1 SAE 15W40 5W 30 5 0 QTS BCI Group 31 925 IGLC75 2G 22 0 20 8 SAE 15W40 5W 30 5 0 QTS BCI Group 31 925 IGLC105 2G 27 2 25 7 SAE 15W40 5W 30 9 0 QTS BCI Group 31 925 IGLC130 2G 25 6 24 2 SAE 15W40 5W 30 9 0 QTS BCI Group 31 925 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 QGensets 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 Genset up
69. ds 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 The exhaust system should be as short and have as few bends as possible Room Air Ifthe 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 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
70. e 0 180 s The protection of IOM PTM inputs is activated by over crossing the limits Calibr 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 EM0046A45 MRS19 Continued Figure 4 4 Controller Connection Diagram ENGINE GENERATOR FUEL SOLENOID Remote lt 4 Start PE EMERGENCY STO STARTER 2293 9 21818 8555 IL NT MRS 19 ei GENSET Control 24 mec A A CAN BINARY OUTPUTS PRESTART ALARM STARTER MN2408 Operation 4 11 4 12 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 s manual for specific engine maintenance instructions for your generator set Any maintenance
71. e 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 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 WARRAN
72. e no loose wires or components Tighten if necessary Verify that the ground conductor is of correct wire size and properly connected Verify engine oil level is full Refer to engine manual if necessary Verify engine coolant level is full Refer to engine manual if necessary Verify exhaust system to assure it is in properly connected and pointing away from combustible materials 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 Verify the fuel select source jumper is set to select operation on the correct fuel type Verify the fuel source is ON and the pressure and flow rate are correct Remove all tools rags etc from inside the Genset enclosure Close all enclosure doors and be sure no hands are inside the Genset enclosure when it starts Verify all loads are disconnected Start the Genset Refer to Section 4 Operation for details 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 With the engine running several checks must be made a 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 b Verify there are no coolant or oil leaks If a leak is detected stop the engine imm
73. e 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 General Information 2 9 Battery Starting System This section describes the battery starting system nominal 12 or 24 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 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 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 Battery Location Battery Size Locate batteries as close as possible to the Genset to minimize starting circuit resistance see Figure 2 6 High starting circuit resistance substantially reduces starting cranking ability The Genset data sheet lists the maximum allowable cranking system resistance Mount batteries ona level rack away from dirt and liquids Allow space for servicing checking water level and level of charge Baldor Gensets can be ordered
74. ed to the Genset prior to shipment see Genset Mounting diagrams See GLC Circuit Breaker amp Wire Size in Appendix B for recommendations Wire Size 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 Genset output to an electrical load a UL listed circuit breaker with the appropriate ratings must be provided within 25 feet of the Genset Use only copper wires Genset ratings are given in Table 3 7 Table 3 7 Genset Ratings Voltage 125 Rise Altemator Standby 125 Rise Alternator Standby Catalog Number Model Number Alternator Voltage L UL N PH Rating LP Fuel Rating NG Fuel kW kVA Amps kW kVA Amps GLC10M240LS IGLC25 2GU 282PSL1714 240 240 120 1 10 10 42 10 10 42 GLC15M240LS IGLC25 2GU 282PSL1715 240 240 120 1 15 15 63 15 15 63 GLC20M240LS IGLC25 2GU 282PSL1716 240 240 120 1 20 20 83 20 20 83 GLC25M240LS IGLC25 2GU 283PSL1717 240 240 120 1 25 25 104 25 25 104 GLC30M240LS IGLC35 2GU UCI224C 06 240 240 120 1 30 30 125 30 30 125 GLC43M240LS IGLC45 2GU UCI224E 06 240 240 120 1 43 43 179 40 40 167 GLC55M240LS IGLC55 2GU UCI224F 06 240 240 120 1 55 55 229 52 52 217 GLC72M240LS IGLC75 2GU UCI224G 06 240 240 120 1 72 72 300 67 67 279 GLC32M208MS IGLC35 2GU PI144J 311 208 208 120 3 32 40 111 31 39 108 GLC44M208MS IGLC45 2GU UCI224D 311 20
75. ediately and repair the leak before proceeding c Verify that operation is smooth If belt squeals vibrations or other sources of noise exist stop the engine immediately and repair before proceeding d Verify that the correct voltage exists line to line and line to neutral at the Genset and at the transfer switch e 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 can be checked 24 25 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 Close all enclosure covers The post installation checks are now complete 3 16 Receiving amp Installation MN2408 Section 4 Operation Digital Engine Controller Description EM0046A45 MRS19 LED Indicators Manual Run Start Stop Display Page Mode 4 and gt Horn Reset Fault Reset V Enter Enter and Figure 4 1 Operator Control Panel Operating Modes and Horn amp Fault Reset BALDOR GENERATORS Manual Display
76. emote 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 Genset 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 MN2408 Receiving amp Installation 3 11 Figure 3 5 Single Phase Connections From Alternator Factory Wired Bond Jumper Note Remove the Bonding jumper to meet local codes if required zd LJ NEUTRAL ey LI LOAD Connections T 7 AC Power Connections GROUND Ground Customer Connections Connections Figure 3 6 Three Phase WYE and DELTA Connections Parallel WYE TE we oy var mE 139 240 VOLT B NO LEAD c NO LEAD w2 we v2 N V6 U6 U2 wi ws 7030 wi v5 12 v5 3 13 Ws we Lt us 2 Series Delta berm Leg REGULATOR mm
77. flex pipe clamps silencer and rain cap Figure A 4 traight Pi RainCap Sraight Ripe Exhaust Flex Straight Pipe EE 3 90 Elbow N Clamp Clamp Clamp Muffler Straight Pipe 10 35kW Muffler 45 Elbow 90 Elbow ra 45 Elbow 90 Elbow C Exhaust Flex Rain 45 75kW Muffler O Clamp 1 1 Reducer HEH 90 Elbow X Gasket Gaskel UA 7 Rain aH cmi Exhaust Flex 105 130kW Silencer refer to Figure A 4 for specific details 1 Attach the Silencer to the Exhaust Output of the engine refer to Figure 4 2 Use correct size clamp to attach extension pipe to Exhaust Output pipe from engine 3 Be sure the Extension pipe fits securely over Exhaust Output pipe so that no exhaust leaks can occur LY000125 MN2408 Options amp Accessories A 3 Flexible Fuel Lines A flexible fuel 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 Fuel Solenoid Valve GLCFFL1 3 4 NPT Male fittings 12 long GLCFFL2 1 1 4 Male fittings 18 long GLCFFL3 2 NPT Male fittings 12 l
78. gas flow ft min m3 min 6000 1 Z D diameter of pipe mm 00005 L 01 S Specific weight of gas Ib ft kg m3 4000 L 0 05 S 39 6 3500 7 5 6 Exhaust Temperature 4609F 3000 2500 m 0 005 S 352 05 Exhaust Temperature 273 16 2000 0 001 8 To obtain equivalent length of straight pipe for 1500 0 0005 9 each long radius 90 bend e je L 15xD L m 15xD 1000 4 ed 15xD 15xD 900 L L 1000 800 13 0 00001 Note For 90 bends radii of 1 5 times pipe diameter helps reduce resistance and backpressure MN2408 General Information 2 7 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 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 isolato
79. ge 0 60 0 s Operation 4 9 Table 4 11 Sensor Spec Setpoints Al1 Al2 AIS 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 12 IOM PTM Module Setpoints INPUT 1 alarm detection Step 1 Range 100 to 10000 AnllnlOM1 lev2 The level for IOM ANALOG INPUT 1 alarm detection Step 1 Range 100 to 10000 AnllnlOM1 del Delay for 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 for 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 ANALOG INPUT 3 alarm Step 1 s Range 0 180 s AnllnlOM4 lev1 The level for IOM ANALOG INPUT 4 alarm detection Step 1 Range 100 to 10000 lev2 The level for IOM ANALOG INPUT 4 alarm detection Step 1 Range 100 to 10000 AnlInIOMA del Delay for IOM ANALOG INPUT 4 alarm Step 1 s Rang
80. gine 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 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 MN2408 Operation 4 5 Analog Inputs Set points 4 6 Operation Three analog inputs for resistive sensor 0 to 2400 ohms measuring are available on the controller Use LiteEdit software to modify configuration The Analog inputs values assignment Oil press 12 Water temp Fuel level 15 fixed It is possible to configure on each Analog input Reading from Analog inputs or from Engine Control Unit via CAN bus J1939 Sensor characteristics from the list e Value dimension e g psi bars F 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 6 Analog Inputs Oil press Oil pressure analog input Default VDO sensor in
81. he battery terminals on the starter Make control connections to the Genset control using a conduit with a flexible section at the Genset to avoid damage due to Genset vibrations 2 10 General Information MN2408 Battery Cables The wire size wire gauge of the cables connecting the starter to the batteries must be large Resistance in Ohms at 77 F 25 C MN2408 0 00400 0 00380 0 00360 0 00340 0 00320 0 00300 0 00280 0 00260 0 00240 0 00220 0 00200 0 00180 0 00160 0 00140 0 00120 0 00100 0 00080 0 00060 0 00040 0 00020 0 enough to ensure the resistance of the cranking circuit is less than the Maximum Allowable Resistance of the Cranking Circuit as shown on the Engine Generator Set Data Sheet 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 7 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 7 illustrates an example of a typical cranking circuit resistance calculation Figure 2 7 Typical Battery Cable Calculations 4 3 2 1 0 00 000 2 0 2 00 Maximum allowable resistance of
82. he 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 Genset 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 WARNING 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 Genset MN2408 Receiving amp Installation 3 13 Caution This Genset must have a battery installed for operation The battery is used during starting and during operation If engine operation is attempted while the battery is removed damage to the engine s electrical components may result Battery Connections WARNING 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 batter
83. ibutor Note If you 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 flexible coupling Exhaust Gas Restriction The maximum allowable back pressure or system restriction is stated in the product specifications data inches Hg 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 engine exhaust systems have the least possible restriction to exhaust gas flow This can be calculated as shown in Figure 2 3 Figure 2 3 Exhaust System Calculations I L x SL x Q2 D in 5184 x D gt Where Q cfm ft min psi kPa 10000 psi 0 4912 x in Hg 9000 P in Hg per ft F 8000 4 0 1333 x in Hg aj r 1 0 4 AG 7000 EX L Length of pipe in ft m 0 5 e Q Exhaust
84. ies WARNING 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 WARNING 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 WARNING 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 3 Wear rubber gloves and boots WARNING 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 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
85. 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 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 im
86. in Figure 2 5 Figure 2 5 Typical Emergency Power System Installations Utility Non Emergency Loads utility 9 Gensets Genset Main Disconnect Branch Generator Paralleling Control Panel Priority Control Protection Branch Transfer Protection TS 1 Switch TS 2 9 Transfer Transfer 2 Switch1 y Switch2 Loads Non Emergency Level 1 Level 2 Loads Loads Loads Multiple Gensets can be arranged either in parallel or separately connected to dedicated emergency loads Figure 2 5 also shows a typical 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 NFPA 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 inc
87. ing bolts in the base frame secure the Genset to the shipping pallet Remove these bolts lift the Genset and remove the shipping pallet Secure the Genset to the concrete pad using 3 5 anchor hardware not provided the base frame mounting holes See Figure 3 2 Anchor bolts must be long enough to extend through the Genset mounting frame e Engine Cooling A sufficient flow of clean cool air is required for combustion and to dissipate the heat produced 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 Genset The exhaust fan must be connected to the AC power terminals of the Genset so that when the Genset starts it will provide immediate cooling air flow The fan will operate until the Gen
88. ing do not direct them towards anything that could catch fire or explode WARNING Exhaust fumes gases are extremely dangerous and can cause severe illness or death Never Installation 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 The Genset 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 Starting Battery 4 Ground Connection After installation the post installation checks must be performed prior to starting the engine After these che
89. ions 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 Itis electrically conductive and corrosive The following precautions are to be followed when working on batteries 1 Wear full eye protection safety 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
90. lation 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 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 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 q
91. ludes the paralleling of dissimilar generators contract your nearby Baldor Distributor Transfer Switch Location MN2408 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 breaker or fuses should be installed in the line between the generator and the transfer switch Baldor Gensets are available with properly sized circuit breaker built into the generator control The circuit breaker can be separately mounted In the case of very large circuit breakers a separate floor mounted circuit breaker may be 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 6 Conduit wire circuit protective devic
92. mediately 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 Product 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
93. nformation 2 1 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 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 National Fire Protection Association 30 Storage Handling and Use of Flammable Liquids No 37 Stationary Combustion Engines and Gas Turbines 99 Essential Electrical Systems for Health Care Facilities 101 Life Safety Code No Systems No 110 1985 Emergency and Standby Power Systems e NEMAMG1 e Local Codes applicable to Genset Installation See your local building inspector National Fire Protection Association 617 770 3000 includes NEC 1 Batterymarch Park Quincy MA 02169 7471 USA NEMA National Electrical Manufacturers As
94. nnect the Positive battery terminal from the battery 3 Remove battery hold down bracket 4 Remove battery 5 Install Heating Pad in battery tray refer to Figure A 2 The and dimensions should match the battery tray 6 Install battery on top of Heating Pad 7 Install battery hold down bracket 8 Carefully install the Positive battery terminal to the battery 9 Carefully install the Negative battery terminal to the battery 10 Connect the AC power cord to shore power outlet 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 or wiring must be located close to block heater Figure A 3 OUTLET HOSEBARB 625 1 0 67 Brackets 1 4 mmm p lt 15 48 16 3 HF Block Heater refer to block heater manual for specific details 1 The block heater is mounted as shown in Figure 2 Connect the AC power cord to shore power outlet A 2 Series GLC MN2408 Silencers 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
95. o prevent operator burns and reduce pipe radiant heat losses 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 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 any nearby wall or structure Attention must also be given to exhaust noise in selecting placement of the exhaust system Level Of Attenuation In general manufacturers offer multiple grades of silencers industrial residential and critical Select the silencer to assure the desired level of silencing is met 2 6 General Information MN2408 Multi Engine Installations Caution not connect multi engine exhaust systems together Each engine must have its own exha
96. 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 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
97. olutions 2 sae ep pedes 5 2 Appendix Options amp Accessories RR ER ee A 1 Battery huu Decr 1 Battery Heaters uu sso q oum e te SU ma AU dea A TA ATAA E A 2 Engine Block Heater 222 each eins evita NS e EE CREAR D YN A 2 pedibus R t A 3 Flexible Fuel Lines ee ee s a eee A 4 i x 4 Remote AnnuntiatorS uou a ROME AU KR eae 5 Radiator DuctiFlange_ t e kee eu 6 Appendix B Series GLC Information amp Wiring Diagrams B 1 GLC Circuit Breaker amp Wire Size B 1 Wiring Diagrams a Rp aA 1 ii Table of Contents MN2408 Section 1 Product Safety Information Safety Notice Responsibility 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 Always disconnect all electrical loads before starting the generator Instal
98. on Step 1 s Range 0 300 s MinStpValvTime Idle Function Stabil Time Start RPM Binary output Stop solenoid closes when stop sequence begins and closes at least for MinStpValvTime Example MinStpValvTime 20 sec a 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 lt 10 VAC Stop fail is detected when is difference between those conditions e g RPM O and Generator voltage gt 10V RPM RPM BO Starter BO IDLE RATEL Idle time Min stab time X d Electric protections active Start Fail Voltage autodetection STARTER 990 4 i T a GCB Idle time Stabil time Closepelay close open opened closed Operation 4 7 Table 4 8 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 3600 CoolingSpeed
99. on problems are related to the installation techniques used Do Not guess be sure pipe size is adequate for required flow rate 1 e MN2408 Connect the proper size gas pipe at the inlet connection to the Fuel Lock Solenoid 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 Genset verify that fuel system pressure is 11 Water Column 6 oz pressure and fuel pipe sizes comply with Table 3 6 To run on LPV fuel install jumper on TB1 terminals 12 and FS Proceed to Electrical Connections Receiving amp Installation 3 9 Electrical Connections Class 1 wiring methods must be used for field wiring connections to terminals of a class 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 Warning Never connect this Genset to the electrical system of any building unless a licensed electrician has installed an approved transfer
100. ong GLCFS1 3 4 Strainer female Inlet male outlet GLCFS3 2 NPT Fuel Strainer female Inlet male outlet ft Fuel Flex Line Fuel Strainer Installation Use appropriate thread sealer as required by plumbing codes 1 Thread Fuel strainer onto NPT close pipe nipple Thread Flex Fuel Line into Fuel Strainer input 4 Connect other end of Flex Fuel Line to site fuel supply pipe as required by plumbing codes E Stop E Stop Switch Kit Mounts to an Enclosure remote from the Genset 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 15 oH 3 75 182 12 12 S U REMOTE E STOP REMOVE JUMPER FROM 12 REMOTE Tc UR 1B WHEN REMOTE E STOP IS INSTALLED 1B Bo d o2 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 GLCESS PONS A 4 Series GLC MN2408 Remote Annunciators Remote Annunciator provides remote annunciation of faults and generator status Individual fault conditions are remotely monitored using both visual LED lights amp audible alarm annunciation Lamp test and alarm horn silence pushbuttons are
101. oundation s 35 ua lt gt 2 4 EXhaust System SURGIR TR ARN RAS we Ore RA ace 2 6 Level Of AttenBdatiohr Soins duels enue ote ied tl Seagate ps 2 6 Multi Engine Installations cx cx 2 7 Exhaust Mariifold aD e 2 7 Exhaust Gas Restriction ere u nw DEC ROC 2 7 Exhaust PIPING hee Bea ae E VEM 2 8 Rain Protector de deena nein i ae eee E ae Seeger aad Rein eel 2 8 Transfer ie 2 9 Battery Starting sve ete Eo ER ER dint ss ated a dde dust aet t oed nd 2 10 Battery Hm E sa iia Rd 2 10 i i Eolo DEI DU E a Sa 2 10 Battery Charger bebe bsp oU Etu sb oes pde deis 2 10 Battery Cables c b urbe ipe DI E teu the e yasa 2 11 Formulas sa ma ayara qaa e norte Ed bore 2 12 Section 3 Receiving amp Installation Receiving amp Inspection x suis EO Ra EK US 3 1 Litting the Genset 45 o Rus GS RI PAS AG a 3 1 Physical Location am ud 3 1 Secure Gensel
102. ounting Locations GLC35 Battery Charger GLC45 105 Battery Charger Mounting Location Mounting Location oo Frame oo ore gus Battery BTCGR10A BTCGR10A Battery Tray 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 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 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 BTHTR81 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 must be located close to battery heater Figure A 2 Battery Heating Pad Installation BTHTR81 Heater 1 Carefully disconnect the Negative battery terminal from the battery 2 Carefully disco
103. r 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 WARNING 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 preca
104. re E H LINES INDICATE WIRING FOR OPTIONAL ACCESSORIES 5 5 110 INCLUDES REMOTE ANNUNCIATOR REMOTE 5 AND LOW COOLANT LEVEL INDICATOR AC FAIL ALARM IS CONNECTED ie IF BATTERY CHARGER OPTION IS SELECTED me 90408 MN2408 Figure B 14 DC Schematic for 10 25kW Continued BWO710D ez n sz oi 20 0102 50 20 2 71 36 ASONVTIR q 2228000000 EET 5805350 I U SO WO 3WT 3 S3lHOSS325v TVNOlLdO 3LV9IQNI SININ LSNrav M3 V 338 39V 10 1Snrav 03345 5 O ININNNY O 0nv AQv38 0 LONO O o EN LJ mmn 2 OO
105. re 4 3 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 3 Adjustment Menu Stop Stop fail Some output conditions are optional and may require additional programming of field connection See appropriate wiring diagram 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 Operation 4 3 Alarms Following alarms are available Sensor fail FLS see Table 4 3 Sensor fail is detected when measured value is 6 out of selected sensor characteristic Sensor fail is indicated by symbol instead measured value Warning WRN see Table 4 3 When warning comes up only alarm outputs and common warning output are closed Shut down SD see Table 4 3 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 4 4 Operation common shutdown output are closed Active or not reset protection disables start
106. ree 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 60 s CrnkFail pause Pause between crank attempts Step 1s Range 5 60 s 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 elapses the IDLE NOMINAL output closes Binary output IDLE NOMINAL opens during Cooling period again Step 1 5 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 5 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 detecti
107. requency 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 may not keep perfect time when powered by a 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 components 4 Inspect and replace any control panel components that are broken or not working properly receptacles circuit breakers switches etc 9 BON 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 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 fuel Check that fuel valves are ON Check fuel level in fuel tank Low Oil Level Low Oil Pressure Sutdown
108. 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 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 BTCGR10A Battery Charger 12 Volt 10 Amp Float Includes terminal strip for AC input power and DC output UL Listed Figure A 1 Recommended M
109. ried 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 flexible coupling 3 ltis 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 sec
110. rmation relative to engine operation maintenance recommendations and additional safety warnings Copyright Baldor 2009 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 materials for a period of time as set forth in the Warranty Period chart below All 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 th
111. rs 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 4 Note Water is one of the by products of combustion This water must be kept from draining back into the engine Slanting the horizontal section of the exhaust system piping downward slightly away from the engine can do this A water trap tee extension with a drain cock should also be used The 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 Figure 2 4 Exhaust Pipe Thimble Installation Installation 9 229 mm Through Roof Minimum 9 229 mm Minimum Holes in End of Inner Sleeve installation Through Flashing Wall or Partition Holes in End of 9 229 mm Minimum Inner Sleeve Wall or Partition
112. rt the generator 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 install 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 info
113. rvice Low power factor 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 Ground generator frame at local reference ground see Section 3 Grounded armature or field coil Contact service Mechanical noise Internal failure of Alternator Contact service Loose or misaligned coupling Tighten align coupling and alternator shaft to engine shaft 5 2 Troubleshooting and Maintenance MN2408 Table 5 2 Troubleshooting Guide Digital Controller Only Problem Controller does not power up even with correct DC power applied Possible Cause Wiring Mistake Overload Condition Remedy Check that there no wiring errors short circuits connected to the controller Check breaker on the Control Panel Check Fuses on Control Panel LCD Display cannot be viewed Improper Supply Voltage Improper contrast adjustment Check DC supply voltage at terminals B amp B 10 30VDC Adjust LCD contrast for best display see Section 4 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 rese
114. s 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 EM0046A45 MRS19 Continued Operating Mode Display Menus Operating Horn amp Fault Reset MODE gt HORN FAULT RESET RESET 4 2 Operation Press Mode lt q to scroll though the list of operating modes Off Manual and Automatic The control mode is shown in the highlighted area at the top of the display Figure 4 2 When the desired Control Mode is highlighted press Start to begin operation Press Stop to terminate operation Generator set operation is not allowed 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 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 2 displays the operating mode and operating parameters such as kW engine RPM etc Figure 4 2
115. s 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 for 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 Specification Sheet The wet weight includes the fluids coolant and oil 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 be a minimum of 2 0 times the Genset wet weight Figure 2 2 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 must be added to spread the load over a
116. sent 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 DispBackLightT O 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 MAN AUT Equivalent to Controller mode changes buttons Note Controller Mode change can be separately password protected RS232 mode Standard Modbus Communication protocol switch 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 MN2408 Table 4 8 Engine Setpoints Firing speed when iL controller stops cranking starter goes OFF Step 1 of nominal RPM Range 5 50 Starting POil When reached controller stops cranking starter goes OFF Step 0 1 psi Range 100 10000 Note There are th
117. 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 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 the cooling air flow across the Genset This may result in overheating fire or explosion 3 2 Receiving amp Installation MN2408 Figure 3 2 Genset Mounting 10 25kW 30 HS S2 01219 9NILNnON YINOLSNO 0500099 0102 92 10 01 22 20 035 38 LZZNOLO00N VON
118. sociation 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 Never use the Genset room for storage as well e 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 A minimum of feet preferably 4 feet must be allowed on the two sides of the engine for service access e Onthe generator end of the engine allow a space equal to the length of the generator generator length only not the entire genset e At the 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 2 2 General Information MN2408 Room Location 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 MN2408 Maintain the building at a satisfactory temperature year round to meet applicable codes Assure the genset is not located so far from the emergency loa
119. t No RUN output signal Shutdown Faults not reset Engine speed not detected at cranking All shutdown faults must be 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 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 controller 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
120. t have power to maintain the generator set components and allow fast easy starting 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 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 accommodate dynamic loads e The actual mounting arrangement surface area in contact with the floor will determine the compressive strength required The Genset should be securely fastened to the floor slab with expansion anchors that fit the mounting holes shown on the Genset installation diagram e Forinstallations not expected to be permanent elastomer pad wi
121. t 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 1 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 Oil 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 Wrn Wtemp 10000 Wrn Water temp Warning threshold level for ANALOG INPUT 2 Step 1 F Range Wrn Wtemp low Sd Water temp Wrn Wtemp low Warning threshold level for low value on ANALOG INPUT 2 Step 1 F Range 100 Water temp Water temp Low del Delay for ANALOG INPUT 2 Wrn Wtemp low Step 1 s 1 180 s Water temp del Delay for ANALOG INPUT 2 alarm Step 1 s Range 0 180 5 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 4 8 Operation NextServTime Counts down when engine running If reaches zero an alarm appears Step 1h Range 0 65535h MN2408 Overload
122. talled outdoors The factory installed enclosure is designed to keep out undesirable weather elements while providing cooling and ventilation When the Genset is installed in a building it is essential to provide 1 Adequate control and exhausting of the heated air 2 An adequate and constant supply of incoming cooling air 3 Adequate control and discharge of the engine s hot exhaust gases 4 Adequate ventilation of the building when the engine shuts down MN2408 Receiving amp Installation 3 1 Several other factors should be carefully evaluated when selecting a location for installation 1 Foreffective cooling and maintenance the system is mounted on a flat smooth noncombustible level surface A concrete pad is ideal 2 Installation should prevent water levels from reaching the Genset 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 Genset as close as possible to the fuel supply and transfer Switch At least thirty six 36 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 50 Secure the Genset Mount
123. th non slip surface placed between the base and the floor will also prevent movement Anylloor slab surface should be as flat as possible to prevent sub base deflection Vibration Isolators e Vibration isolators are commonly used to mount the Genset to a concrete pad Figure 2 1 The 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 is determined by the rating of the pads and the Gensets weight Figure 2 1 Typical Installation J Bolt or Spring Type Isolator Generator Base Spring Type Isolator Fill with Grout 8 remm Pipe N A x gt of expansion gt gt gt bolts also acceptable Foundation ws E J or L Bolt J or L Bolt 2 4 General Information MN2408 Caution Caution e Steel spring isolators 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 The base should be mounted to the foundation pad as shown in Figure 2 1 or a
124. 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 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 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 nea
125. tion of the exhaust piping 5 Itis also recommended that an exhaust rain cap 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 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 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 3 6 Receiving amp Installation MN2408 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 build
126. 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 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 an
127. ualified 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 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 It is the responsibility of the owner operator of this generator to ensure that this equipment is correctly and safely installed 2 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 the responsibility of the owner operator of this generator to ensure that any person operating this equipment has been properly trained 4 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 operation of this equipment 5 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
128. um UL 210 5718 222 FUSE 25 PSS a G 16 E 3 1 00 Ste 7 63 2 8 AS480 UL CONTROL PANEL VOLTAGE 210 REGULATOR 9 lt 19 ant 20 INTELILITE NT L1 gt x N gt 8 21 Sus 2 22 as gp 2 os N N zje N 5 8 c1 9 zg cn t 25 12 lt 4 26 2 13 ez e 2 2 28 2 CONTROL PANEL 9 e 5 58 8 g 5 gt gt gt 3 BE 50 UNLESS OTHERWISE STATED ALL CONTROL WIRING IS 16AWG SEE BREAKER WIRE SIZE CHART BW0707D 0 LINES INDICATE OPTIONAL ACCESSORIES NEUTRAL GROUND 5 BOND CUSTOMER CONNECTION F 32 GCB GENERATOR gt CIRCUIT i FAKER n 33 E GND i 2 34 1 PHASE 3 WIRE 2980000 9 4 Series GLC MN2408 Figure B 12 Three Phase Diagram GW0000B61
129. ust 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 Do not use check valves in the exhaust system because they can 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 significantly 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 Distr
130. utions 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 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
131. zed personnel away from batteries 1 Open access doors and locate battery tray 2 Place the correct battery see Table 3 8 on the tray 3 10 25kW ONLY Install the Battery Hold Down Bar and Rods as shown in Figure 3 8 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 flat washer lock washer and nut c Repeat steps a and b for the other Battery Hold Down Rod 3 14 Receiving amp Installation MN2408 Figure 3 8 Battery Installation 10 25kW only 5 The terminals of your battery may be different than shown Be sure that the Positive lead is connected to the positive terminal of your battery Battery Washers amp Nut an Battery Hold Down Bar Install away from terminals Washers amp Nut 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 accidentally touches the positive battery terminal or wire The risk of such shock is reduced when the ground lea

Download Pdf Manuals

Related Search

Related Contents

市政情報「おおさか掲示板」  User Manual - Quick Access - Thermo King Michigan, Inc.  Phase One IQ2 User Guide  取扱説明書（PDF: 0.8 MB）      3-WAY LIGHT SEQUENCER 160.375  Digitus Lifestylebag 15.4"  Möbel-Gütepass  

Copyright © All rights reserved. Failed to retrieve file