Baldor GLC60 Installation & Operating Manual

GLC Generator

(Gaseous Liquid Cooled)

GLC30, 35, 45, 50, 60, 80, 100 and 125

5/04

Installation & Operating Manual

MN2408

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:


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 Notice

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2

General Information

Limited Warranty

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Site Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Room Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Room Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Foundation Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Level Of Attenuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Multi–Engine Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Gas Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Piping

Rain Protection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System

Air System

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Other Engine Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Crankcase Ventilation

Transfer Switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Starting System

Battery Location

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3

Receiving & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Receiving & Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting the Generator

Physical Location

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Secure the Generator

Engine Cooling

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hot Exhaust Gasses

Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Engine Oil and Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Post Installation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

1-1

1-1

1-2

3-6

3-9

3-12

3-13

3-13

3-1

3-1

3-1

3-1

3-3

3-3

3-4

3-6

2-9

2-9

2-9

2-9

2-9

2-10

2-10

2-11

2-1

2-1

2-3

2-3

2-3

2-4

2-5

2-9

2-17

2-17

2-18

2-18

2-19

2-20

2-20

2-20

2-21

2-21

MN2408 Table of Contents i

Section 4

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Control Panel (Digital Engine Controller Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Procedures

Manual Start/Stop

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Start/Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Fault Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Mains Failure (AMF)

Standard Faults

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Output Contacts

Display Modes

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Operating Status

Fault Display

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Timer Countdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator AC Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Parameter Display

Program Menus

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Menu Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Fault Menu Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Fault Menu Loop

Calibration Menu Loop

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Sensing Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Sensing Calibration

Battery Voltage Calibration

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Temperature & Oil Pressure Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Control Panel (Analog Engine Controller Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Procedures

Manual Start/Stop

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Start/Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Fault Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Garretson Model KN Fuel Valve Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5

Troubleshooting and Maintenance

Maintenance

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Problems and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A

Series GLC Parts & Wiring Diagrams

Replacement Parts

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GLC Circuit Breaker & Electrical Data

GLC Wire Size

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start–up Inspection Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1

5-1

5-2

A-1

A-1

A-4

A-9

A-9

A-33

4-17

4-22

4-22

4-23

4-23

4-23

4-25

4-13

4-14

4-15

4-15

4-15

4-15

4-16

4-16

4-8

4-9

4-9

4-9

4-10

4-11

4-12

4-12

4-1

4-1

4-2

4-2

4-2

4-3

4-3

4-5 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.

Installation and repair procedures require specialized skills with electrical generating equipment and liquid cooled engine systems. Any person that installs or repairs this generator must have these specialized skills to ensure that this generating unit is safe to operate. Contact Baldor service department for repairs or any questions you may have about the safe installation and operation of this system.

The precaution statements are general guidelines for the safe use and operation of this generator. It is not practical to list all unsafe conditions. Therefore, if you use a procedure that is not recommended in this manual you must determine if it is safe for the operator and all personnel in the proximity to the generator and connected loads. If there is any question of the safety of a procedure please contact Baldor before starting the generator.

This equipment contains high voltages. Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the start–up procedure or troubleshoot this equipment.

This equipment may be connected to other machines that have rotating parts or parts that are driven by this equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt the start–up procedure or troubleshoot this equipment.

– System documentation must be available to anyone that operates this equipment at all times.

– Keep non-qualified personnel at a safe distance from this equipment.

– Only qualified personnel familiar with the safe installation, operation and maintenance of this device should attempt start-up or operating procedures.

– Always stop engine before making or removing any connections.

– 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.

It is the responsibility of the owner/operator of this generator to ensure that this equipment, when installed fully complies with all federal, state and local codes.

3.

It is the responsibility of the owner/operator of this generator to ensure that any person operating this equipment has been properly trained.

4.

It is 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.

It is the responsibility of the owner/operator of this generator to ensure that it is properly maintained and safety inspected at regular scheduled intervals.

6.

It is the responsibility of the owner/operator of this generator to ensure that any person who has not been trained on the safe use of this equipment does not have access to this equipment.

Read This Manual Thoroughly

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.

Baldor Generators

3815 Oregon Street

Oshkosh, WI 54902

(920) 236–4200 (voice); or (920) 236–4219 (fax); or www.baldor.com

MN2408 Product Safety Information 1-1

Symbols

This symbol is shown throughout the manual to indicate a connection to ground reference point.

Indicates a potentially hazardous situation which, if not avoided, could result in injury or death.

Indicates a potentially hazardous situation which, if not avoided, could result in injury or death.

Precaution Statements Used In This Manual

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:

WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in injury or death.

Caution: Indicates a potentially hazardous situation which, if not avoided, could result in damage to property.

Note: Additional information that is not critical to the installation or operation.

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

– This manual contains important instructions for the generator that should be followed during installation, operation and maintenance of the generator and battery (batteries).

For ease of reading, the Warning statements are divided into four categories: Operation, Burn, Installation, and Maintenance.

Operation

WARNING: 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.

WARNING: 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.

WARNING: Exhaust fumes/gases are extremely dangerous and can cause severe illness or death. Never breath exhaust fumes produced by a running engine. Only run the engine outdoors where ventilation is plentiful. Exhaust gases contain carbon monoxide, a colorless, odorless and extremely dangerous gas that can cause unconsciousness or death. Symptoms of carbon monoxide poisoning include: dizziness, nausea, headaches, sleepiness, vomiting or incoherence. If you or anyone else experiences these symptoms, get out into fresh air immediately. Stop the engine and do not restart the engine until it has been inspected and if necessary repaired or reinstalled in a well ventilated area.

WARNING: Hot exhaust gasses must never be directed toward anything that may catch fire or explode.

WARNING: 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.

WARNING: 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.

WARNING: 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: Never connect or disconnect loads during operation. Always connect load circuits before starting the engine and use external branch disconnects etc. to switch loads On/Off.

WARNING: 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.

WARNING: Always wear safety glasses with side shields and hearing protection when working near the generator.

WARNING: Improper operation may cause violent motion of connected equipment. Be certain that unexpected movement will not cause injury to personnel or damage to equipment.

WARNING: 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.

WARNING: 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.

WARNING: 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.

WARNING: Never operate the generator unless all guards, covers, shields and other safety items are properly installed.

WARNING: Do not put hands, feet, tools clothing or other objects near rotating parts such as drive shaft, pulley, belt etc. Rotating parts cause extremely dangerous situations because they can catch loose clothing or extremities and cause serious or fatal injury.

WARNING: 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.

WARNING: Never operate the engine when the air cleaner is removed. An engine backfire can cause serious burns.

WARNING: Never “jump start” a generator to start the engine. If the battery charge is insufficient to start the engine, charge or replace the battery and try to restart. Jump starting a battery can cause the battery to explode and cause severe injury or death to anyone in the area.

WARNING: 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.

WARNING: 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.

WARNING: 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.

WARNING: Keep generator at least three feet away from buildings and other structures.

WARNING: Keep generator away from flammable or hazardous materials (trash, rags, lubricants, explosives, paints etc.) and grass or leaf build up.

WARNING: Keep a fire extinguisher near the generator while generator is in use. An extinguisher rated

“ABC” by the National Fire Protection Association is appropriate.

Burn

WARNING: 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.

WARNING: 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.

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.



Warning Statements Continued

Installation

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 batteries.

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 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.

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.

WARNING: 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.

WARNING: 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.

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 generator systems.

WARNING: 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.

WARNING: 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.

WARNING: 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.

Warning: 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 utility lines.

WARNING: Circuit overload protection must be provided in accordance with the National Electrical Code and local regulations.

WARNING: Check Ground Fault Circuit Interrupt (GFCI) receptacles monthly by using the “Test” and

“Reset” buttons.

WARNING: 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.

WARNING: Have electrical circuits and wiring installed and checked by licensed electrician or qualified technician. Electrical shock can cause serious or fatal injury.

WARNING: 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.




Warning Statements Continued

Maintenance



WARNING: 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.

WARNING: Do not mutilate the battery or dispose of a battery 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: A battery presents a risk of electrical shock hazard and high short circuit current. Electrical shock can cause serious or fatal injury. Never wear jewelry, watch or any metal objects when in the area around the battery.

WARNING: The battery electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes. It is electrically conductive and corrosive. If electrolyte contacts the skin, flush the area immediately with water and wash it off using soap and water. If electrolyte contacts the eyes, immediately flush the eye thoroughly with water and seek medical attention quickly.

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.



WARNING: Before servicing the generator set, be sure to disconnect the spark plug wires and the battery terminals to prevent accidental engine rotation or starting.

WARNING: 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.

WARNING: 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.

WARNING: Check all fuel supply piping, and their connections monthly for fuel leaks. LPG and natural gas fuels are flammable and can cause fire, explosions, injury or death. If a leak is found, replace only with approved pipe or components.



Caution Statements

Caution: 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.

Caution: Do not apply high voltage to windings (do not start the generator) in a moisture–saturated condition. Moisture can cause insulation breakdown, making it necessary to return the generator to the factory for repair, and consequent expense and loss of time.

Caution: Use only original equipment or authorized replacement parts. Using the correct parts will assure continued safe operation as designed.

Caution: Do not support the generator from the top of the frame or enclosure.

Caution: Do not tamper with or change the engine speed. Engine speed is factory set to produce the correct voltage and output frequency.

Caution: 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.

Caution: The Programmable Output Contacts selection must agree with the external control wiring prior to energizing the controller. Failure to do so may cause severe equipment damage.


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 information relative to engine operation, maintenance, recommendations and additional safety warnings.

Copyright Baldor © 2004. 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 Generators 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, at the risk of the party requiring warranty service, to a Baldor Generator repair facility, or to Baldor Generators

Department in Oshkosh, Wisconsin. Written notification of the alleged defect in addition to a description of the manner in which the Baldor generator is used, and the name, address and telephone number of the party 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 party requiring warranty service.

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 party requesting warranty service will be responsible for the cost of any necessary repairs.

EXCEPT FOR THE EXPRESSED WARRANTY SET FORTH ABOVE, BALDOR GENERATORS DISCLAIMS ALL

OTHER EXPRESSED AND IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF FITNESS

FOR A PARTICULAR PURPOSE AND MERCHANTABILITY. NO OTHER WARRANTY, EXPRESSED OR

IMPLIED, WHETHER OR NOT SIMILAR IN NATURE TO ANY OTHER WARRANTY PROVIDED HEREIN, SHALL

EXIST WITH RESPECT TO THE GOODS SOLD UNDER THE PROVISIONS OF THESE TERMS AND

CONDITIONS. ALL OTHER SUCH WARRANTIES ARE HEREBY EXPRESSLY WAIVED BY THE BUYER.

UNDER NO CIRCUMSTANCES SHALL BALDOR GENERATORS BE LIABLE OR RESPONSIBLE IN ANY

MANNER WHATSOEVER FOR ANY INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES, OR

ANTICIPATED PROFITS RESULTING FROM THE DEFECT, REMOVAL, REINSTALLATION, SHIPMENT OR

OTHERWISE. This is the sole warranty of Baldor Generators and no other affirmations or promises made by

Baldor Generators shall be deemed to create an expressed or implied warranty. Baldor Generators has not authorized anyone to make any representations or warranties other than the warranty contained herein.

Warranty Period

Generator Series Labor* Parts

Portable Products

(Premier, Powerchief, DG Series, K Series)

Towable Products (TS)

3600 RPM Standby Systems

(Some AE Models)

1800 RPM Standby Systems

(Some AE Models, DLC, GLC)

Industrial Standby Systems

Industrial Prime Power Systems

International

1 Year

1 Year or 3,000 Hours

Whichever comes first











3 Years

3 Years or 3,000 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).

No warranty registration card is necessary to obtain warranty on Baldor Generators.

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.

For all other products, 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.

MN2408 General Information 2-1

2-2 General Information MN2408

Important Be sure you are completely familiar with all Safety Instructions detailed in Section 1 of this manual. Do not proceed if you are unsure of any detail. Contact your Baldor Distributor, they are experienced and are happy to assist you and to answer your questions.

Installation Guidelines

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:

S National Electric Code, Articles 230, 250, 445, 517, 700.

S National Fire Protection Association

No. 30 – Storage, Handling and Use of Flammable Liquids.

No. 37 – Stationary Combustion Engines and Gas Turbines.

No. 99 – Essential Electrical Systems for Health Care Facilities.

No. 101 – Life Safety Code No. Systems.

No. 110 – 1985 Emergency and Standby Power Systems.

S NEMA MG1

S Local Codes applicable to Genset Installation. See your local building inspector.

NFPA (National Fire Protection Association (617) 770–3000 (includes NEC)

1 Batterymarch Park, Quincy, MA 02169–7471 USA

NEMA (National Electrical Manufacturers Association) (703) 841–3200

1300 N. 17th Street, Suite 1847, Rosslyn, VA, 22209 USA

Site Planning

Room Size 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:

S Never use the Genset room for storage as well.

S The room must be large enough to contain the genset and all the accessories, such as batteries and their charging system, transfer switch and other controls, and elements of the cooling and fuel systems.

S A minimum of 2 feet (preferably 4 feet), must be allowed on the two sides of the engine for service access.

S On the generator end of the engine, allow a space equal to the length of the generator

(generator length only, not the entire genset).

S 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.

S Certain safety and building codes may require the genset room not to be used to house any other mechanical or electrical equipment.


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:

S Maintain the building at a satisfactory temperature year round (to meet applicable codes).

S Assure the genset is not located so far from the emergency loads that reliability is compromised.

S The floor’s load carrying capacity must be checked and must exceed the weight of the genset and its associated equipment.

S 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.

S Exhaust System

The exhaust system must minimize exhaust restriction. Exhaust restriction must be limited to 3 in. Hg (76 mm Hg) maximum, to ensure proper engine operation. The exhaust system should be as short and have as few bends as possible.

S Room Air

If the genset is cooled with an engine mounted radiator, and sufficient air is brought into and exhausted from the room to satisfy the radiator cooling requirements and the combustion air requirements, the room will not overheat when the genset is running.

If a remote mounted radiator or a heat exchanger is used, and adequate air is circulated through the room to keep it at a reasonable temperature, there will be adequate air for combustion.

S Fuel Tanks (Diesel Only)

Locate the fuel storage tank as near the genset as possible. This will minimize the cost of fuel system installation and will maximize fuel system reliability.

S 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.

S Genset Noise

Internal combustion engines produce noise, so the room should be located away from occupied buildings. In addition the genset room can be treated to reduce noise transmission. In locating the genset room, both engine, fan and exhaust noise must be considered.

If noise within the genset room, or noise transmitted to the surrounding parts of the building are a concern, then the room must be made large enough to allow for installation of noise attenuating walls and noise absorbing walls.

Light weight concrete blocks filled with sand or special “sound block” concrete blocks are commonly used. Noise attenuating, tight fitting windows and doors also help reduce noise transmission to the rest of the building.

A double–walled room should be considered. Vibration isolators under the genset rails will also reduce the transmission of noise through the floor.

S 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.


Foundation Design


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

S If an existing floor is used, the floor slab must be strong enough to carry 1.50 times the genset wet weight (including coolant and oil) to accommodate dynamic loads.

S The actual mounting arrangement (ie., surface area in contact with the floor) will determine the compressive strength required.

S The genset should be securely fastened to the floor slab with expansion anchors that fit the mounting holes shown on the genset installation diagram.

S For installations not expected to be permanent, elastomer pad with non–slip surface placed between the base and the floor will also prevent movement.

S Any floor/slab surface should be as flat as possible to prevent sub–base deflection.

Vibration Isolators

S Mounting to the pad, will result in overall reduced motion on other parts of the genset.

The trade–off is that slightly more vibration is transmitted to the structure.

S A more common practice when mounting to a concrete pad is to use vibration isolators.

The two most common types of vibration isolators are steel spring and elastomer pad.

The primary purpose of vibration isolators is to reduce the noise and vibration which would be transmitted from the genset to the foundation or supporting structure.

S A simple and effective method of mounting and applying pad type isolators is to place non–skidding type isolation pads directly between the sub–base and floor.

The number of pads required will be determined by the load bearing capability of the pads and the genset’s weight.

Figure 2-1 Typical Installation of Spring Type Isolator


S Steel spring isolators are a very effective and commonly used. Steel spring isolators are typically 95–98% efficient (reduces the transmitted vibration 95–98%) while a pad type can be 75–88% efficient. Spring isolators also level the genset sub–base in the event the foundation pad is not perfectly level.

Spring steel isolators offer the highest level of vibration isolation, however higher levels of vibration (although not detrimental) may be seen on some areas of the genset when mounted on steel springs, due to the (almost) total isolation from the foundation. The base of most steel spring isolators contains a non–skid pad. The base should be mounted to the foundation pad as shown in Figure 2-1 or as recommended by the isolator manufacturer.

A common practice is to pour a concrete pad directly on top of the floor slab and to mount the genset on this pad. The purpose of the pad is to facilitate cleaning around the genset and to provide a more level base. When using this method, floor strength must support the pad and the genset. The pad should be at least 6in (150mm) thick and extend beyond the genset in all directions 12in (300mm).

Weight Of The Genset

The dry weight of the entire genset is shown on the Generator Set Specification Sheet. The wet weight includes the fluids (coolant and oil). Figure 2-2 can be used to design the foundation except in critical situations.

Figure 2-2 Approximate Weight vs. kW Output


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 2-3 shows a method to calculate foundation thickness and the soil bearing load of the foundation and generator set. The soil load bearing capacity under the foundation must equal or exceed the load from the foundation and genset. If it does not, then a footing, as shown in Figure

2-4 must be added to spread the load over a larger area.

Figure 2-3 Calculate Soil Bearing Load (SBL) Capacity

Figure 2-4 Typical Footing on Foundation in Soil With Low Soil Load Bearing Capacity


Table 2-1 Approximate Load Bearing Capacities of Various Soil Types

Safe Bearing Capacity lb per ft 2 kilo Pascals

Hard Rock – Granite etc.

Medium Rock – Shale etc.

Hardpan

Soft Rock

Compacted Sand and Gravel

Hard Clay

Gravel and Coarse Sand

Loose, Medium and Coarse Sand

Compacted Fine Sand

Medium Clay

Loose Fine Sand

Soft Clay

50,000 – 200,000

20,000 – 30,000

16,000 – 20,000

10,000 – 20,000

10,000 – 12,000

8,000 – 10,000

8,000 – 10,000

8,000 – 10,000

6,000 – 8,000

4,000 – 8,000

2,000 – 4,000

2,000

2,395 – 9,576

958 – 1,436

766 – 958

479 – 958

479 – 575

383 – 479

383 – 479

383 – 479

287 – 383

192 – 383

96 – 192

96

Table 2-1 shows approximate load bearing capacities for various types of soil if the actual load bearing capacity of the soil under the foundation is not known.

Caution: Check the local building codes for load bearing capacity requirements.

Caution: If the soil is subject to freezing and thawing, the foundation must be extended below the frost line. Check the local building codes.

S Reinforce the foundation with No. 8 gauge steel wire mesh placed horizontally on

6in (150mm) centers. As an alternative, use No. 6 re–bars on 12in (300mm) centers horizontally. Minimum cover over the bars should be 3in (76mm).

S 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).

S 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.

S 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” or

“L” type bolts are recommended for the foundation bolts.

S After the foundation is cured and the genset is located, the sleeves are filled with grout.

Figure 2-5 shows a typical foundation installation.

Figure 2-5 Typical Foundation Installation


Exhaust System

Exhaust Checklist

A. Exhaust outlets are not located upwind or near any building air intakes.

B. Flexible piping section is used at engine exhaust outlet.

C. Exhaust piping material is adequate for expected service.

D. Exhaust piping sizing is adequate to prevent back pressure.

E. Exhaust piping components are insulated as necessary to prevent operator burns and reduce

pipe radiant heat losses.

F. Pipe sleeves or fire proof materials are used where exhaust pipe passes through building

materials as per local and state codes.

G. Exhaust pipe includes rain cap or is horizontal.

The purpose of the exhaust system is to safely discharge the engine combustion products into the atmosphere outside the building. A silencer should be installed in the exhaust system to reduce noise levels. Compliance with local noise codes is always required.

Level Of Attenuation

In general, manufacturers offer three grades of silencers: industrial, residential, and critical. In most cases, these grades are comparable from make to make. However, attenuation curves for the silencer should be checked to assure the desired level of silencing is met.

System Placement

By this time, the general genset placement within the room or building has been decided. The routing of the exhaust system should be as direct as possible to the building exterior.

WARNING: Never allow the exhaust outlet to be positioned so that the exhaust gases are directed towards any openings or air entry routes (doors, windows, vents, etc...) of an occupied building. When discharging the hot exhaust gases out of the building do not direct them towards anything that could catch fire or explode.

For aesthetic reasons, consider exhaust placement in relation to the building. Over a period of time, exhaust gas carbon deposits will tend to accumulate on any nearby wall or structure.

Attention must also be given to exhaust noise in selecting placement of the exhaust system.

Multi–Engine Installations

Caution: Do not connect multi–engine exhaust systems together. Each engine must have its own exhaust system for proper operation.

Exhaust gases from an operating engine will migrate back through a non–operating engine and cause a hydraulic lock. This may interfere with starting of the second engine. The migrating gases will also tend to turn the turbos which are not being provided lubrication if the engine is not running. The use of check valves in the exhaust system are discouraged due to their tendency to “stick”.

Exhaust Manifold

There are two exhaust manifold types. Dry type which is standard and the optional water cooled.

The dry type is simply exposed to the surrounding air and becomes very hot. Shields, insulating wraps, or other types of guards can be used to limit operator contact with the hot surfaces. This practice is common where engine room size is small, creating cramped conditions.

Water cooled exhaust manifolds are not available on all engine models. This type manifold has passages through which engine coolant is circulated to remove heat from the manifold surface. It also will help protect the operator from contact with the hot manifold surface. This will reduce the amount of heat that is radiated by the engine to the surrounding air by approximately 20%. 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 Distributor.

Exhaust Gas Restriction

The maximum allowable back pressure, or system restriction, is 3 inches of mercury. If this back pressure is exceeded, the air–fuel ratio is reduced due to incomplete scavenging of the cylinders, fuel economy and power output is reduced, engine life is reduced and exhaust temperatures and smoke levels increase. Any restriction of the exhaust gas reduces horsepower. Take every precaution to reduce restriction. Proper design and installation will provide safe genset operation.

It is essential that all engine exhaust systems by designed with the least possible restriction to exhaust gas flow. This can be calculated through the use of Figure 2-6, or in the case of simple exhaust systems, the nomograph in Figure 2-6 may be used.


Figure 2-6 Exhaust System Calculations

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 isolators, increase the length to 24 inches.

This component can be specified to be provided by your Baldor distributor. Flexible pipe should never be used for pipe bends or to cure misalignment problems.

Exhaust piping systems may be supported by a wide variety of methods to long as the system remains flexible, and capable of withstanding thermal expansion.

The material most commonly used for straight runs and elbows in exhaust systems is Schedule

40 black iron. If hanging weight is a problem, other materials may be used. Galvanized piping should never be used in exhaust system. Where exhaust piping passes through combustible material, exhaust thimbles must be used. See Figure 2-7.

Figure 2-7 Exhaust Pipe Thimble Installation

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 2-7.


Cooling System

Cooling System Checklist

A. Have noise considerations been taken into account?

B. Has system piping been properly sized?

C. Has system been properly protected from freeze up and corrosion?

D. Have standby equipment heaters been specified?

E. Have all electrically driven devices been connected to load side of EPS connection points?

F. Have system drain valves and air eliminators been installed?

The system consists of the cooling medium which is generally a solution of water and ethylene glycol, a method of rejecting engine produced heat, and a means to transport cooling medium between the engine and heat rejection system. The first determination is the type of cooling system to use – radiator cooling or heat exchanger cooling.

Radiator Cooling

The first and simplest is the engine mounted radiator shown in Figure 2-8. The radiator, water circulating pump, fan and fan drive are mounted to the generator set base rails by the factory.

This method of engine cooling is the most economical, but may require large ventilation vents and ducts. An added advantage of this arrangement is that the cooling air removes radiated heat from the engine, generator, and other equipment located in the emergency power system room.

The only remaining design work with the engine mounted radiator is arranging a method of providing air to the room, and exhausting it from the radiator. See “Air Systems”.

Figure 2-8 Engine Mounted Radiator Cooled System With Wind/Noise Barrier

The radiator can be mounted remotely (not mounted directly at the engine). The remote/close system uses the same radiator type except it is mounted in another room or outside the building, but within close proximity to the genset. See Figure 2-9.

Figure 2-9 Remote Radiator Cooled System


The remote radiator may be mounted either vertically or horizontally. In general, the radiator will have an electric fan to provide cooling air and may be able to utilize the engine mounted coolant pump to provide coolant flow.

The piping system friction and head loss between engine and radiator must be calculated and not exceed the capacity of the engine pump. If the maximum coolant friction head loss external to the engine is exceeded, a hot well system must be used. Before designing the piping system using an auxiliary pump and hot well, the consultant should look very closely at increasing the system’s pipe size.

The electric fan and auxiliary pump, if used, must be connected to the emergency power system.

Radiator and cooling fan must be sized to provide the cooling capacity required at an acceptable sound level.

Caution: In cold climates, the high volume of outside air drawn into the genset room can quickly reduce temperatures in the room to freezing. Any water piping or other equipment susceptible to freeze damage should be properly insulated or located elsewhere.

Heat Exchanger

In the heat exchanger system, engine coolant is circulated through the shell side of a heat exchanger, while city water, well water, or some other cooling medium, is circulated through the tube side. The primary consideration in this type cooling system is to remember that during certain types of disasters, these cooling mediums may not be available, especially city water. The system is relatively inexpensive to install and maintenance is low. See Figure 2-10.

Figure 2-10 Heat Exchanger Cooled System

The heat exchanger cooling system can be used with a cooling tower. These systems are complex, and consists of circulating pumps, heat exchanger for engine coolant, and cooling tower for heat rejection. The system design requires that several pieces of equipment be sized and installed. Overall, this system is more expensive than other methods of engine cooling.

Cooling System Determination

After cooling system selection, gather the required basic information before proceeding through this section. Information required includes engine heat rejection load, pumping capacity of the engine mounted pump, engine coolant flow requirements and pressure drop through the engine, and allowable operating temperature. This information is found on the engine data sheet.

Cooling System Design

Engine Mounted Radiator Cooling

If the engine mounted radiator is selected, the only remaining design work is arranging a method of providing air to the room, and exhausting that air from the radiator. See “Air Systems”.


90 Elbow

45 Elbow

Long Sweep Elbow

Close Return Bend

Tee–Straight Run

Tee–Side Inlet or Outlet

Globe Valve Open

Angle Valve Open

Gate Valve Fully Open

Gate Valve Half Open

Check Valve

Remote Radiator Cooling

Remote Radiator Airflow generally assumed there will be no external restrictions to airflow. If this is not true, restriction must be considered in sizing and selection of a cooling fan and drive motor.

Typical examples of restrictions include landscaping, nearby buildings, air turbulence created by buildings or other structures, and sight or noise “screens”. See Figure 2-9.

Remote Radiator Fan Motor. Remote radiator cooling systems require the use of an electrically driven fan. This fan must be connected to the emergency power source. Size of the motor is determined by the fan size and fan speed.

1.

To specify a radiator to cool the coolant you will need to determine the amount of heat rejected to the coolant. This is listed on the Engine Data Sheet as Heat Rejected to

Coolant in BTU/min. for engines using dry or water cooled type exhaust manifolds, as applicable.

2.

Determine the minimum water flow required at the engine, and the maximum top tank temperature. Using this information, determine the heat rejection capacity required of the radiator. Radiator systems should be sized with approximately 15% greater capacity than the engine’s maximum full load heat rejection to allow for overload and cooling system deterioration. Whether water flow is produced by an engine mounted or auxiliary pump, total piping system friction loss must be calculated. To do this, genset location, remote radiator location and friction loss within the radiator, and piping system must be estimated.

3.

Pressure drop through the radiator must be obtained from radiator manufacturer.

4.

If total piping system pressure exceeds the allowable Maximum Coolant Friction Head

External to the engine as listed on the Engine Data Sheet, the coolant piping size should be increased and/or a radiator with less restriction must be used.

5.

Pressure drop in pipelines may be determined by the use of information in Table 2-2

Figure 2-11, and friction of water tables which may be found in most mechanical handbooks such as “Cameron Hydraulic Data” handbook.

Table 2-2

Flow Restriction of Fittings Expressed as Equivalent of Straight Pipe (in inches)

1.5

4.4

2.8

9.3

55

27

1.2

27

19

2

5.5

2.5

3.5

13

3.5

12

67

33

1.4

33

23

2.5

6.5

3

4.2

15

4.2

14

82

41

1.7

41

32

3

8

3.8

5.2

18

5.2

17

110

53

2.3

53

43

7

24

7

22

4

11

5

140

70

2.9

70

53

5

14

6.3

9

31

9

27

6

16

7.5

11

37

11

33

3.5

100

8

21

10

14

51

14

43

4.5

130

10

26

13

17

61

17

53

5.8

160

12

32

15

20

74

20

68

6.8

200

14

37

17

24

85

24

78

8

230

16

42

19

27

100

27

88

9

260

Hot Well Installations

One final consideration on the water side is the Maximum Static Head. This is the maximum height allowable from the engine crank center line to the highest point in the coolant system. The maximum static head is specified on generator specification sheets. If this number must be exceeded, a hot well tank system must be used. A typical example is shown in Figure 2-12.

The design of hot well tanks and piping systems is somewhat complex. Your authorized Baldor

Distributor has experience in the design and installation of hot well systems. Consult your Baldor

Distributor if the static head of the coolant system in your genset application exceeds this criteria and requires a hot well system.


Figure 2-11 Valves & Fittings and Fluid Flow in Pipe

2-14 General Information

Figure 2-12 Hot Well Installation

MN2408

MN2408

Other Considerations

General:

1.

Deaeration of the coolant. This can be accomplished through the use of the system deaerators in very large systems, or simply ensuring the radiator top tank or surge tank is at the highest point in the piping system. Unvented piping systems can create air pockets which reduce coolant flow and can lead to engine overheating. Baldor furnished radiators are equipped with deaerating top tanks.

2.

Flexible hoses must be installed at all engine connections and to the radiator to isolate vibration and allow for thermal expansion.

3.

Drain valves must be installed at the lowest point of the cooling system to facilitate system cleaning and flushing.

4.

Water treatment and antifreeze must be added to system coolant. Baldor recommends

50/50 ethylene glycol and coolant treatment for all engines.

5.

Thermostatically controlled engine coolant heaters are required to be installed on all standby gensets. These will increase starting reliability under cold conditions, and improve the start–up load handling ability.

6.

According the NFPA 110, priority level 1 equipment jacket water heaters shall maintain coolant at a minimum of 90 °F (32 °C). In outdoor installations where temperatures will be expected to drop below 32 °F (0 °C), a battery heater should be employed to keep the batteries at a minimum of 50 °F (10 °C), and will shut off at 90 °F (32 °C).

All heaters will shut off when the engine is operating. Adequate antifreeze protection will be provided and ether starting aids will not be permitted.

7.

The consultant should also consider oil sump heaters if conditions warrant.

Heat Exchanger Cooling:

1.

If the engine is to be heat exchanger cooled, the system will require a reliable raw cooling water source and controls to regulate water flow during genset operation.

2.

The system will also need a reliable method of starting and stopping water flow automatically. The heat exchanger cooled system may be used with a cooling tower.

3.

Baldor Gensets are available with heat exchangers sized and mounted on the engine by the factory. If a heat exchanger cooled system is required, specify with order.

4.

Shell and tube type heat exchangers are connected such that raw cooling water flows through the tube side of the heat exchanger, and engine coolant through the shell side.

Tubes are more easily cleaned and the potential for fouling is much greater on the raw water side.

5.

For economic reasons, the raw water flow can be regulated by varying the flow of raw cooling water through the heat exchanger. This control can be accomplished with a temperature actuated control valve. The thermostatic bulb for this control must be in the engine jacket water discharge line. The control valve should be a fully modulated type with a minimum flow setting. NEVER attempt to regulate engine water flow.

6.

Water flow regulators are used only if raw water is from a city or well water source. Do not attempt to regulate flow if a cooling tower is used. Maintain at least 2 ft/second of water flow through the tube side of the heat exchanger.

7.

Heat exchanger cooled systems using city or well water, and cooling, tower heat rejection, however, will not be protected on the tube side of the heat exchanger, nor interconnecting piping and cooling tower as engine coolant is not circulated through these components. These systems must be heat traced, and have sump heaters installed to protect the various components when the genset is on standby.

It must also be noted that if an antifreeze solution is used in the shell side of the engine cooling system heat exchanger, local codes may restrict the discharge of the tube side cooling water after flowing through the heat exchanger.

General Information 2-15

Coolant Treatment: See Figure 2-13.

1.

Engine coolant should be treated with a Diesel Coolant Additive (DCA) to minimize corrosion of the engine and cooling system components. A 50/50 ethylene glycol antifreeze solution is recommended for all genset engines. This will provide freeze protection and increase the boiling point of the engine coolant. A solution can be increased to 65%. Do not exceed 65% as freeze protection begins to diminish at 65%.

2.

It is recommended that the consultant specify Baldor supplied DCA and water filters, and Baldor antifreeze.

3.

When the proper solution concentration of antifreeze is used with radiators (engine mounted as well as remote mounted), and hot well systems, the system will be adequately protected from freeze–up.

Figure 2-13 Coolant Mixture


Air System Air System Checklist

A. Air inlet faces the direction of prevailing winds.

B. Air outlet does not face noise sensitive areas without noise attenuating devices.

C. All heat loads have been taken into consideration in sizing air flow.

D. Gravity louvers face inward for air intake and outward for discharge.

E. Where electrically operated ventilation devices are used, power must be present under all

operating situations. Be certain these devices are on the emergency circuit.

The room in which the generator set is to be installed must have adequate air flow through it to provide combustion air, and remove heat radiated from the engine, exhaust system and generator. See Figure 2-14 for air flow calculations.

Figure 2-14 Air Flow Calculations

Radiator Cooling

The engine mounted radiator shown in Figure 2-8. With an engine mounted radiator cooling system, air movement is provided by the engine driven radiator fan. The consultant must design the inlet and outlet duct work and louvers to accommodate the air flow required. The radiator fan is limited in the amount of external static pressure it will tolerate. The maximum air restriction on the discharge side of the radiator is shown under the heading of Cooling System on the Engine

Data Sheets. Cooling fan air flow is listed under Engine Data by dry type and water cooled exhaust manifold for 100 °F and 125 °F cooling systems.

The ideal setup for cooling air would be to arrange the inlet or inlets such that relatively clean, cool, dry air is drawn across the electrical switchgear, generator, and engine. The air is then drawn into the radiator fan, and is blown through the radiator and exhausted by duct work outside the building. Air inlets must be sized to minimize air restriction and provide the quantity of air required by the radiator fan, engine combustion air, and any other air exhausts which might be used in the room. On engine mounted radiator cooled systems, the engine mounted fan will handle 0.25” of water column. This is combined intake and exhaust restriction.

The room air intakes must be located so as to minimize drawing exhaust fumes and other outside contaminants into the room. Be very cautious about the location of the engine exhausts in relation to room air intakes. Also, when locating the inlet and outlet, the consultant should consider prevailing winds and noise. Motor operated louvers or properly designed and sized gravity louvers should be used on the air intake and exhaust to minimize static pressure drop.

Electric motorized louvers used with engine mounted radiators should be connected to the standby genset and controlled to open whenever the genset is running. Operable outlet louvers should be temperature actuated on remote radiator or heat exchanger cooled units. Louvers have resistance to air flow. Openings with louvers should be twice the area of an unobstructed opening to provide proper air flow. At times duct work is necessary to provide cooling air for the room, see Figure 2-15. Duct work must be sized and installed according to SMACNA Standards.

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.


Figure 2-15 Radiator Cooling with Ducted Air Handling

Other Engine Cooling Systems

Remote radiator and heat exchanger cooled engine cooling systems will not have an engine driven fan. As a result, the consultant must provide a means of supplying air to the room, and exhausting it. The air movement must be provided by an electrically driven fan. This fan may be located in the air inlet or exhaust opening. If the fan is located on the exhaust side, care must be taken to not create a high negative pressure in the room and starve the engine of combustion air.

If the fan is located in the air inlet, it must be noted that odors may be forced into other parts of the building if the room is not properly sealed. This electrically driven fan must be connected so as to run whenever the generator is operating. Any fans for the engine room should be on the emergency circuit. An example may be seen in Figure 2-16.

Figure 2-16

Engine Crankcase Ventilation

For gensets operating more than 1000 hours per year, the engine crankcase breather should be vented upward and outside of the engine room. This prevents the buildup of oil vapors inside the building.


Transfer Switch

Transfer Switch Checklist

A. Locate transfer switch in a clean, dry place, near the emergency load.

B. Provide a circuit breaker between the genset and the transfer switch.

C. Put a flexible connection between the conduit and genset.

D. Observe applicable codes in wiring–in the transfer switch and genset.

The transfer switch connects the genset to the emergency power system. The emergency power system may include several gensets and several transfer switches. Typically, the genset is wired to the emergency power system through a transfer switch as shown in Figure 2-17.

Figure 2-17 Typical Emergency power System Installations

Multiple Gensets can be arranged either in parallel or separately connected to dedicated emergency loads. Figure 2-17 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 includes the paralleling of dissimilar generators, contract your nearby Baldor

Distributor.

Transfer Switch Location

The transfer switch location is important and key considerations are:

1.

Locate the transfer switch as close to the emergency load as practical to avoid interruptions of the emergency power system due to natural or man–made disasters, or to equipment failures. Consider several small transfer switches instead of one large one to increase reliability.

2.

Locate the transfer switch in a clean, dry, well ventilated location, away from excessive heat. When the ambient air is above 104 °F (40 °C), fuses and circuit breakers must be derated. Allow adequate working space around the transfer switch.

3.

A circuit breaker (or fuses) should be installed in the line between the generator and the transfer switch. Baldor Gensets are available with properly sized circuit breaker built into the generator control through 1200 amp breakers. The circuit breaker can be separately mounted. In the case of very large circuit breakers, a separate floor mounted circuit breaker is easier to wire up than a wall mounted breaker.

4.

Install power and control wires in separate solid conduit with flexible sections at the genset. The flexible sections prevent vibration from damaging the conduit. All power conduits from the genset must contain all three phases.

5.

Never install control wires in the same conduit as power conductors.


6.

Conduit, wire, circuit protective device sizes, insulation etc. must conform to applicable local and national codes and regulations.

7.

Be certain to seal around conduits that penetrate the walls of the genset room to reduce the amount of noise that is transmitted to the surrounding areas of the building and maintain site fire code rating.

Battery Starting System

This section describes the battery starting system (nominal 12 volt rating of the battery supply) for the engine, battery charger, and precautions to take if the ambient temperature is expected to be below 70 °F (20°C).

WARNING: If batteries are not mounted in the battery rack supplied with the genset, protect batteries from vibration and do not locate them near a source of flame or spark. A battery presents a risk of fire and explosion because they generate hydrogen gas. Hydrogen gas is extremely 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

Locate batteries as close as possible to the genset to minimize starting circuit resistance, see

Figure 2-18. High starting circuit resistance substantially reduces starting cranking ability. The genset data sheet lists the maximum allowable cranking system resistance. Mount batteries on a level rack away from dirt and liquids. Allow space for servicing (checking water level and level of charge). Baldor gensets can be ordered with battery racks already installed. Cold ambient temperature at the battery location substantially reduces the battery output.

Figure 2-18 Battery Starting System

Battery Size

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. Baldor requires thermostatically controlled coolant heaters on all after cooled standby gensets. After cooling is called out on the Engine Data Sheet under General

Engine Data section as “aspiration“.

Oil pan immersion heaters are recommended for standby gensets housed outside where ambient temperatures may drop below 0 °F (–18 °C). Coolant heaters and oil pan immersion heaters are available from Baldor as factory installed options.


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 the 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.

Battery Cables

The wire size (wire gauge) of the cables connecting the starter to the batteries must be large 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 2-19. 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 2-19 illustrates an example of a typical cranking circuit resistance calculation.

Figure 2-19 Typical Battery Cable Calculations



Section 3

Receiving & Installation

Receiving & Inspection

When you receive your generator, there are several things you should do immediately.

1.

Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered your system.

2.

Verify that the part number of the system you received is the same as the part number listed on your purchase order.

3.

If the system is to be stored for several weeks before use, be sure that it is stored in a location that conforms to published storage temperature and humidity specifications.

Lifting the Generator

When lift or hoist equipment is used to lift the generator and move it to position, be careful not to contact overhead wires or other obstacles. The generator can weigh as much as 3,000 lbs. Be 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 generator. If the shipping pallet has been removed, use two steel pipes through the “Lift Point” holes to lift the generator. See Figure 3-1.

Figure 3-1 Generator Lifting

Height

To lift the generator, always use spreader bars, chains eyehooks and other hardware that is of sufficient strength to lift at least three times the weight of the generator.

Lift

Point

Length

Width

Lift Point

Physical Location

The mounting location of the system is important. It should be installed in an area that is protected from direct harmful gases or liquids, dust, metallic particles, shock and vibration.

It should be installed in an outdoor location so the exhaust fumes are vented to the atmosphere.

When the Generator is installed outdoors

If the generator is installed outdoors there should not be a cooling problem. The factory installed enclosure is designed to keep out undesirable weather elements while providing cooling and ventilation.

When the Generator is installed in a building it is essential to provide:

1.

Adequate control and exhausting of the heated air.

2.

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 & Installation 3-1


Several other factors should be carefully evaluated when selecting a location for installation:

1.

For effective cooling and maintenance, the system should be mounted on a flat, smooth, noncombustible level surface. A concrete pad is ideal and provides a secure installation.

2.

Installation should prevent water levels from reaching the generator. Drainage must be adequate to keep concrete pad free from standing water.

3.

Installation should prevent obstructions by buildup of leaves, grass, sand, snow, etc. If these items pose a problem, consider building a small fence or other break to protect the unit from accumulation of debris.

4.

Installation should place the generator as close as possible to the fuel supply and transfer switch.

5.

At least forty–eight (48) inches clearance must be provided on all sides for air flow.

6.

Access must be provided to allow the enclosure covers to be opened or removed for service and maintenance.

7.

Maximum Ambient temperature is 122 °F (50°C).

Figure 3-2 Generator Mounting

Fuel Stub Up

GLC125 ONLY

Large Exhaust Area

For GLC50, 60, 80, 100, 125 only

Generator

GLC30

GLC35

GLC45

GLC50

GLC60

GLC80

GLC100

GLC125

A

78.0

78.0

78.0

118.0

118.0

118.0

118.0

118.0

30

A

A1

6.0

6.0

6.0

6.0

6.0

6.0

6.0

6.0

Fuel Stub Up

(All except GLC125)

B2

A2

A

Table 3-3 Mounting Dimensions

A2

33.0

33.0

B

44.0

44.0

B1

42.5

42.5

33.0

38.0

38.0

38.0

38.0

38.0

44.0

44.0

44.0

44.0

44.0

44.0

42.5

42.5

42.5

42.5

42.5

42.5

F1

A2

B2

6.25

6.25

6.25

6.25

6.25

6.25

6.25

6.25

Electrical

Stub Up

B1

B

E1

A1

E1

17.0

17.0

17.0

17.0

17.0

17.0

17.0

17.0

F1

32.0

32.0

32.0

32.0

32.0

32.0

32.0

32.0

3-2 Receiving & Installation MN2408

Secure the Generator

Six (eight for the GLC125) mounting bolts in the base frame secure the generator to the shipping pallet. Remove these bolts, lift the generator and remove the shipping pallet. Secure the generator to the concrete pad using generator mounting frame.

3 /

8

″ anchor hardware (not provided) in the base frame mounting holes. See Figure 3-2. Anchor bolts must be long enough to extend through the

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 generator set.

The exhaust fan must be connected to the AC power terminals of the generator set so that when the generator set starts it will provide immediate cooling air flow. The fan will operate until the generator set stops. To test the ventilation system, do the following:

Ventilation Test

1.

Place a thermometer as close to the cool air intake of the engine’s blower housing as you can without allowing the thermometer to touch any material surface.

2.

Place another thermometer outside 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.

The temperature difference between the two should not exceed 15 degrees F.

Note that opening any door, window or other opening can upset the air–flow pattern and result in a significant reduction in the cooling air–flow across the generator set. This may result in overheating, fire, or explosion. To find out if this is true with your specific application run the

Ventilation Test with all doors and windows closed. Then repeat this test with different doors and windows open, and eventually with all the windows and doors open. If any of these tests result in a temperature difference in excess of 15 ° F, you must not run the generator set under those specific conditions.


Hot Exhaust Gasses


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. In extreme cases this extremely hot air could cause dried grass or other debris to ignite.

Exhaust lines should be as short and straight as possible. Long pipe lengths and elbows tend to resist the flow of gases and accumulate carbon deposits. Each pipe fitting and elbow will further restrict the exhaust flow.

Guidelines for Exhaust System

1.

If you 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.

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.

3.

It is extremely important that you do not allow the hot exhaust gases to re–circulate into the engine’s cooling air intake.

4.

Water is one by–product of combustion and is present in the exhaust pipes or muffler.

This water must be kept from draining back into the engine. This can be done by slanting the horizontal section of the exhaust system piping downward slightly, away from the engine. A water trap consisting of a tee extension with a drain cock should also be provided. This water trap should be located between the flex coupling and the muffler, but as close to the engine as possible on a horizontal section of the exhaust piping.

5.

It is also recommended that an exhaust rain 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.

The engine’s exhaust system is the hottest component of the installation and extreme care and considerations must be given to it.


8.

As much of the 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).

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.



Installation The generator is completely assembled, tested and adjusted at the factory before it is shipped to you. The procedures presented in this manual are suggestions and it is the responsibility of the

Owner/Operator to arrange for these procedures to be performed by licensed contractors according to all applicable codes including local codes for your Municipality/City/County and

State. External connections required at the time of installation are:

1.

Fuel System.

2.

Electrical Connections – power wiring (optional transfer switch) and control wiring.

3.

Battery (not included).

4.

Ground Connection.

After installation, the post installation checks must be performed prior to starting the engine.

After these checks have been performed and the system operation is verified to be good, refer to

Section 5 Maintenance for periodic checks that must be performed at scheduled intervals to ensure continued operation with minimal problems.

Fuel Connections

Fuel selection is Natural Gas or LPG (Liquid Propane Gas). If natural gas supply is used, follow the “Natural Gas Connections” procedure. If LPG supply is used, follow the “LP Gas

Connections” procedure. Table 3-4 defines the flow rate required for each fuel type.

Table 3-4 Fuel Consumption Natural and LPG

Generator Model

GLC30

Fuel Consumption at 100% load (cubic feet per hour)

Natural Gas LP Gas

14.9

5.6

GLC35

GLC45

GLC50

GLC60

GLC80

GLC100

GLC125

16.3

16.5

20.7

22.1

28.7

32.1

46.8

6.0

6.9

8.2

9.1

12

13.8

16.5

General Considerations

1.

A generator set needs the engine to deliver 2 hp of energy to the alternator for every

1000 watts of electric output power (example: an 8000 watt generator needs the engine to deliver 16 hp of energy to the generator end).

2.

An engine needs 10,000 BTU’s of fuel energy per horsepower of engine power to provide a sufficient supply of fuel (example: a 16 Hp engine needs 160,000 BTU’s of fuel energy for it to work properly). This fuel must be supplied to the regulator on the generator set at a pressure of 6 oz (11 inches of water column). To achieve this 6 oz.

pressure in a L.P. System, you will normally have to reduce the tank pressure by means of a primary regulator or a regulator system of 2 or more regulators.

3.

There are 2,516 BTU’s in one cubic foot of Propane (LP Fuel).

There are 1,096 BTU’s in one cubic foot of Natural Gas.

4.

There are 36.39 cubic feet in one gallon of Propane.

There are 57.75 cubic feet in one gallon of Natural Gas.

5.

There are 8.58 cubic feet per pound of Propane.

There are 23.56 cubic feet per pound of Natural Gas.

6.

When installing the piping for the gaseous fuel supply please refer to the pipe chart in

Tables 3-5 and 3-6 to be sure you are using piping of significantly large size to deliver the necessary amount of fuel.

7.

If copper tubing is used, it should be “K” or “L” having a minimum wall thickness of

0.032 inches. Black Iron Pipe is recommended but follow building codes for your area.

The following pamphlets are available from:

National Fire Protection Association (NFPA) P.O. Box 9101 Quincy, MA 02269

No. 37 – Combustion Engines

No. 54 – Gaseous Appliances and piping

No. 58 – Storage and handling LPG


90

105

120

150

180

210

240

270

300

Pipe

Length

(Feet)

15

30

45

60

75

Example: Determining Pipe Size for Natural Gas

A generator has a 16Hp engine 60 feet from the supply.

Determine the supply pipe size for Natural Gas fuel.

16 x 10,000 = 160,000 BTU’s / per hour for proper operation.

160, 000

1, 096 +

146 cubic feet per hour.

From Table 3-6, 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).

1 /

2

″

73

50

41

37

Table 3-5 Natural Gas Flow Rate (Cubic Feet per Hour) per Pipe Length

Iron Pipe Size

3 /

4

″

165

115

95

83

74

67

63

1 ″

137

126

115

105

96

89

332

232

191

166

149

298

274

260

233

216

197

183

171

164

722

515

418

366

332

1– 1 /

4

″ 1– 1 /

2

″

1174

818

673

587

524

433

404

366

337

308

289

274

260

2 ″

2386

1712

1419

1241

1077

962

885

827

750

693

635

596

558

524

2– 1 /

2

″

3704

2646

2213

1924

1684

1501

1376

1289

1174

1077

991

933

875

827

3 ″

6253

4521

3752

3319

2886

2597

2357

2213

2011

1876

1712

1616

1520

1433

4 ″

13352

9331

7600

6542

5772

5291

4906

4618

4185

3848

3559

3357

3127

2886

6 ″

37229

26330

22462

18595

16652

15200

14064

13160

11775

10736

9937

9235

8658

8177

8 ″

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 generator, verify that fuel system pressure is 11 ″ Water

Column (6 oz. pressure) and fuel pipe sizes comply with Table 3-5.

3.

Proceed to Electrical Connections.

Figure 3-3 Gas Line Connections

Air Cleaner

Carburetor

53728

43867

37999

33959

31025

28715

26859

24050

21934

20298

18990

17903

16998

Mounting Bracket

MN2408

Solenoid, Fuel Lock

Inlet Connection

External Supply Piping (by installer)

U.L. requires a second shutoff valve and regulator to be installed in the supply piping to control the gas supply to the generator.

Supply Piping

To Inlet

Connection

Additional Regulator

(11 - 14" water column pressure)

Additional Valve

(Safety Shutoff Valve)

Receiving & Installation 3-7

Example: Determining Pipe Size for LPG

A generator has a 16Hp engine 60 feet from the supply.

Determine the supply pipe size for Natural Gas fuel.

16 x 10,000 = 160,000 BTU’s / per hour for proper operation.

160, 000

2, 516 +

63.5 cubic feet per hour.

From Table 3-6, a 60 foot run requires a minimum 1” pipe at full engine load.

LP Gas Connections (vapor withdrawal only)

The LPG connections should only be made if your generator is setup to run on LPG. If it is setup to run on Natural Gas, contact your Baldor representative and do not continue with installation.

90

105

120

150

180

210

240

270

300

Pipe

Length

(Feet)

15

30

45

60

75

1 /

2

″

48

33

27

24

The incoming pressure must be 11 inches water column (6 oz. pressure).

Table 3-6 LP Gas Flow Rate (Cubic Feet per Hour) per Pipe Length

Iron Pipe Size

3 /

4

″

109

76

63

54

49

44

41

1 ″

89

83

76

69

63

58

218

153

126

110

98

1– 1 /

4

″ 1– 1 /

2

″

196

180

171

153

142

130

120

113

108

475

339

275

241

218

310

285

266

241

222

202

190

180

171

772

538

443

386

345

2 ″

1570

1127

934

817

709

633

582

544

494

456

418

393

367

345

2– 1 /

2

″

2437

1741

1456

1266

1108

987

905

848

772

709

652

614

576

544

3 ″

4115

2975

2469

2184

1899

1709

1551

1456

1323

1234

1127

1063

1000

943

4 ″

8786

6140

5001

4304

3798

3482

3228

3038

2754

2532

2342

2209

2057

1899

6 ″

24497

17325

14781

12236

10957

10001

9254

8659

7748

7064

6439

6077

5697

5381

8 ″

50007

35353

28865

25004

22345

20414

18895

17673

15825

14432

13356

12405

11780

11179

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 input to the LP Gas regulator. Connect the

LPG 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.

2.

Verify Fuel Supply Pressure

Prior to initial operation of generator, verify that fuel system pressure is 11 ″ Water

Column (6 oz. pressure) and fuel pipe sizes comply with Table 3-6.

3.

Proceed to Electrical Connections.


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 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 utility lines.

Warning: 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.


Intended Use The intended purpose of this generator set is to provide emergency power when the main utility power supply is interrupted. Therefore, it is important that all the wiring that connects the generator set with your house, transfer switch, distribution box, battery charger, etc. be properly installed.

Circuit Protection Circuit protection is not provided within the generator. Circuit Breaker protection is an option.

If purchased with your generator, the breaker box is mounted to the generator prior to shipment.

If the optional circuit breaker protection was not ordered, see “GLC Circuit Breaker & Wire Size

Data” in Appendix A 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 generator output to an electrical load, a UL listed circuit breaker with the appropriate ratings must be provided within 25 feet of the generator set. Use only copper wires.

Catalog No.

GLC30

GLC35

GLC45

GLC50

GLC60

GLC80

GLC100

GLC125

Kilowatt (kW)

Rating

30

35

45

50

60

80

100

125

Input Breaker Rating (at 115% FLA)

3 Phase Amps (240VAC) * 3 Phase Amps (480VAC) *

Nat. Gas

Delta (Wye)

110

125

150

175

200

300

300

450

LPG

Delta (Wye)

110

125

175

175

200(225)

300

350

400

Nat. Gas

Delta (Wye)

60

60

70

90

100

150

150

225

LPG

Delta (Wye)

60

60

80

90

110

150

175

200

Transfer Switch Considerations

The following are general considerations for the safe use of a transfer switch:

1.

The transfer switch should be located inside the building near the main breaker box or the disconnect box.

2.

The 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 it’s elements.

4.

Do not mount the transfer switch on the generator set.

5.

Do not mount the transfer switch where flammable liquids or vapors are present.


Figure 3-4 Three Phase WYE and DELTA Connections


Battery Charger Considerations

1.

Mount the battery charger on the generator or as close to the generator as possible.

2.

If you mount the battery charger inside the building, mount it near the main breaker box or disconnect box.

3.

If you mount the battery charger outside, you must protect it from the environment and the elements.

4.

Do not mount the battery charger where flammable liquids or vapors are present.

General Wiring Considerations

1.

When routing the interface wiring, do not route it up against anything that could cut or chafe the wiring. do not route the wire up against any hot or potentially hot object.

2.

Make sure that all the electrical components (generator set, transfer switch, battery charger, etc.) share a common hard wired ground.

3.

Check with your local building inspector to determine what you must do to comply with the local regulations for grounding of this type of permanent installation.

Frame Ground Connection


It is important for safety reasons that the Generator set, 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 generator installation site. Make the ground connection as shown in

Figure 3-5. Use the appropriate size wire as required by NEC and local codes.

Warning: Do not connect the generator output neutral to the frame or local ground. The generator output is isolated from ground. NEC and local codes require that the generator output remain isolated from local ground reference.

Figure 3-5 Frame Ground Connection

Nut

Washer

Ground Wire Lug

Washer

Earth Ground Stud

Frame

1.

Open the enclosure access panel door 2 ( Figure 3-2).

2.

Connect the ground wire to the “earth ground” terminal shown in Figure 3-5.

This ground is the local reference ground to ground the generator frame only.


Battery Connections The generator is shipped with no battery installed.


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.

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.


Procedure: The correct type battery must be installed in the battery compartment provided, see Table 3-7.

Installation and servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions.

Keep unauthorized personnel away from batteries.

1.

Open access doors and locate battery tray.

2.

Place the correct battery (see Table 3-7) on the tray.

3.

Install the Battery Hold Down Bar and Rods as shown in Figure 3-6.

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.


Washers & Nut

Battery Hold Down Bar

(Install away from terminals)

Figure 3-6 Battery Installation

The + and – terminals of your battery may be different than shown. Be sure that the

Positive lead is connected to the positive

(+) terminal of your battery.

Battery

Washers & Nut

Battery Hold Down Rod

Battery Tray

4.

Connect the positive lead to the positive (+) battery terminal.

5.

Connect the negative lead to the negative (–) battery terminal.

6.

Do not lay tools or metal parts on top of batteries.

7.

Connect charging source to the battery terminals.

8.

Disconnect the battery’s ground terminal before working in the vicinity of the battery or battery wires. Contact with the battery can result in electrical shock when a tool accidently touches the positive battery terminal or wire. The risk of such shock is reduced when the ground lead is removed during installation and maintenance.

Recommended Engine Oil and Battery Type

When replacing batteries, use only the recommended battery for your generator, see Table 3-7.

Table 3-7

GLC30

GLC35

GLC45

GLC50

GLC60

GLC80

GLC100

GLC125

SUMMER

OIL

SAE. 30

SAE. 30

SAE. 30

SAE. 30

SAE. 30

SAE. 30

SAE. 30

SAE. 30

WINTER

OIL

5W/30

5W/30

5W/30

5W/30

5W/30

5W/30

5W/30

5W/30

OIL

CAPACITY

6.0 QTS

6.0 QTS

6.0 QTS

6.2 QTS

6.2 QTS

6.5 QTS

6.5 QTS

6.5 QTS

RECOMMENDED

BATTERY

BCI Group 31

BCI Group 31

BCI Group 31

BCI Group 31

BCI Group 31

BCI Group 31

BCI Group 31

BCI Group 31

(AMPS) COLD

CRANKING

925

925

925

925

925

925

925

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.

Generators that have been in transit or storage for long periods may be subjected to extreme temperature and moisture changes. This can cause excessive condensation, and the generator windings should be thoroughly dried before bringing the generator up to full nameplate voltage. If this precaution is not taken, serious damage to the generator can result.

Caution: Do not apply high voltage to windings (do not start the generator) in a moisture–saturated condition. Moisture can cause insulation breakdown, making it necessary to return the generator to the factory for repair, and consequent expense and loss of time.

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. Prevention of a failure is better than being forced to make a repair.


2.

Verify that the transfer switch is in Utility Power mode. No power must be present at the generator 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 generator is securely mounted and anchored to its cement pad.

5.

Verify that proper clearance exists on all sides and top of enclosure.

6.

Verify that generator power is properly connected to the transfer switch.

7.

Verify that generator and transfer switch are properly grounded.

8.

Assure that generator is a safe distance from any flammable or combustible material.

9.

Verify that the generator and transfer switch load are voltage compatible.

10. Verify that no load is connected to the circuit breaker and/or transfer switch.

11. Inspect the engine and generator and verify that there are no loose wires or components. Tighten if necessary.

12. Verify that the ground conductor is of correct wire size and properly connected.

13. Verify engine oil level is full. Refer to engine manual if necessary.

14. Verify engine coolant level is full. Refer to engine manual if necessary.

15. Verify exhaust system to assure it is in properly connected and pointing away from combustible materials.

16. 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.

17. Verify the fuel source is ON and the pressure and flow rate are correct.

18. Remove all tools, rags, etc. from inside the generator enclosure. Close all enclosure doors and be sure no hands are inside the generator enclosure when it starts.

Post Installation Checks Continued

19. Verify all loads are disconnected.

20. Start the generator. (Refer to Section 4 Operation for details).

21. 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.

22. 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 (move the

Master Control Switch to the “Stop” position) immediately and repair the leak before proceeding.

b.

Verify there are no coolant or oil leaks. If a leak is detected, stop the engine

(move the Master Control Switch to the “Stop” position) immediately 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 (move the Master Control Switch to the “Stop” position) immediately and repair before proceeding.

d.

Verify that the correct voltage exists (line–to–line and line–to–neutral) at the generator and at the transfer switch.

e.

Minor adjustment of the output voltage is made using the “Voltage Adjust” potentiometer on the control panel.



23. After the operation checks are made, stop the engine (move the Master Control Switch to the “Stop” position) and wait at least 2 hours for the engine to cool. When the engine is cool, check engine oil and coolant levels as instructed in the engine operation manual.

24. Close all enclosure covers. The post installation checks are now complete.


Section 4

Operation

Operator Control Panel (Digital Engine Controller Only)

The Operator Control Panel is shown in Figure 4-1.

WARNING: Never connect this generator to any buildings electrical system unless a licensed electrician has installed an approved transfer switch. The National Electrical Code (NEC) requires that connection of a generator to any electrical circuit normally powered by means of an electric utility must be connected by means of approved transfer switch equipment so as to isolate the electrical circuit from the utility distribution system when the generator is operating.

Failure to isolate the electrical circuits by such means may result in injury or death to utility power workers due to backfeed of electrical energy onto the utility lines.

Figure 4-1 Digital Operator Control Panel

MICROPROCESSOR ENGINE CONTROLLER

ALARM

SHUTDOWN

Vavg

000

Aavg

000

Freq

000

READY

SPEED SIGNAL

EXIT

SILENCE LAMP TEST

DECREMENT

RESET

INCREMENT ENTER

RUN OFF AUTO

LOAD

TEST

EMERGENCY

STOP

–

VOLTAGE

ADJUST

+

LCD Display -

Alarm LED-

Shutdown LED-

Ready LED-

Speed Signal LED-

Vavg (average voltage) display 0-999 volts.

Aavg (average amperage) display 0-999 amperes.

Freq (frequency) display 0-999 hertz.

Flashes when a fault is detected.

Flashes when a fault is detected.

On when the generator set is ready for automatic operation and no Shutdown or Alarm faults are detected.

On when the engine speed signal is detected (i.e. the engine is cranking).

Emergency Stop LED- On when the Emergency Stop Switch is used to stop the engine.

Emergency Stop Switch- When pushed, the engine is stopped immediately. The engine cannot be restarted until the controller is reset.

Programming Keys ← Exit pushbutton used to scroll backward through the status menus or programming prompts to the previous item.

Note: The longer the push-button is held down, the faster the menu prompts appear.

↓ Decrement pushbutton used to reduce a programming value while in the programming mode.

Note: The longer the push-button is held down, the faster the value will be decremented.

↑ Increase pushbutton used to increase a programming value while in the programming mode.

Note: The longer the push-button is held down, the faster the value will be incremented.

Run Switch-

Run LED-

OFF Switch-

OFF LED-

→ Enter pushbutton used to scroll forward through the status menus or programming prompts to the next item.

Note: The longer the push-button is held down, the faster the menu prompts appear.

When pushed, initiates a manual start signal to start the engine. The engine will start and operate continuously providing no shutdown faults are active. All protective circuits are operative in this mode. There will be no cool down cycle at the end of a manual run sequence.

On when the Run switch is used to start the engine (generator set).

When pushed, sends a stop signal to the engine to stop the engine.

On when the OFF Switch is used to stop the engine.

MN2408 Operation 4-1

Operator Control Panel Continued

Auto Switch -

Auto LED-

Load Test Switch -

Load Test LED -

When pushed, initiates automatic operation of the engine (generator set). Starting and stopping of the engine is controlled by a remote contact (transfer switch). When the remote start signal is removed the engine will continue to run for the cool down period

(if selected) then stop. Pushing the Off switch will stop the engine immediately, even if the cool down period is not complete.

On when the Auto Switch is used to start automatic operation.

When pushed, initiates a load test of the generator set with the associated transfer switch. Only operative for AMF connections or if one of the programmable output contacts is configured for ATS Test" and the remote transfer switch has remote testing circuitry.

When pushed, a signal is issued to the remote transfer switch to permit an automatic engine start and load transfer. Once initiated, the engine will receive a start signal from the transfer switch and upon the generator reaching nominal voltage and frequency levels, a load transfer will be initiated. The generator set will remain running at load until a different operating mode is selected or the generator set develops an alarm or shutdown fault condition.

On when the load test of the generator set is active.

Special Function Switches Silence Horn Silence. Press both Exit and Decrement" at the same time.

This will silence the audible alarm horn without resetting the fail condition.

Lamp Test Press both Decrement and Increment" at the same time.

Causes the LED's and LCD display to illuminate for approximately 2 seconds then return to their original status.

Voltage Adjust -

Note: The emergency stop LED is not affected by this test.

Reset Fault Reset. Press both Increment and Enter" at the same time.

Resets the controller when in a shutdown mode.

Note: To reset after a fault, the engine must come to a complete stop and the controller's OFF" switch must be pressed.

Increase or Decrease the Generator output voltage (displayed on VOLTAGE meter)

Operating Procedures The engine–generator controller is designed to start and stop an engine from either a local

(“Manual”) or remote (“Automatic”) modes. When a start command is issued, the controller issues a run and crank output signal. The controller then monitors engine speed and when crank disconnect speed is reached, the crank signal is terminated. While the engine accelerates to normal speed, the controller continuously monitors the engines speed signal. Should the engine speed exceed the maximum predetermined setpoint, the overspeed shutdown fault circuit will activate, terminating the run signal.

In addition to overspeed shutdown, the engine controller also monitors many other engine protection circuits and should they be activated, the engine will be stopped and/or alarm initiated.

The engine will automatically stop for any shutdown condition, or when the remote and/or local start signal is removed. The engine controller operation includes time delay circuits for normal operating conditions such as start delays, cool down and cranking periods.

Manual Start/Stop

To manually Start the Gen–Set, push the “RUN” push–button. The following happens:

1.

When the “RUN” push–button is pressed, an ENGINE START DELAY timer is initiated.

(The start sequence will not be initiated if any shutdown fault condition is present.)

2.

When the engine start delay time expires, an engine RUN and CRANK output signal will be initiated. (The RUN output may be programmed to only energize when a start signal is initiated and an engine speed signal is detected.)

3.

When the engine starts and begins to accelerate to nominal speed, the controllers speed sensor will terminate the CRANK output when engine speed reaches approximately 20% speed (i.e. CRANK DISCONNECT speed setpoint). Immediately upon reaching crank disconnect speed, the controller will initiate the BYPASS DELAY time delay function. After the BYPASS DELAY time period (typically 10 seconds) all fault circuits programmed as BYPASS DELAY=YES are active. (All fault circuits programmed as BYPASS DELAY=NO are continuously armed irrespective of any operation sequence.)

To manually Stop the Gen–Set, push the “OFF” push–button. The controllers RUN output will be immediately terminated which will initiate the engine stop sequence.

Automatic Start/Stop

To setup the generator for automatic operation, pressing the “AUTO” push–button.

The following happens:

1.

The engine will automatically start upon activation of the remote start contact input. The remote device initiates a start sequence upon contact closure.

2.

When the remote start signal is activated, the engine will start as per the sequence of operation described for the manual start sequence.

3.

The automatic stop sequence will be initiated by removal of the remote start signal.

4.

When the start signal is removed, a cool down delay function will be initiated.

4-2 Operation MN2408

5.

When the cool down time delay period expires (typically 5 minutes), the controllers

RUN output will be immediately terminated which will initiate the engine to stop.

Automatic Fault Shutdown

When a fault circuit is programmed as a SHUTDOWN, the engine will immediately stop when the fault is activated. A specific shutdown fault can be programmed with a definite time transient delay period that must expire before the shutdown is activated. The stop sequence will cause the controllers RUN output to be immediately terminated which will cause the engine to stop. This will prevent subsequent operation of the generator set. The Run/Stop/Auto selector switch on the operator control panel must be momentarily placed in the “Stop” position to reset the fault.

Automatic Mains Failure (AMF)

Figure 4-2 Auto Mains Failure (AMF) Connections


4-4 Operation

When the controller is applied in an Auto Mains Failure (AMF) application with a transfer switch, it must be wired as shown in Figure 4-2. Programmable output #3 must be selected for Utility

Ready To Load and programmable output #4 must be selected for Gen Ready To Load. After the controller is programmed, the AMF sequence of operation will be as follows:

Utility Normal Condition:

1.

Remote Start input signal (terminals 16 & 17) is not activated (i.e. normal).

2.

Utility Ready To Load output is energized (i.e. signal to transfer switch to transfer to utility power).

3.

Generator Ready To Load output is de–energized.

Utility Power Failure Conditions:

1.

Remote Start input signal is activated (i.e. remote start contact closes when utility power fails, as sensed by utility voltage sensor).

2.

Engine starts after the Engine Start Delay timer (Utility Ready To Load output stays energized).

3.

After the engine has started and the generator output rises above the programmed voltage and frequency limits, a Warm–Up timer is initiated.

4.

After the Warm–Up timer expires the Utility Ready to Load output de–energizes and the

NEUTRAL Delay timer is initiated.

5.

After the NEUTRAL DELAY timer expires the Gen Ready to Load output energizes to signal the transfer switch to transfer to the generator supply. Note: The neutral delay function is only operative with an electrically–held type transfer switch mechanism

(ie. electrical contactor type).

Utility Power Restored:

1.

Remote Start input signal is removed and the Return Delay timer is initiated (i.e. Utility

Voltage returns to normal and the Utility voltage sensor contact opens).

2.

After the Return Delay timer expires, the Generator Ready to Load output de–energizes and the Neutral Delay timer is initiated.

3.

After the Neutral Delay timer expires the Utility Ready to Load output energizes to signal the transfer switch to transfer to the utility supply. Note: If the generator has a shutdown during the Return or Neutral Delay periods, the timers are bypassed, and the

Utility Ready to Load output immediately energizes.

4.

The generator Cool down Timer starts after the Return Delay timer.

5.

The generator stops after the Cool down Timer.

Load Test Push–button Operation

1.

When the Load Test pushbutton is pressed, the logic will internally simulate receiving a remote start input.

2.

Engine starts after the Engine Start delay timer.

3.

After the engine has started and the generator output rises above the programmed voltage and frequency limits, a Warm–Up timer is initiated.

4.

After the Warm–Up timer expires the Utility Ready to Load output de–energizes and the

Neutral Delay timer is initiated.

5.

After the Neutral Timer expires the Gen Ready To Load output energizes to signal the transfer switch to transfer to the generator supply.

Note: If a generator shutdown occurs during a Load Test Operation, the Load Test mode will be de–activated.

When Auto Mode is restored (after Load Test Operation) the following occurs:

1.

Simulated Remote Start input signal is removed.

2.

Gen Ready To Load output de–energizes, and Neutral Delay timer is initiated.

3.

After the Neutral Delay timer expires The Utility Ready To Load output energizes to signal the transfer switch to transfer to the utility supply.

4.

The generator Cool down timer starts timing following the transfer to the utility supply.

5.

The generator stops after the Cool down timer.

MN2408

No Load Test

To allow a timed No Load Test of the engine/generator set while using the AMF control application, a digital input contact from an external timer must be programmed for NO LOAD Test

The sequence of operation for a No Load Test condition is as follows:

1.

With the utility supply normal and the generator stopped, a no load test sequence may be initiated by closing an external exercise timer contact to the programmed digital input for No Load Test.

2.

After the external exercise timer contact closes, the engine will start and come–up to normal operating speed and voltage. The controller will issue an alarm of a No Load

Test condition. The connected transfer switch will remain on the utility and the generator will not transfer on load. Note: should the utility supply fail, the generator will automatically transfer on load.

3.

The engine will continue to run as long as the external exercise timer contact remains closed.

4.

After the external exercise timer contact opens, the engine will continue to run for its cool down time as programmed, then it will automatically stop.

Standard Faults When a fault occurs, information about the fault is displayed. The engine controller has many analog and digital inputs for monitoring and control operations. Three types of faults are used:

1.

Internal Faults are derived from a combination of digital and analog inputs.

2.

Digital Input Faults are initiated from external contact inputs.

3.

Analog Input Faults are initiated from external analog signal inputs.

Figure 4-3 shows how the controller inputs and outputs are organized.

A description of each is provided.

Internal Faults

Overspeed Shutdown

Loss of Speed

Alarm/Shutdown

Digital Input Faults

Overspeed Shutdown is initiated when the engine's speed has increased above the overspeed setpoint. The overspeed fault circuit is internally programmed as a latching shutdown fault. The overspeed shutdown fault circuit is programmable for the percentage of nominal engine speed (i.e. overspeed setpoint) and for the transient time delay period. The programming prompts for overspeed are located in the main menu programming loop.

Loss Of Speed is initiated when the engine's speed sensing circuit does not detect a speed signal for a period more than 2 seconds following a run signal. The loss of speed fault may be user programmed as a latching shutdown fault or alarm only.

The programming prompts for loss of speed are located in the main menu programming loop.

Overcrank Shutdown is initiated when the engine fails to start after the selected crank time or number of crank cycles. The Overcrank Shutdown

Switch not in AUTO overcrank fault circuit is internally programmed as a latching shutdown fault and is not user programmable.

Switch not in AUTO is initiated when the controller's operating mode switch is changed from the auto position to any other position (ON the keypad). This fault is internally programmed as a non latching alarm. In the main programming loop, this alarm may be user programmed to initiate the common fail output relay.

Four digital faults are provided and these are user programmable. Each digital fault input circuit is activated by a remote

Digital Inputs (N/O or N/C) sensing contact that is external to the controller. Each digital fault input circuit may be programmed with a unique fault label description as stored in the controller's non-volatile memory.

Factory settings have four standard digital faults as follows:

Fault

Name

Low Oil Pressure

High Engine Temperature

Battery Charger Input Fail

Low Fuel Level

The following is a list of all digital faults:

High Bearing Temp

High Cooler Vibration

High Engine Temp

High Engine Vibration

High Fuel Level

High Oil Level

High Oil Temp

High Winding Temp

*Highintkmanftemp

Fault

Action

Shutdown

Shutdown

Alarm

Alarm

Failed To Sync

Low Fuel Press

Low Engine Temp

Low Oil Pressure

Low Fuel Level

Low Oil Level

Fuel Leak

Low Fuel Press

Low Coolant Level

Blank" (i.e. no text for unused inputs)

3

4

1

2

Digital Inputs

Terminal #

Reverse Power

Fail To Sync

Vent Damper Fail

Gen Breaker Open

Ground Fault

No Load Test

ATS In Bypass

Remote Emerg. Stop

Air Damper Tripped

Bat Charger Input Fail

Bat Chrg Trouble

Bat Charger Fail

DC Fail

Breaker Tripped

Basin Rupture


Figure 4-3 Engine Controller Inputs & Outputs


Analog Faults Eight analog fault inputs are user programmable for 12 fault conditions. Each analog fault input requires a specific analog signal type.

Fault

Name

Fault

Action

Low Engine Temperature Alarm

High Engine Temperature #1 Alarm

High Engine Temperature # 2 Shutdown

Low Oil Pressure #1

Low Oil Pressure #2

Low Battery Voltage

High Battery Voltage

Weak Battery

Undervoltage

Under frequency

Alarm

Shutdown

Alarm

Alarm

Alarm

Shutdown

Shutdown

Inputs

Signal

Engine Temperature

Engine Temperature

Engine Temperature

Oil Pressure

Oil Pressure

Battery Voltage

Battery Voltage

Battery Voltage

Voltage

AC Frequency

Low Engine Temperature An analog DC signal is provided from an engine mounted sender. The low engine temperature fault is activated when engine temperature is below a pre-determined setpoint for a specified time delay. This fault is programmable for temperature setpoint level, transient time delay settings and other functions.

High Engine Temperature #1 An analog DC signal is provided from an engine mounted sender. The high engine temperature fault is activated when engine temperature is above a pre-determined setpoint for a specified time delay. This fault is programmable for the level of temperature setpoint, transient time delay settings and other functions.

High Engine Temperature # 2 An analog DC signal is provided from an engine mounted sender. The high engine temperature fault is activated when the engine temperature rises above a pre-determined setpoint for a specified time delay. This fault is programmable for the level

Low Oil Pressure #1 of temperature setpoint, transient time delay settings and other functions.

An analog DC signal is provided from an engine mounted sender. The low oil pressure alarm fault is activated when the oil pressure is below a pre-determined setpoint for a specified time delay. This fault is programmable for pressure setpoint level, transient time delay settings and other functions.

Low Oil Pressure #2

Low Battery Voltage

High Battery Voltage

Weak Battery

Undervoltage

An analog DC signal is provided from an engine mounted sender. The low oil pressure shutdown fault is activated when the oil pressure is below a pre-determined setpoint for a specified time delay. This fault is programmable for pressure setpoint level, transient time delay settings and other functions.

The low battery voltage alarm fault is activated when the battery voltage drops below a pre-determined setpoint for a specified time delay. This fault is programmable for the voltage setpoint level, transient time delay settings and other functions.

The high battery voltage alarm fault is activated when the battery voltage rises above a pre-determined setpoint for a specified time delay. This fault is programmable for voltage setpoint level, transient time delay settings and other functions.

The weak battery alarm fault is activated when the battery voltage drops below a pre-determined setpoint for a specified time delay. The weak battery alarm detects a low capacity (i.e. weak) battery condition during the cranking cycle. The weak battery alarm is programmed for a lower battery voltage setpoint and shorter time delay than the low battery alarm function.

This fault is programmable for voltage setpoint level, transient time delay settings and other functions.

All 3-phases of the generator output are monitored for an undervoltage condition. The undervoltage sensor is programmable for type of fault action (alarm or shutdown), pickup and dropout voltage setpoints (i.e. adjustable hysteresis) and transient time delay settings.

The generator output is monitored for an under frequency condition. The under frequency sensor is programmable for type of Under frequency fault action (alarm or shutdown), frequency setpoint, and transient time delay settings.

Engine Speed Analog Input A magnetic pickup (engine speed sensor) measures engine speed. The engine speed sensor allows the controller to perform the following control functions:

Overspeed shutdown

Crank Disconnect control

Loss of speed signal detection

Starter Re-engage control

RPM display


Output Contacts All output contacts are non–powered (i.e. dry contacts) and are rated 10A/240VAC, 8A/28VDC resistive (3A inductive, 0.4pf). Output contacts are not fused therefore external overcurrent protection (maximum 10A) is required for all control circuits using these contacts. Contacts are shown in a de–energized state and will change state upon activation.

Run

Crank

Energize To Stop

The Run contact is a Form A" dry contact to control the engines Run" circuit. This typically includes external control devices such as Fuel Rack Solenoids" or electronic governors.

Note: An additional pilot relay will be required to energize high current devices that exceed the 10A resistive rating. The run output control logic provides an Energize To Run Signal (i.e. the run contact closes when a run condition is activated).

For energize to stop control logic, refer to the programmable output control function.

The Crank output contact is a Form A" dry contact and is used to control an external crank pilot relay that directly controls the engine starter motor.

Note: An external crank pilot relay is required to energize the high current starter motor pinion solenoid that exceeds the 10A

Programmable Contacts resistive crank output contact rating. The crank output contact closes when a crank condition is activated and the contact will automatically open when crank disconnect speed is obtained and/or the generators output AC voltage exceeds 10% of nominal level. The generators output AC voltage is utilized for back-up crank disconnect protection should the speed sensor fail.

Four (4) standard programmable output contacts are provided, #1, #2, #3 and #4. Each programmable output is a Form C" dry contact that is programmable for any of the following conditions:

The output relay will energize when a stop signal has been activated. The output will remain energized for 10 seconds after the engine has come to a complete stop, then de-energizes.

Switch Not In Auto

Engine Ready

Preheat

GEN Ready To Load

Utility Ready To Load

The output relay will energize when the controller's operation mode switch is not in the auto position.

The output relay will energize when the controller's mode switch is in the auto mode and no shutdown or alarm conditions are present.

The output relay will energize during the start delay timer period and cranking period until the engine starts and reaches crank disconnect speed. The preheat output is typically used for an engine starting aid such as glow plugs.

Note: An external pilot relay is required to switch the high current glow plug load.

The output relay will energize when the generators output voltage and frequency exceeds predetermined setpoints (e.g.

voltage 90% nominal, frequency 95% nominal as user programmed) and a warm-up time delay period expires. After the output has energized, it will remain on (regardless of voltage/frequency levels) until the controller either has a stop/shutdown signal, or the engine's speed drops below crank disconnect level. The voltage, frequency and time delay levels are programmable. This output is typically used in an Auto Mains Failure (AMF) application.

The output relay will energize when the remote start input has not been activated (i.e. contact on terminals 16 & 17 not closed) and the Return Delay & Neutral Delays have expired (if programmed). The output will de-energize when the remote start input has been activated and the Engine Start Delay & Warm-Up Delays have expired (if programmed). This output is typically used for Auto Mains Failure (AMF) applications.

The output relay will energize when the engine has started and has reached crank disconnect speed.

Engine Running

Engine Run (Fuel)

Airflap

ATS Test

The output relay will energize when the engine RUN" (i.e. FUEL) energizes prior to the engine starting. The output will remain on until the engine has reached a stop" or shutdown" command.

The output relay will energize when the engine's speed exceeds the overspeed setpoint level. The output will remain energized until the engine's speed drops below the low speed setpoint (typically 5% of rated speed).

Note: An external pilot relay is required if the main air flap solenoid current rating exceeds the contact rating.

This feature is only operative if the remote transfer switch is interconnected with remote testing capability.

The output relay will energize when a load test operating mode is selected by the Load Test" keypad push-button. After initiated, the engine will receive a start signal from the transfer switch and when the generator reaches nominal voltage and frequency levels, a load transfer will be initiated. The generator set will remain running on load until a different operating mode is selected or the generator set develops an alarm or shutdown condition.

Note 1: When the Utility Ready to Load" and Generator Ready to Load" outputs are programmed, the Load Test" programmable output is not required as the engine starting logic is internally initiated.

Note 2: When both Utility Ready to Load" and Generator Ready to Load" outputs are programmed for an AMF control configuration, the ATS Output is not used (i.e. engine start signal is internally generated).

Oil Bypass Timer Complete The output relay will energize when the controller's oil bypass delay timer expires, following a normal start sequence.

Common Alarm

Common Fail

Common Shutdown

EPS Supplying Load

The output relay will energize when any alarm fault has been activated.

The output relay will energize when any alarm or shutdown fault has been activated.

The output relay will energize when any shutdown fault has been activated.

The output relay will energize when the engine is running and the generator is supplying current to the load more than or equal to 10% of nominal CT ratio.


Display Modes

The controller is in the display mode at all times except when in the programming mode. The display screens and menus may be selected by pressing the Enter or Exit keys to access

Operating Status Display, Fault Display, Timer Countdown, Generator AC Metering or

Programming Menus. The LCD display shows the status of the generator output:

Operating Status The controller will power–up into an Emergency Stop failure mode, preventing possible engine operation. The controller must be manually reset before normal operation can be established. To reset the Emergency Stop condition, press the “OFF” push–button first, then press both

“INCREMENT” and “ENTER” push–buttons simultaneously. The controller will then reset, if a remote emergency stop condition is not activated. The Utility Ready to Load programmable output will energize if the remote start contact is open. The Main LCD Display will be shown.

Action

Apply Power and

Reset faults.

Description

Main LCD Display.

Vavg

000

Display

Aavg

000

Freq

000

Comments

Press Enter key

Press ↑ or ↓ key




Show Operating Status screens

Scroll to next.

Scroll to next.

Scroll to next.

Scroll to next.

UNIT READY

SWITCH IN OFF

UNIT RUNNING

UNIT SHUTDOWN

UNIT ALARM

Controller is in Auto" position and there are no active faults.

Controller is in OFF" position from the front panel keypad push-button.

Engine is running and all conditions are normal.

A shutdown fault is active. The specific fault will be automatically displayed.

One or more faults are active. The display will automatically scroll through all active faults at a two second rate.

Fault Display The fault display menu is automatically displayed when an alarm or shutdown fault is activated.

The specific alarm or shutdown fault label will be displayed and if multiple alarm conditions are present, the display will automatically scroll through all active faults.


Timer Countdown Timer countdown menus are automatically displayed when a specific time delay function occurs during a control sequence. When a time delay begins, the LCD display will show the time delay function name (i.e. Engine Start Delay) and the current time remaining in the countdown sequence. When the timing function has expired, the LCD display will automatically change to either the next timing sequence countdown display or return to the original system status menu.

Action

Apply Power and

Reset faults.

Description

Main LCD Display.

Vavg

000

Display

Aavg

000

Freq

000

Comments

Show Operating Status screens

ENGINE START

DELAY 45 SEC

Displays specific time delay function name and remaining time.

Other time delay functions are:

ENGINE START

DELAY 45 SEC

CRANK PERIOD

XX SEC

REST PERIOD

XX SEC

STARTER RE–ENGAGE

DELAY XX SEC

BYPASS

DELAY XX SEC

COOLDOWN

DELAY XXXX SEC

WARMUP

DELAY XX SEC

RETURN

DELAY XX SEC

NEUTRAL

DELAY XX SEC

Note: Countdown screens only appear if Utility/Gen Ready To Load outputs are programmed.


Generator AC Metering The controller is in the display mode at all times except when in the programming mode. The display screens and menus may be selected by pressing the Enter or Exit keys to access Operating Status Display, Fault Display, Timer Countdown, Generator AC Metering or

Programming Menus. The LCD display shows the status of the generator output:

Generator Average Output Display

Vavg

000

Aavg

000

Freq

000

Average Voltage

Average Current

Frequency

Displays the average generator voltage as follows:

3-phase system: AVERAGE LINE TO LINE VOLTAGE--Phases

1-phase system: LINE TO LINE VOLTAGE--Phases A to B

Displays the average generator current as follows:

3-phase system: AVERAGE LINE CURRENT--Phases A,B,C

1-phase system: AVERAGE LINE CURRENT--Phases A,B

Displays generator frequency in hertz (HZ). The frequency is displayed with a resolution of 1/10 of a hertz.

Generator KVA Display

KVA

632.23

KVA Displays the generator's total power output in kilo-voltamperes (KVA).

Generator Phase Voltage Display

(Line to Line)

Vab

600

Vbc

600

Vca

600

Vab

Vbc

Vca

Displays the generator's output voltage:




3-phase system: LINE TO LINE VOLTAGE--Phases B to C

1-phase system: LINE TO NEUTRAL VOLTAGE--Phases A-N


3-phase system: LINE TO LINE VOLTAGE--Phases C to A

1-phase system: LINE TO NEUTRAL VOLTAGE--Phases B-N

Generator Phase/Neutral Voltage Display

(Line to Neutral)

Van

347

Vbn

347

Vcn

347

Van

Vbn

Vcn

Note: The generator's neutral must be connected to controller terminal TB1-VN and the neutral connected" prompt in the main program menu must be selected as Yes".

Displays generator voltage Phase A to Neutral.

Displays generator voltage Phase B to Neutral.

Displays generator voltage Phase C to Neutral.

Generator Phase Current Display

Amps a

408 b

451 c

415

Amps a

Amps b

Amps c

Displays generator load current as follows:

3-phase system: PHASE A CURRENT

1-phase system: PHASE A CURRENT


3-phase system: PHASE B CURRENT

1-phase system: PHASE B CURRENT


3-phase system: PHASE C CURRENT

1-phase system: not applicable

Generator Frequency/Hourmeter Display

FREQ

HOURS

60.1 Hz

56788 Hrs

FREQ

HOURS

Displays generator frequency in hertz (HZ). The frequency is displayed with a resolution of 1/10 of a hertz.

Displays unit operating hours.


Engine Parameter Display Two engine operating parameter screens are provided.

Battery Voltage/Engine Speed

(Tachometer)

BATTERY

SPEED

27.0 Vdc

1800 rpm

Battery

Speed

Displays battery voltage in DC volts. The voltage is displayed with a resolution of 1/10 of a volt.

Displays engine speed in revolutions per minute (RPM).

Engine Temperature/Oil Pressure

ENG TEMP

OIL PRESS

57 Deg C

200 KPA

ENG TEMP

OIL PRESS

Displays engine temperature in either degrees Celsius or Fahrenheit (as selected).

Displays engine oil pressure in either pounds per square inch (PSI) or in Kilopascals (KPA) (as selected).

Program Menus The programming menu is used to change values such as time delays, analog fault settings, digital fault settings. Access to the programming sub–menus may only be obtained with a security password number. The sub menus are organized as follows:

Program Menu

PROGRAM MENU?

NO

Displays two messages that may be toggled between YES and NO by pressing the INCREMENT push-button.

NO Programming sub-menus are disabled when NO is displayed.

YES Programming sub-menus are enabled when YES is displayed and a valid password number is entered.

PASSWORD

0

Press INCREMENT or DECREMENT to change the password. Press ENTER when the correct number is displayed.

Read Only Mode

User can view the parameters but cannot change any values. The factory setting for this level is one (1).

Read / Write Mode

User can view and modify any parameter value. The factory setting for this level is two (2).

Master Read / Write Mode

User can view and modify any parameter value and view/modify the security password level numbers.

Contact Baldor for master password if required.

The values of the parameter settings for your generator–set can be recorded for future reference using the Configuration Data Sheet shown in Figure 4-4.

After the correct password number is entered, the you may choose one of four programming menus. Press INCREMENT or DECREMENT to find the desired menu then press ENTER.

MAIN MENU LOOP

ANALOG FAULT MENU LOOP

DIGITAL FAULT MENU LOOP

CALIBRATION MENU LOOP


Navigation Hints

Programming parameters are displayed in the same order as the Programming Sheets (see

Figures 4-5 to 4-8). To skip over parameters that do not require changes, push and hold the

ENTER push–button until the desired parameter is displayed. The EXIT push–button may be used to scroll backwards through the programming parameter loops.

To change a parameter value, use the INCREMENT or DECREMENT push–buttons to scroll through the available options or to adjust a value as desired and press the ENTER to accept the new value.

Note: If programming mode is terminated before the last change is accepted (pressing ENTER), that parameter value will remain unchanged.

Main Menu Loop The Main Menu Loop contains general system configuration programming such as system input voltages, currents, transformer ratios, as well as standard operating time delay functions.

System Voltage

System Frequency

System Phases

Neutral Connected

Set to nominal system voltage as expressed in phase to phase voltage (i.e. a 347/600 volt system would be entered as

600). The programmable range of values is 120V-15,000V.

Set to nominal system frequency of either 50 HZ or 60 HZ.

Set to match the power distribution system used on the generator set (i.e. either single phase or 3 phase system).

Set to Yes if generator's neutral conductor is connected to controller terminal TB1-VN and it is desired to display line-neutral AC voltages for a 3 phase, 4 wire system.

Voltage Sensing Ratio For direct voltage sensing wiring connections from 208 to 600 volts, enter 1 (i.e. a ratio of 1:1). When potential transformers are utilized for voltage sensing, enter the calculated transformer ratio (e.g. when using 600:120 transformers, enter a number of 5).

Current Sensing Ratio For current sensing wiring connections from current transformers (CT's), enter the calculated CT ratio (e.g. when using a

Temperature Scale

600:5 CT, enter a number of 120).

Select the desired units for engine temperature display and analog setpoints: Degrees Fahrenheit or Degrees Celsius.

Pressure Scale

Start Delay

Crank Time

Rest Time

Note: Alarm setpoints do not automatically re-configure when changing between Fahrenheit or degrees Celsius.

Select the desired units for engine pressure display and analog setpoints: Pounds per square inch (PSI) or Kilopascals

(KPA). Note: Alarm setpoints do not automatically re-configure when changing between PSI and KPA.

Select desired engine start delay time in seconds. If engine start delay is not required, set to zero. Note: If preheat and or prelube functions are used, the engine start delay time should be set as required for these functions.

Select desired cranking time in seconds. If cycle cranking is selected, this time will be the crank time per attempt.

Select desired rest time between cranking attempts. (Only valid if multiple crank attempts are selected).

Note: This value will be ignored if only one attempt has been programmed.

Starter Re-Engage Duration This feature checks for a speed signal during cranking. If no speed signal is sensed, the controller assumes that the engine starter is not turning the engine over and disengages it after the programmed time delay, and re-engages it again. This process will repeat until a speed signal is sensed or cranking time expires, whichever occurs first.

If a speed signal is sensed, cranking continues until the engine starts or an overcrank condition occurs.

Set time in seconds as desired (i.e. a setting of 5 seconds will attempt cranking for 5 seconds after which time if no speed signal is detected, the crank output will be removed for a preset 1 second delay before re-engaging.)

Note: This action is more than a cycle cranking function and is independent of the number of attempts selected.

Therefore, the crank" time should be considered. To disable this feature, set to zero.

Number Of Crank Cycles Set to the number of cranking cycles required. (Zero will default to one.)

Bypass Delay This setting is the time period that Alarm or Shutdown faults will be ignored after crank disconnect, allowing the engine to settle into its normal operating mode (i.e. proper oil pressure, etc.). Typically 10 seconds.

Cool down Time

Nominal Engine RPM

Flywheel Teeth

Set to desired cool down time in seconds. Up to 9999 seconds of cool down time may be programmed. Set to zero if not required.

Note: If the controller is used in an AMF application it is recommended to set the cool down timer to a minimum of 10 seconds to allow the generator to transfer Off Load before enabling the cool down time. (Ensures the load is transferred off of generator prior to stopping the engine.)

Set to the nominal engine speed in revolutions per minute (RPM).

Set to the number of ring gear teeth on the engine flywheel. The magnetic pick-up must be installed to sense the same teeth for speed sensing as programmed.

Crank Disconnect Speed Set crank disconnect speed in percentage of nominal speed, i.e. 30% or 540 RPM on an 1800 RPM engine.

Overspeed

Run Output Fail-safe

Set overspeed shutdown point in percentage of nominal speed (i.e. 110% or 1980 RPM on an 1800 RPM engine).

Overspeed Transient Delay Select desired overspeed transient delay time in seconds. Time setting may be entered in tenths of seconds.

When enabled (factory setting), this feature inhibits the run output until the controller receives a speed sensing signal.

This prevents possible damage caused by starting the engine with no speed sensing for crank disconnect and overspeed. If selected, ensure that the speed signal is not less than 3.0VAC from the magnetic pick up while the engine is cranking.

Note: If this feature is disabled, no overspeed protection or crank disconnect will be provided if the speed signal fails. If you disable this feature Baldor strongly recommends that backup crank disconnect protection and additional overspeed protection is provided.


Main Menu Loop Continued

Loss Of Speed Signal Select the desired action (i.e. alarm or shutdown) when a loss of speed signal is detected during operation.

Note: A loss of speed signal must be detected for longer than 2 seconds to initiate the desired action.

Common Fail For Not In Auto" Function Selects if a common fail alarm condition is to be activated during manual operation.

Horn For Not In Auto

Warm-up Delay

The Horn may be programmed to sound when the controllers operating mode is switched from the Auto position. If the

Horn is not to sound, select program setting No.

The WARM-UP Delay menu appears when the Gen Ready To Load programmable output is selected (typically for AMF application). Set to the desired time in seconds, which the generator requires to effectively warm-up" before accepting

Neutral Delay

Return Delay load. This is typically set for 3 seconds. The Warm-Up Delay is initiated after the generator is above programmed voltage and frequency limits (per the analog programming menus).

The Neutral Delay menu appears when the Utility Ready To Load programmable output is selected (typically for AMF application). The Neutral Delay timer is used when transferring between the available power sources. When transferring from the utility supply to the generator supply, the Neutral Delay timer will start when the Utility Ready To Load output de-energizes. When the Neutral Delay time period expires, the Generator Ready To Load output is energized. The purpose of the Neutral Delay timer is to prevent out of phase transfers, which may be caused by a fast transfer and the two sources of supply are out of synchronism. The Neutral Delay timer ensures the load voltages decay before the transfer is initiated. Set to the desired time in seconds. The Neutral Delay timer is typically set for 3 seconds.

Note: The Neutral Delay feature is only effective when an electrically held contactor-type" transfer switch is connected.

Contact Baldor for further application information on use with other types of transfer switch mechanisms.

The Return Delay menu appears when the Utility Ready To Load output is selected (typically for AMF application). The

Return Delay is initiated when the remote start signal is removed (signaling utility power is available). After the Return

Delay timer expires, the Generator Ready To Load output is removed, and the Utility Ready To Load output energizes to signal transfer the load back to the utility supply. The purpose of the Return Delay timer is to ensure that the utility power has returned to a steady state for the selected time period before the load is transferred back to the utility supply. The

Return Delay timer is typically set for 120 seconds.

Caution: The Programmable Output Contacts selection must agree with the external control wiring prior to energizing the controller. Failure to do so may cause severe equipment damage.

Programmable Output Contacts Select the desired function that will activate the programmable relay output contact.

One of the following functions may be selected:

Reset Run Hours

Energize To Stop Gen Ready To Load

Oil Bypass Timer Complete Common Fail

Overspeed

Low Bat Voltage

ATS Test

Low Oil Press #2 Shutdown

Engine Ready

Preheat High Bat Voltage

Low Oil Press #1 Alarm

High Eng Temp #1 Alarm

Air Flap Eps Supplying Load Utility Ready To Load

Digital Faults #1 to4

Loss Of Speed Signal

Engine Running

Common Alarm

High Eng Temp #1 Shutdown

Switch Not In Auto

Engine Run (Fuel)

Weak Bat Voltage

Common Shutdown

The hourmeter may be reset to zero hours when yes is programmed.

Note: This programming prompt is only accessible while using the Master" programming security password.

Analog Fault Menu Loop The controller’s analog fault settings are described as follows:

Level

Action

Alarm Latch

Sets the actual analog signal setpoint at which the selected fault type will be activated.

Note: For AC voltage fault circuits, two levels (i.e. pick-up & drop-out) must be programmed.

Allows a fault to be either an Alarm fault or a Shutdown fault.

If an fault was set as an Alarm, it may be selected as a Latching" alarm or Non-latching" alarm. A Latching alarm is not cleared until a reset command clears it.

Note: This value only appears if alarm faults are programmed. Shutdown faults are automatically set as latching.

Bypass On Start Delay Allows the alarm or shutdown fault to be disabled until after the bypass timer has expired. Faults that are not delayed are enabled at all times (i.e. engine running or stopped).

Transient Delay Times Allows the selected fault to be disabled until the delay period has expired. Delay times are 0.0 to 999.9 seconds.


Digital Fault Menu Loop The controller’s digital fault settings are described as follows:

Caution: The Digital Fault Label selection must agree with the external control wiring prior to energizing the controller. Failure to do so may cause severe equipment damage.

Digital Fault Label

Action

Alarm Latch

Select the desired fault label, these are stored in non-volatile memory.

Air Damper Tripped

Bat Chrg Trouble

DC Fail

Gen Breaker Open

High Bearing Temp

High Engine Temp

High Fuel Level

No Load Test

High Fuel Level

High Oil Temp

Low Coolant Level

Low Fuel Level

Low Oil Level

Remote Emerg.stop

Basin Rupture

Fuel Leak

Bat Charger Fail

Fail To Sync

Allows a fault to be either an Alarm fault or a Shutdown fault.

Bat Charger Input Fail

Breaker Tripped

Failed To Sync

Ground Fault

High Cooler Vibration

High Engine Vibration

High Oil Level

*Highintkmanftemp

High Winding Temp

Low Engine Temp

Low Fuel Press

Low Oil Pressure

Reverse Power

ATS In Bypass

Low Fuel Press

Vent Damper Fail

Blank" (i.e. no text for unused inputs)

Note: Any activated alarm or shutdown fault will energize the Common fail" fault and sound the alarm horn.

If an fault was set as an Alarm, it may be selected as a Latching" alarm or Non-latching" alarm. A Latching alarm is not cleared until a reset command clears it.

Note: This value only appears if alarm faults are programmed. Shutdown faults are automatically set as latching.

Polarity Allows the digital fault circuit to be set for Open to Fail or Close to Fail sensing contacts.

Bypass On Start Delay Allows the alarm or shutdown fault to be disabled until after the bypass timer has expired. Faults that are not delayed are enabled at all times (i.e. engine running or stopped).

Transient Delay Times Allows the selected fault to be disabled until the delay period has expired. Delay times are 0.0 to 999.9 seconds.

Idle Control Digital Input Programming When a digital input is set to Idle function, these settings must be programmed to ensure correct operation:

Action

Alarm Latch

Polarity

Alarm

No

Close

Bypass On Start No

Transient Time 0.1

Note: The corresponding digital output must also be programmed for IDLE to enable correct operation.

No Load Test Control Digital Input Programming

The No Load Test digital input feature is typically used in an AMF application where it is required to do an automatic timed No Load Test of the engine/generator set. A contact from an external exercise clock timer is required to be connected to the digital input circuit which is programmed for No Load Test". When a digital input is programmed as No

Load Test, these settings must be programmed to ensure correct operation:

Action

Alarm Latch

Polarity

Alarm

No

Close Or Open (dependent on external circuit used)

Bypass On Start No

Transient Time 0.1

Calibration Menu Loop AC Voltage, AC current and battery voltage analog circuits are factory calibrated and should not require field calibration. If field calibration is required, refer to the calibration procedure.

Voltage Sensing Calibration (Phase To Phase or Phase To Neutral)

VOLTS AB ZERO

99 600V

Displays the generator phase voltages to be calibrated.

Displays the type of calibration function, either ZERO or SPAN.

Displays the calibration correction factor number (0-255) used to obtain the correct voltage reading.

Note: To correctly calibrate any of the voltage sensors, the ZERO function must be calibrated before the SPAN function.

Displays the actual voltage measurement that will be the same value as shown on the MEC 2 display menus for generator supply. This voltage reading may be calibrated higher or lower by changing the correction factor number.

Voltage Calibration Procedure

Zero Calibration

Note: Zero Calibration must be completed before Span Calibration.

Connect an external AC voltmeter of adequate voltage range and accuracy to the MEC 2 controller terminals associated with the voltage phases to be calibrated. With the generator stopped, confirm there is Zero volts on the phases to be calibrated. In the programming mode, scroll to each of the desired generator supply voltage phases (i.e. phase to phase or phase to neutral) with the ZERO function selected. Use the INCREMENT or DECREMENT push-buttons to adjust the correction factor number to obtain zero volts on the right hand side of the display as confirmed with the external voltmeter. The factory default correction factor is 127. Increasing this will raise the displayed value, conversely decreasing this value will decrease the displayed value. Note: Adjusting the ZERO function with voltage applied will result in non-linear voltage readings.

With the correct voltage displayed, press the ENTER push-button to accept the correction factor number. Record the correction factor number on the programming sheet for future reference. Repeat this procedure for all remaining phases.


Span Calibration Energize the generator supply voltage to the controller at nominal level. Note: It may be necessary to program the optional under and over voltage shutdowns as alarms to ensure the generator will continue to operate during calibration.

Caution must be taken to ensure the generator output voltage is set within nominal limits. In the programming mode, scroll to the desired generator supply voltage phases with the SPAN function selected. Connect an external AC voltmeter of adequate voltage range and accuracy to the controller terminals associated with the voltage phases to be calibrated.

Use the INCREMENT or DECREMENT push-buttons to adjust the correction factor number while observing the displayed voltage level. Adjust the correction factor number to obtain an identical voltage reading as measured with the external AC voltmeter. With the correct voltage displayed, press the ENTER push-button to accept the correction factor number. Record the correction factor number on the programming sheet for future reference.

Note: When the span calibration setting is complete, re-confirm the zero calibration points. If the zero calibration setpoint needs further adjustment, the span calibration point must also be re-calibrated.

Current Sensing Calibration To accurately calibrate the current sensors, an external test AC ammeter and current clamp is required, with an accuracy of 0.5% or better.

CURRENT A ZERO

99 350A

Zero Calibration

Span Calibration

Displays the generator load current (phase A, B or C) to be calibrated.

Displays the type of calibration function, either ZERO or SPAN.

Displays the calibration correction factor number (0-255) used to obtain the correct current reading.

Note: To correctly calibrate any of the current sensors, the ZERO function must be calibrated before the SPAN function.

Displays the actual current measurement that will be the same value as shown on the MEC 2 display menus for generator supply. This current reading may be calibrated higher or lower by changing the correction factor number.

Connect an external AC ammeter with current clamp of adequate current range to the controller terminals associated with the current phases to be calibrated. With the generator stopped, confirm there is 0" current on the phases to be calibrated. In the programming mode, scroll to each of the desired generator supply current phases with the ZERO function selected. Use the INCREMENT or DECREMENT push-buttons to adjust the correction factor number while observing the displayed current level. Adjust the correction factor until 0" amps is displayed.

With the correct current displayed, press the ENTER push-button to accept the correction factor number. Record the correction factor number on the programming sheet for future reference. Repeat for each phase.

Apply 50%-100% load to the generator set. It is recommended to load the generator set to 100% rated load for calibration purposes to obtain good accuracy throughout the full span of operation. Do not exceed the current rating of the CT. Non-linear output of the CT will result when the secondary current exceeds 5 amps and will similarly effect the displayed values.

In the programming mode, scroll to the desired generator supply current phases with the SPAN function selected.

Connect an external AC ammeter and current clamp of adequate current range to the controller terminals associated with the current phases to be calibrated. Use the INCREMENT or DECREMENT push-buttons to adjust the correction factor number while observing the displayed current value. Adjust the correction factor number to obtain an identical current reading as measured with the external AC ammeter. With the correct current displayed, press the ENTER push-button to accept the correction factor number. Record the correction factor number on the programming sheet for future reference.

Repeat for each phase.

Note: When the span calibration setting is complete, re-confirm the zero calibration points. If the zero calibration setpoint needs further adjustment, the span calibration point must also be re-calibrated.

Battery Voltage Calibration To accurately calibrate the MEC 2 battery voltage sensor, an external test DC voltmeter is required, with an accuracy of 0.5% or better.

BAT VOLTS SPAN

99 24.6V

SPAN Calibration

Displays the type of calibration function (SPAN).

Displays the calibration correction factor number (0-255) used to obtain the correct voltage reading.

Displays the actual battery voltage measurement that will be the same value as shown on the MEC 2 display menu.

This voltage reading may be calibrated higher or lower by changing the correction factor.

Energize the battery supply voltage to the controller and connect the external test DC voltmeter to the battery terminals,

B+ and B-. In the programming mode, scroll to the battery span calibration point. Use the INCREMENT or

DECREMENT push-buttons to adjust the correction factor number while observing the displayed battery voltage level on the MEC 2. Adjust the correction factor number to obtain an identical voltage reading as measured with the external DC voltmeter. With the correct voltage displayed, press the ENTER push-button to accept the correction factor number.

Record the correction factor number on the programming sheet for future reference.


Engine Temperature & Oil Pressure Calibration

To accurately calibrate the controller’s temperature sensor, an external temporary engine mounted temperature gauge is required. The external temperature gauge should be connected as close as possible to the temperature sender.

To accurately calibrate the controller’s pressure sensor, an external temporary engine mounted pressure gauge is required. The external pressure gauge should be connected as close as possible to the pressure sender.

ENGINE TEMP

127 95 5C

Displays the type of calibration function.

Displays the calibration correction factor number (0-255) used to obtain the correct Temperature or Pressure reading.

Displays the actual temperature or pressure measurement shown on the display menus.

This reading may be calibrated higher or lower by changing the correction factor number.

Engine Temperature The engine temperature analog circuit must be calibrated with the engine temperature sender mounted on the engine.

Connect a temporary engine mounted temperature gauge of suitable accuracy and start the engine. After the engine reaches normal operating temperature, enter the programming mode and scroll to the Engine Temperature Offset" calibration point. Use the INCREMENT or DECREMENT push-buttons to adjust the correction factor number while

Oil Pressure observing the displayed temperature. Adjust the correction factor number to obtain the identical temperature reading as measured with the external temperature gauge. With the correct temperature displayed, press the Enter" push-button to accept the correction factor number. Record the correction factor on the programming sheet for future reference.

Connect a temporary engine mounted pressure gauge of suitable accuracy and start the engine. After the engine reaches normal operating pressure and temperature, enter the programming mode and scroll to the Engine Pressure

Offset" calibration point. Use the INCREMENT or DECREMENT push-buttons to adjust the correction factor number while observing the displayed pressure. Adjust the correction factor number to obtain the identical pressure reading as measured with the external pressure gauge. With the correct pressure displayed, press the Enter push-button to accept the correction factor. Record the correction factor on the programming sheet for future reference.

194

176

150

140

266

248

230

212

338

320

302

284

5F

392

374

356

122

104

86

68

50

32

90

80

70

60

130

120

110

100

170

160

150

140

5C

200

190

180

50

40

30

20

10

0

147

197

290

426

65

76

90

106

Ohms

20

24

28

33

39

46

55

622

952

1486

2322

3644

6284

276

207

138

69

552

483

414

345

KPA

1034

965

896

827

758

689

621

40

30

20

10

80

70

60

50

120

110

100

90

PSI

150

140

130

142

160

183

206

89

101

114

127

Ohms

38

42

48

54

62

70

79

Note: Sender resistance data shown are for Oil Pressure Sender p/n-003654 (Thompson p/n), Manufacturer- Datcon, p/n

102227. Datcon Sender must be used with MEC software version 1.81 or greater (previous software versions cannot be used).


j j j j j j

Figure 4-4 Configuration Data Sheet j j j


Parameter

System Voltage (Line To Line)

System Frequency

Temperature Scale

Pressure Scale

Start Delay

Crank Time

Rest Time

Starter Re–engage Delay

Number Of Cranks

Bypass Delay

Cool down Delay

Nominal RPM

Flywheel Teeth (Engine Speed

Sensing, Magnetic Pick Up

Crank Disconnect

Overspeed

Overspeed Transient

Run Output

Loss Of Speed Signal

Common Fail For

Horn For Not In Auto

Prog Output #1

Prog Output #2

Prog Output #3

Prog Output #4

Prog Output #5

Prog Output #6

Warm–up Delay

Neutral Delay

Return Delay

Reset Run Hours

Yes/No

Figure 4-5 Main Menu Loop Parameters

XXXXX VAC

Setting Range

120–15000VAC

50Hz/60Hz

1 Phase/3 Phase

Neutral Connected

Voltage Sensing

Ratio XXX

Current Sensing

Ratio XXX

Deg C/Deg F

PSI/KPA

XXX Seconds

XX Seconds

XX Seconds

XX Seconds

XX Cranks

XX Seconds

XX Seconds

XXXX RPM

XXX Teeth

Toggle Between 50/60 Hz

Toggle Between 1 & 3 Phase

Toggle Between Yes/No

Voltage Sensing Pt Ratio

Enter Number 1–208 (1=Direct)

Current Sensing Ct Ratio

Enter Number 1–999 (1=Direct)

Toggle Between Deg C/Deg F

Toggle Between Psi/Kpa

0–999 Seconds

0–99 Seconds

0–99 Seconds

0–99 Seconds 0=Disabled

0–99 Times 0=Continuous

0–99 Seconds

0–9999 Seconds

0–4000RPM

0–999 Teeth

XX %

XX %

X.X Seconds

Fail Safe Yes/No

Shutdown Alarm/Shutdown

Not In Auto Yes/No

0–100%

100–150%

0.0–9.9 Seconds


Toggle Between Alarm/Shutdown



Common Fail (Factory setting)






0–99 Seconds

0–99 Seconds

0–999 Seconds

Access by Master Password Only



Parameter

Volts A-B

Volts A-B

Volts B-C

Volts B-C

Volts C-A

Volts C-A

Volts A-N

Volts A-N

Volts B-N

Volts B-N

Volts C-N

Volts C-N

Current A

Current A

Current B

Current B

Current C

Current C

Battery Voltage

Engine Temperature

Oil Pressure

Fault Name Input Analog

Type

Figure 4-6 Analog Fault Menu Loop Parameters

Fault

E=Enable

D=Disable

Setpoint Level

(Pick-up)

Setpoint Level Action

(Drop-out)

S Shutdown

A=Alarm

Alarm Latch

Y=Yes

N=No

Under Voltage AC Voltage E*

Under Frequency AC Frequency E*

Weak Battery

Low Battery

Voltage

High Battery DC Voltage E*

Voltage

Low Engine Temp Temp Sender E*

Temp Sender E* High ENG Temp #1

Alarm

High ENG Temp #2

Shutdown

DC Voltage

DC Voltage

Temp Sender

E*

E*

E*

Low Oil Press #1

Alarm

Low Oil Press #2

Shutdown

Press Sender E*

Press Sender E*

* Indicates parameter is non-programmable.

Fault Name Input #

Low Oil Pressure 1

High ENG TEMP 2

Batt Chgr Input Fail 3

Low Fuel Level 4

18.0

25.6

30.4

95 °F

198 °F

206 °F

30PSI

20PSI

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

S

S

A*

A*

A*

A*

A

S

A

S

Y

N

Y

Y

N

Y

Y

Y

Y

Y

A

A

S

S

Figure 4-7 Digital Fault Menu Loop Parameters

Action

S=Shutdown

A=Alarm

Y

N

-

-

Alarm Latch

Y=Yes

N=No

C

C

O

O

Polarity

O=Open

C=Close

Bypass On

Start

Y=Yes

N

N

Y

Y

Y=Yes

N=No

Transient

Delay (Sec)

0.5

1.0

30.0

0.1

Figure 4-8 Calibration Menu Loop Parameters

Setting

Zero XXX

Span XXX

Zero XXX

Span XXX

Zero XXX

Span XXX

Zero XXX

Zero XXX

Zero XXX

Zero XXX

Zero XXX

Zero XXX

Zero XXX

Span XXX

Zero XXX

Span XXX

Zero XXX

Span XXX

Span XXX

XXX

XXX

XXXVAC

XXXVAC

XXXVAC

XXXVAC

XXXVAC

XXXVAC

XXXVAC

XXXVAC

XXXVAC

XXXVAC

XXXVAC

XXXVAC

XXXAAC

XXXAAC

XXXAAC

XXXAAC

XXXAAC

XXXAAC

XX.X VDC

XXX C/F

XXXX PSI/KPA

Y*

Y*

N*

N*

Y

Y

Bypass On

Start

Y=Yes

N=No

Y*

Y*

N*

N*

Transient

Delay (Sec)

2.0

2.0

5.0

5.0

3.0

120.0

10.0

5.0

2.0

2.0


12VDC (24VDC)

STARTING

BATTERY

CRANK PILOT RELAY

RUN CIRCUIT

SPEED SENSING

MAGNETIC PICKUP

OIL PRESSURE SENDER

ENGINE TEMPERATURE SENDER

REMOTE EMERGENCY STOP

(CLOSE TO STOP)

REMOTE FAULT RESET

(CLOSE TO RESET)

REMOTE START CONTACT

DIGITAL FAULT INPUT

CONTACTS

(MEC 2 = 1–4

MEC20 = 1–12)

(Not used in MEC 2)

Figure 4-9 Engine Control Connections

– +

10A

B + VA

B –

VB

CR

GRD

RUN CIRCUIT

(FUEL SOL., GOV.)

23

24

18

19

CRANK

RUN

MEC 20

VC

VN

IA

IB

IC

IN GRD

MP1

MP2

37

38

13

14

15

1

2

16

17

8

9

10

11

5

6

3

4

7

12 20

25

26

27

32

33

34

36

22

21

30

31

28

29

1A

1A

1A

VA

VB

VC

N

GENERATOR

OUTPUT VOLTAGE

(DELETE PHASE VC

FOR SINGLE PHASE

SYSTEMS)

φA

φB

φC

GENERATOR OUTPUT

CURRENT SENSING

TRANSFORMERS

5 Aac SECONDARY

(DELETE PHASE C

FOR SINGLE PHASE

SYSTEMS)

GRD

COMMON FAIL CONTACT

(OPERATES ON AN ALARM OR

SHUTDOWN CONDITION)

(25, 26, 27 Not used in MEC 2)

PROGRAMMABLE

CONTACT #1

PROGRAMMABLE

CONTACT #2

PROGRAMMABLE

CONTACT #3

PROGRAMMABLE

CONTACT #4


Operator Control Panel (Analog Engine Controller Only)

Figure 4-10 Analog Operator Control Panel

Panel Light

VOLTAGE HERTZ AMPERAGE

PANEL LIGHTS

ON OFF

PANEL LIGHT

FUSE

RUN TIME (HOURS)

Panel Light

HIGH TEMPERATURE

LOW OIL PRESSURE

OVERSPEED

OVERCRANK

Battery

Volts

Engine

Temp

Oil Pressure

AMMETER

OFF

3 1

2

–

VOLTAGE

ADJUST

+

STOP

MANUAL

RUN

MASTER

CONTROL

AUTO

START

Panel Lights switch (On-Off )

Turns on two lamps to illuminate the operator panel.

Panel Light Fuse

Fuse for panel lights.

Master Control switch (Manual Run-Stop - Auto Start)

Manual Run - Starts the engine manually.

Stop - Stops the engine and generator.

Auto Start - Starts the engine when the Remote start" terminals are closed.

Display Lamps

High Temperature - Indicates excessive engine coolant temperature.

Low Oil Pressure - Indicates low engine oil pressure.

Overspeed - Indicates engine speed is greater than preset limit.

Overcrank - Failure of the engine to start by the end of the crank period

results in an overcrank" shutdown and alarm indication.

Voltage Adjust

Increase or Decrease the Generator output voltage (displayed on

VOLTAGE meter)

AC Voltage meter

Analog display of generator output voltage in RMS volts.

AMMETER switch (3 position)

Off - No current is measured by the Amperage meter.

1 - Phase 1 current is measured by the Amperage meter.



Amperage meter

Analog display of generator output current in RMS amps.

Hertz meter

Analog display of generator output frequency in Hertz.

Battery Voltage meter

Displays the voltage of the engine starting battery.

Engine Temperature meter

Displays the temperature of the engine coolant.

Oil Pressure meter

Displays engine oil pressure.

Run Time (Hours) meter

Total elapsed time indicator of generator set operation.

Operating Procedures The engine–generator controller is designed to start and stop an engine from either a local

(“Manual”) or remote (“Automatic”) mode. When a start command is issued, the controller issues a run and crank output signal. The controller then monitors engine speed and when crank disconnect speed is reached, the crank signal is terminated. While the engine accelerates to normal speed, the controller continuously monitors the engines speed signal. Should the engine speed exceed the maximum predetermined setpoint, the overspeed shutdown fault circuit will activate, terminating the run signal.

In addition to overspeed shutdown, the engine controller also monitors many other engine protection circuits and should they be activated, the engine will be stopped and/or alarm initiated.

The engine will automatically stop for any shutdown condition, or when the remote and/or local start signal is removed. The engine controller operation includes time delay circuits for normal operating conditions such as start delays, cool down and cranking periods.


Manual Start/Stop

To manually Start the Gen–Set, set the Master Control switch to the “Manual Run” position. The following happens:

1.

When the “Manual Run” push–button is pressed, an Engine Start Delay timer is initiated. (The start sequence will not be initiated if any shutdown fault condition is present.)

2.

When the engine start delay time expires, an engine RUN and CRANK output signal will be initiated. (The RUN output may be programmed to only energize when a start signal is initiated and an engine speed signal is detected.)

3.

When the engine starts and begins to accelerate to nominal speed, the controllers speed sensor will terminate the CRANK output when engine speed reaches approximately 20% speed (i.e. CRANK DISCONNECT speed setpoint).

To manually Stop the Gen–Set, set the Master Control switch to the “Stop” position. The controllers RUN output will be immediately terminated which will initiate the engine stop sequence. The engine is locked out and will not run with the Master Control switch in “Stop”.

Automatic Start/Stop

To setup the generator for automatic operation, set the Master Control switch to the “Auto Start” position. The following happens:

1.

The engine will automatically start upon activation of the remote start contact input. The remote device initiates a start sequence upon contact closure.

2.

When the remote start signal is activated, the engine will start as per the sequence of operation described for the manual start sequence.

3.

The automatic stop sequence will be initiated by removal of the remote start signal.

4.

When the start signal is removed, a cool down delay function will be initiated.

5.

When the cool down time delay period expires (typically 5 minutes), the controllers

RUN output will be immediately terminated which will initiate the engine to stop.

Automatic Fault Shutdown

When a fault circuit is programmed as a SHUTDOWN, the engine will immediately stop when the fault is activated. A specific shutdown fault can be programmed with a definite time transient delay period that must expire before the shutdown is activated. The stop sequence will cause the controllers RUN output to be immediately terminated which will cause the engine to stop.

Figure 4-11 9957N Analog Engine Controller Connections

Manual

Off

10A

Auto

Starting Battery

Fuel Relay

Start Relay

High Water

Temperature

Low Oil

Pressure

3

2

1

6

5

4

15 14 13 X1

Remote Start

Contact

Display

LED’s

12

11

10

9

Switches shown in

OFF position

8

7

Low Oil Pressure

High Water Temperature

Overcrank

Overspeed

RUN (Engine Started – Not Used)

Common Alarm (Not Used)

Magnetic

Pickup

External Components

Overspeed Verify (Off = True Speed,

On = 13% increase)

Single (On) or Cycle Crank (Off)

Crank Attempts

Crank Cycle

Crank Disconnect

Overspeed

Oil Pressure Water Temperature Delay

Off

Off

On

On

1

Off

Off

On

On

Off

On

Off

On

2

Off

On

Off

Off

On

On

On

On

3

Off

Off

Off

Crank Attempts

1

2

3

6

7

8


Lamp Test

High Water

Temperature

Low Oil

Pressure

Cycle Crank

Remote Start

Contact

Figure 4-12 A121H Analog Engine Controller Connections

Display

LED’s

Run

Auto

Off

Run

AGC1

Starting

Battery

Auto

Off

LT

HTI

LPI

CCI

RR

TDI

Ground

B+

Contacts are shown below *

LC

AL

COM

FS

CS

OSL

HTL

LPL

OCL

CS

+

Overspeed


Low Oil Pressure

Overcrank

Alarm

Fuel Relay

Start Relay

External Components

Starting Battery

Fuel Relay

Figure 4-13 ASM160 Analog Engine Controller Connections

Auto

Off

15A

Test

Remote Start

Contact

Start Relay

High Water

Temperature

Low Oil

Pressure

Magnetic

Pickup

External Components

Not Used

Not Used 16

12

13

15

14

18

17

2

1 10 11 9

18 = B+ Relay Com.

8

7

6

Lamp Test (Not Used)

RUN (Engine Started – Not Used)


Low Oil Pressure

5 Overspeed

4 Overcrank

3 At Load (Not Used)

Display

LED’s

Switches shown in OFF position

Overspeed

Warmup (Off) or Glow Plug Mode (On) Select

Crank Attempts

Cooldown Delay

Glow Plug/Warmup Delay (At Load)

Crank Disconnect

1

On

On

Off

Off

2

On

Off

On

Off

Crank Attempts

3

5

10

Infinite


Garretson Model KN Fuel Valve Considerations

General

The KN is designed for sensitivity and simple operation. It is used with low–pressure vaporized gaseous fuels, where dependable starting is a requirement. Because of its extreme sensitivity, the KN offers excellent results in most remote starting applications (Standby power generators, etc.). With proper installation and maintenance, the KN will provide years of trouble–free service.

Operation

The KN is an atmospheric zero governor which acts like the float and needle valve in a gasoline carburetor. Air–flow through a venturi in the carburetor creates a vacuum, which acts through the outlet of the KN on the diaphragm. Atmospheric pressure then forces the diaphragm toward the vacuum, depressing the lever and pulling the valve seat away from the orifice, which allows fuel to flow as long as the demand persists. When the vacuum ceases, a spring force pushes on the lever and forces the valve seat against the orifice shutting off the fuel flow. It is important to remember that fuel should not flow through the KN when the engine is not running.

A properly adjusted KN requires a vacuum of only 0.25” to 0.35” of water column to start the opening sequence. Due to this sensitivity, most installations do not need priming to start unless low cranking speeds or restricted and lengthy piping are required. If priming is necessary and a manual primer is installed, use only 1 or 2 second bursts of fuel and immediately try to start the engine. If there is a choke on the carburetor, do not use it as this will probably cause flooding and hard starting. As you can see, the operation of this unit is simple and basic. If you are having trouble operating the engine, in most cases the fuel controller is not malfunctioning. There is generally a problem with the engine or fuel supply. so do not make adjustments or attempt to service the KN until you are sure it is needed.

Figure 4-14 Garretson KN Fuel Valve

Outlet

Mount

Primer

(Optional)

Lock–Off

Adjustment

Inlet

Mount

Service

The KN should be periodically checked for leakage past the valve seat and the vents on the cover kept clean and free of obstructions. If the KN needs service we suggest you take it to a qualified serviceman. If that help is not available Garretson will furnish you a list of repair shops with the proper service information.


4-26 Operation

Installation

The KN should be mounted as close to the carburetor as possible with the arrow on the cover pointing up and the diaphragm in a vertical position. This helps to minimize the effects of gravity on diaphragm travel. This unit should also be placed for easy access to the primer if provided.

There are two sets of mounting holes provided. either set of mounts will adequately support the

KN. The bottom set of holes has a 1 3/4” bolt spacing for use with all Garretson universal mounting brackets. The mounting bosses on the cover are spaced (5 3/4”) apart for use with 5/16 bolts.

Before installing the fuel supply line, be sure that the gas pressure is no more than the maximum inlet pressure shown on the front of the KN. If the pressure is greater, leakage could result in a fire hazard and or hard starting. The piping to the inlet should be of sufficient size to allow full flow to the KN. This is very important in natural gas installations as any restrictions can affect engine performance. If a solenoid is used ahead of the KN in the low– pressure line, it should have an orifice at least as big as the orifice in the KN. Flexible piping to the inlet should be used to prevent cracking from vibration if the KN is mounted on the engine or other vibrating surface.

Note: Thread sealing compound should be used on all pipe thread fittings between the KN and the fuel supply tank, being careful not to get any inside the inlet or fittings. Excess compound could collect on the seat and orifice and cause hazardous leakage, resulting in poor performance. After piping is complete, turn on the gas and use a soap solution to check all fittings for leaks.

If an electric solenoid primer is used, follow the wiring and adjusting instructions furnished separately. kit by connecting into a pressure line at a reduced pressure, call us. The KN outlet is

3/8 NPT and if an outlet fitting has not been provided, select and insert a suitable vapor fitting taking care not to allow any chips or dirt to enter the outlet. Use of street ells or conventional pipe fittings in the fuel line between the KN and the carburetor is not recommended as they may restrict the flow of fuel.

When installation of a properly sized fuel hose between the KN and carburetor is completed, if you are installing a complete conversion return to the instructions. For field replacement applications the unit is ready for service.

MN2408

Section 5

Troubleshooting and Maintenance

Maintenance 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 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.

2.

Inspect and replace any fuel line that shows signs of deterioration.

3.

Inspect all the fuel clamps to ensure they are tight.

4.

Inspect and clean the battery posts and the associated battery cable terminals.

5.

Inspect the external wire cables and connectors used with the generator set for cuts, fraying, or loose connections. Repair or replace any problems prior to using the unit.

Engine:

1.

Clean and/or replace any fuel, oil, and/or air filters per the engine manufacturers’ guidelines.

2.

Check oil level regularly; at least every 5 to 8 operating hours. Maintain the proper oil level.

3.

Change the oil as is recommended in the engine manufacturer’s owner’s manual.

4.

Replace the spark plug(s) as is recommended by the engine manufacturer.

5.

Clean the cooling fins on the engine to keep the engine’s heat dissipation potential at it’s maximum.

6.

Inspect and clean all governor and carburetor linkages so they operate properly.

7.

Inspect the recoil starting rope for any damage and replace it if necessary (if applicable).

8.

Clean the trash screen around the recoil starter or other cooling air intake.

Alternator: ( also called Generator End)

This generator 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 frequency output. This voltage and frequency variation has no appreciable effect in the operation of motors, lights, and most appliances and tools. However, timing devices and clocks will not keep perfect time when used on this generator.

1.

Clean the generator set and remove any and all dust, dirt, or other foreign material.

2.

Inspect and clean the cooling air intake and exhaust louvers of the generator end.

Make sure they are clean. Remove dirt or any buildup that may restrict the cooling air flow.

3.

Clean the generator set and its components with a damp cloth or sponge.

Never use a water hose or pressure washer as this may damage electrical components.

4.

Inspect and replace any control panel components that are broken or not working properly (receptacles, circuit breakers, switches, etc.)

MN2408 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 the Baldor Generator Service Department by calling (920) 236–4200.

Table 5-1 General Troubleshooting Guide

Problem

Engine cranks but will not start

Engine will not crank (electric start)

Engine starts but will not run smoothly

Engine overheats

No output voltage

Output voltage varies

Low output voltage

High output voltage

Electrical shock when frame is touched

Mechanical noise

Possible Cause

No fuel.

Low Oil Level

Restricted air flow.

No spark.

No engine speed during crank

Dead battery.

Emergency Stop LED is ON

Fuel or ignition problem

Excessive load

Debris or dirt buildup on engine

Ciruit Breaker tripped or failed.

Internal failure of Alternator

Irregular speed (fixed speed mode)

Fluctuating speed (fixed speed mode)

Loose terminal or load connections

Low engine speed

Excessive load

High resistance connections connections will be warm or hot


Low power factor

Excessive speed (fixed speed mode)

Static charge.

Grounded armature or field coil.


Loose or misaligned coupling

Remedy

Check that fuel valves are ON. Check fuel level in fuel tank.

Low Oil Pressure Sutdown activated. Replensih oil to full.

Check/replace air filter.

Check/replace spark plug(s).

Check that engine switch is in Start position.

The magnetic pickup must be correctly adjusted and operating.

Remove battery and trickle charge or replace with new battery.

Never Jump Start.

Reset controller after an Emergency Stop.

Refer to engine manual.

Remove one or more electrical loads.

Remove debris. Clean engine surfaces to allow cooling.

Reset circuit breaker or replace if required.

Return to factory for repair.

Check engine for malfunction or load for fluctuation

Stabilize load. The addition of a lamp load (resistance load) may compensate partially for load changes caused by intermittent motor operation. Do not overload.

Verify all connections and terminal tighness.

Verify engine RPM.

Check engine for malfunction or system for overload. Reduce load.

Verify all connections and terminal tighness.

Return to factory for repair.

Reduce inductive (motor) load. Some AC motors use about the same current regardless of load. Do not use motors of greater horsepower rating than is necessary to move the mechanical load.

Check engine for malfunction. Verify engine RPM.

Ground generator frame at local reference ground (see Section 3).

Return to factory for repair

Return to factory for repair

Tighten; align coupling and alternator shaft to engine shaft.

5-2 Troubleshooting and Maintenance MN2408

LCD Display cannot be viewed

Controller cannot be Reset"

No RUN" output signal

Engine temperature or oil pressure display is incorrect

Table 5-2 Troubleshooting Guide (Digital Controller Only)

Problem

Controller does not power up even with correct DC power applied

Overspeed shutdown occurs at normal speed

Voltage or current metering is incorrect

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

Keypad Buttons (switches) do not operate.

Possible Cause

Wiring Mistake

Overload Condition

Microprocessor failure

Improper Supply Voltage

Improper contrast adjustment

Engine not stopped

Controller not in OFF mode

Shutdown Faults" not reset

Engine speed not detected at cranking

Run Contact not closing (terminals #18 &

#19)

Controller programmed values are wrong or controller has failed.

Controller programmed values are wrong

Ground is missing

Analog input needs to be calibrated

Voltage sensing wiring mistake

Analog input needs to be calibrated

Failed engine sensor

Ground is missing

Sending unit is disconnected (open circuit)

Defective sending unit

Wrong Temp or pressure calibration

Keypad not connected to controller

Remedy

Check that there are no wiring errors/short circuits connected to the controller.

The MEC 20 contains an electronic fuse that trips when an overload condition exists and does not reset until the supply voltage is removed and reapplied after the overload condition is corrected.

Check that the controller's microprocessor is running by observing a red flashing watchdog" LED on the rear of the PCB. Replace controller if failed.

Check DC supply voltage at terminals B+ & B- (10-30VDC).

Adjust LCD contrast potentiometer (R115) on rear of PCB for best display.

Verify the engine is at a complete stop before trying to reset.

Set the controller to the OFF mode before trying to reset.

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).

Check that the RUN output LED (on the rear of the PCB) is on.

If yes, verify relay contact operation on terminals #18 & #19.

Replace controller if failed.

Verify the controller programmed values are correct for the number of flywheel teeth, nominal RPM, and overspeed setpoint percentage. Replace controller if failed.

Verify the controller programmed values are correct for the voltage sensing PT ratio and/or current sensing CT ratio.

Verify that the battery supply DC negative conductor is properly grounded to the engine block (i.e. to a common ground point).

Verify that the controller's analog input is properly calibrated.

Verify the voltage sensing wiring connection to the MEC 20 matches power distribution type.

Note: standard direct voltage connection requires that the generators neutral is solidly grounded.

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).

Verify the sending units wiring to controller terminals #37 & #38 (i.e.

wiring is not open or shorted).

Verify the engine mounted senders have correct resistance values for corresponding input temperature or pressure.

Verify calibration.

Verify the interconnecting ribbon cable between the lexan faceplate and main printed circuit board is correctly connected.

Replace controller if failed.

MN2408 Troubleshooting and Maintenance 5-3

Problem

Controller cannot be Reset"

Note: See Engine Controller manual for additional information.

Table 5-3 Troubleshooting Guide (Analog Controller Only)

Engine alarms are ON for high engine temperature or low oil pressure when engine is operating properly

Overspeed shutdown occurs at normal speed

Possible Cause

Engine not stopped

Controller not in OFF mode

Sending unit is disconnected (open circuit)

Defective sending unit

Controller has failed or input from

Magnetic pickup is incorrect.

Remedy

Verify the engine is at a complete stop before trying to reset.

Set the controller to the OFF mode before trying to reset.

Verify the sending units wiring to controller terminals is not open or shorted.

Verify the engine mounted senders have correct resistance values for corresponding input temperature or pressure.

Verify the adjustments. Replace controller if failed.

Service

Parts

Service for your generator can be obtained from the service department at Baldor Generators by calling (920) 236–4200. Please have the following information available prior to contacting the factory:

The model number and serial number of the generator set.

A complete and accurate description of the problem.

Parts for your generator can be obtained from the service department at Baldor Generators by calling (920) 236–4200. Please have the following information available prior to contacting the factory:

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 A

Series GLC Parts & Wiring Diagrams

WELDMENT, BASE

ISOLATOR, GEN END

ISOLATOR

ISOLATOR, CONTROL BOX

SOLENOID, ENGINE 12V

BRKT, BATTERY TIE DOWN

TANK, COOLANT RECOVERY

CAP, COOLANT RECOVERY TANK

VALVE, FUMOTO F-107-N

VALVE, FUMOTO FG-2N

MAG PICK-UP ASSY

RELAY

DIODE, 1N5408

FUSE, 1A

FUSE, 10A

FUSE, BUSS, AGC 15

RHEOSTAT, 1K, 2W ENCLOSED

KNOB, RHEOSTAT

SOLENOID, FUEL,12VDC

HEATER, BLOCK 120V

CHARGER, BATTERY, 12V, 6 AMP

SWITCH, E-STOP

DECAL BONDED NEUTRAL"

DECAL FUSE TYPE & WARNING"

DECAL, CONTROL PANEL

PLACARD, REMOTE START"

DECAL, BALDOR LOGO,26"

DECAL, BALDOR LOGO

DECAL, DANGER-HIGH VOLTAGE

DECAL, WARNING, AUTO START

PLACARD, LINE"

PLACARD, LOAD"

PLACARD, NEUTRAL"

PLACARD, L1"

PLACARD, L2"

PLACARD, L3"

PLACARD, A.C. CONNECTION"

PLACARD, GROUND"

Replacement Parts Replacement parts information is provided in this section of the manual. Engine parts are identified in the engine manual that was provided with your generator set. 10.95030

IMPORTANT: Fuses are installed in the control box to protect the engine controller and associated control circuits. When replacing fuses, use the exact replacement fuse (manufacturer and part number).

Part No.

GLC30

BA0236A07L2B

RM1088A13

EA0049A01

EA0010A02

SW00925A00

LB0300A00

LB0300A01

LB0094B59

LB0095A42

LB0100A20

LB0100A25

LB0094A11

LB0094A30

LB0095A07

LB0095A08

LB0095A15

LB0095A16

LB0095A17

RM1088A01

SE0057A01

HB6103A06

TA0000A07

TA0002A07

EA0044A07

EA0044A05

EA0007A07

RE5031A01

DI0176A00

FU0071A00

FU0070A00

FU0066A07

SP9134

HW2412A00

SE0052A05

LB0095A51

LB0095A37

FU0070A00

FU0066A07

SP9134

HW2412A00

SE0052A05

EA0049A01

EA0010A02

SW00925A00

LB0300A00

LB0300A01

LB0094B59

LB0095A42

LB0100A20

LB0100A25

LB0094A11

LB0094A30

Part No.

GLC45

BA0236A07L2B

RM1088A13

RM1088A27

RM1088A01

SE0057A01

HB6103A06

TA0000A07

TA0002A07

EA0044A07

EA0044A05

EA0007A07

RE5031A01

DI0176A00

FU0071A00

LB0095A07

LB0095A08

LB0095A15

LB0095A16

LB0095A17

LB0095A18

LB0095A51

LB0095A37

FU0070A00

FU0066A07

SP9134

HW2412A00

SE0052A05

EA0049A01

EA0010A02

SW00925A00

LB0300A00

LB0300A01

LB0094B59

LB0095A42

LB0100A20

LB0100A25

LB0094A11

LB0094A30

LB0095A07

LB0095A08

LB0095A15

LB0095A16

LB0095A17

Part No.

GLC35

BA0236A07L2B

RM1088A13

RM1088A27

RM1088A01

SE0057A01

HB6103A06

TA0000A07

TA0002A07

EA0044A07

EA0044A05

EA0007A07

RE5031A01

DI0176A00

FU0071A00

LB0095A51

LB0095A37

Part No.

GLC60

BA0236A04L2B

RM1088A18

RM1088A27

RM1088A01

SE0057A01

HB6103A06

TA0000A07

TA0002A07

EA0044A07

EA0044A05

RE5031A01

DI0176A00

FU0071A00

FU0070A00

FU0066A07

SP9134

HW2412A00

SE0052A04

EA0049A02

EA0010A02

SW00925A00

LB0300A00

LB0300A01

LB0094B59

LB0095A42

LB0100A20

LB0100A21

LB0094A11

LB0094A30

LB0095A07

LB0095A08

LB0095A15

LB0095A16

LB0095A17

LB0095A51

LB0095A37

Part No.

GLC50

BA0236A04L2B

RM1088A18

RM1088A27

RM1088A01

SE0057A01

HB6103A06

TA0000A07

TA0002A07

EA0044A07

EA0044A05

RE5031A01

DI0176A00

FU0071A00

FU0070A00

FU0066A07

SP9134

HW2412A00

SE0052A04

EA0049A02

EA0010A02

SW00925A00

LB0300A00

LB0300A01

LB0094B59

LB0095A42

LB0100A20

LB0100A21

LB0094A11

LB0094A30

LB0095A07

LB0095A08

LB0095A15

LB0095A16

LB0095A17

LB0095A18

LB0095A51

LB0095A37

MN2408 Series GLC A-1

Replacement Parts Continued

WELDMENT, BASE

ISOLATOR, GEN END

ISOLATOR, CONTROL BOX

SOLENOID, ENGINE 12V

BRKT, BATTERY TIE DOWN

TANK, COOLANT RECOVERY

CAP, COOLANT RECOVERY TANK

VALVE, FUMOTO F-107-N

VALVE, FUMOTO FG-2N

MAG PICK-UP ASSY GM ENGINES

FUSE, 1A

FUSE, 10A

FUSE, AGC 2

FUSE, AGC 15

SWITCH, TOGGLE

SWITCH, DPDT

SWITCH, E, 3PH

RELAY

DIODE, 1N5408

LAMP FIXTURE, DASH

LAMP, #67, 12 VOLT

RHEOSTAT, 1K, 2W ENCLOSED

KNOB, RHEOSTAT

GASKET, EXHAUST RING

DIODE, 1N5408

AIR CLEANER, ELEMENT

SOLENOID, FUEL,12VDC

HEATER, BLOCK 120V

CHARGER, BATTERY, 12V, 6 AMP

BREAKER, W/SHUNT

CURRENT TRANSFORMER

SWITCH, E-STOP

GLC 80

BA0236A06L2B

RM1088A18

RM1088A01

SE0057A01

HB6103A06

TA0000A07

TA0002A07

EA0044A07

EA0044A05

EA0007A07

FU0071A00

FU0070A00

FU0066A07

Part No.

GLC 100

BA0236A06L2B

RM1088A18

RM1088A01

SE0057A01

HB6103A06

TA0000A07

TA0002A07

EA0044A07

EA0044A05

EA0007A07

FU0066A03

FU0066A07

GLC125

BA0236A06L2B

RM1088A18

RM1088A01

SE0057A01

HB6103A06

TA0000A07

TA0002A07

EA0044A07

EA0044A05

EA0007A07

RE5031A01

DI0176A00

SP9134

HW2412A00

GS0089A07

DI0176A00

EA0015A21

SE0052A04

EA0049A02

EA0010A02

CK0070A44

CT0050A06

SW00925A00

RE5031A01

DI0176A00

SP9134

HW2412A00

GS0089A07

DI0176A00

EA0015A21

SE0052A04

EA0049A02

EA0010A02

CK0070A62

CT0050A01

SW00925A00

FU0066A03

FU0066A07

SP9079

SP9094

SP9095

RE5031A01

DI0176A00

DI0179A00

DI0180A00

SP9134

HW2412A00

GS0089A04

DI0176A00

EA0015A21

SE0052A04

EA0049A02

EA0010A02

CK0070A95

CT0050A03

SW00925A00

A-2 Series GLC MN2408

Replacement Parts Continued

DECAL BONDED NEUTRAL"

DECAL FUSE TYPE & WARNING"

DECAL, CONTROL PANEL

PLACARD, REMOTE START"

DECAL, BALDOR LOGO,26"

DECAL, BALDOR LOGO

DECAL, DANGER-HIGH VOLTAGE

DECAL, WARNING, AUTO START

PLACARD, LINE"

PLACARD, LOAD"

PLACARD, NEUTRAL"

PLACARD, L1"

PLACARD, L2"

PLACARD, L3"

PLACARD, A.C. CONNECTION"

PLACARD, GROUND"

GLC 80

LB0300A00

LB0300A01

LB0094B60

LB0095A42

LB0100A27

LB0100A29

LB0094A11

LB0094A30

LB0095A07

LB0095A08

LB0095A15

LB0095A16

LB0095A17

LB0095A51

LB0095A37

Magnetic

Pickup

Cable

Jam

Nut

Flywheel

Housing d+

Part No.

GLC 100

LB0300A00

LB0300A01

LB0094B60

LB0095A42

LB0100A27

LB0100A29

LB0094A11

LB0094A30

LB0095A07

LB0095A08

LB0095A15

LB0095A16

LB0095A17

LB0095A18

LB0095A51

LB0095A37

GLC125

LB0300A00

LB0300A01

LB0094B60

LB0095A42

LB0100A27

LB0100A29

LB0094A11

LB0094A30

LB0095A07

LB0095A08

LB0095A15

LB0095A16

LB0095A17

LB0095A18

LB0095A51

LB0095A37 d

Figure A-1 Magnetic Pickup Replacement

Flywheel

Gear Ring

This procedure is intended to help during the replacement of a Magnetic Pickup speed sensor.

1. Ensure that the battery is disconnected from the generator set prior to performing any service work on the unit. Remove the old Magnetic Pickup sensor.

2. Ensure that a tooth on the flywheel gear ring is centered directly in the hole for the

Magnetic Pickup. If not, rotate the engine/generator to center a tooth by placing a socket on the engine main crank pulley.

DO NOT insert a screwdriver into the hole for the magnetic pickup as the threads in the flywheel housing can be damaged. DO NOT use the generator cooling fan to rotate the engine/generator. The fan may crack and will have to be replaced.

3. With a tooth centered in the hole, measure the distance d" from the top of the tooth to the outside top of the flywheel housing. Set the jam nut on the magnetic pickup slightly beyond that measurement d+" to ensure that the magnetic pickup fully threads into the housing. (If the flywheel housing or magnetic pickup threads are damaged, the magnetic pickup may seem to have bottomed out when it stopped due to bad threads.)

4. Thread the magnetic pickup into the flywheel housing until it bottoms out on the flywheel tooth.

5. Back the magnetic pickup out 1/2 turn and tighten the jam nut to the flywheel housing.

Note: The 1/2 turn out is very important. Too little can ruin the magnetic pickup and create extra cleanup work. Too much can result in poor operation.

6. Verify proper operation. (1.3 VAC while cranking)

7. Apply a drop of wicking fastener adhesive to the locking nut of the magnetic pickup.

(Loctite, Permabond, etc.)


GLC Circuit Breaker & Electrical Data

GLC

Model

GLC125

GLC125

GLC125

GLC125

Alternator

Model

UCI274E

UCI274E

UCI274E

UCI274E

Leads/

Winding

4/06

12/311

12/311

12/311

Fuel

Type

Nat Gas

Engine

Nat Gas

Nat Gas

Nat Gas

Size

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GLC125 UCI274E 12/311 Nat Gas




GLC125 UCI274F 4/06 Nat Gas








GLC125 UCI274E 4/06

GLC125 UCI274E 12/311

GLC125 UCI274E 12/311

GLC125 UCI274E 12/311

LPG

LPG

LPG

LPG

GLC125 UCI274E 12/311

GLC125 UCI274E 12/311

GLC125 UCI274E 12/311

GLC125 UCI274E 12/311

GLC125 UCI274F 4/06

GLC125 UCI274F 12/311

GLC125 UCI274F 12/311

GLC125 UCI274F 12/311

GLC125 UCI274F 12/311

GLC125 UCI274F 12/311

GLC125 UCI274F 12/311

GLC125 UCI274F 12/311

LPG

LPG

LPG

LPG

LPG

LPG

LPG

LPG

LPG

LPG

LPG

LPG

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

110

105

110

110

110

KW

Rated Phase

115 1

125

125

125

3

3

3

130

125

130

125

130

130

130

130

125

130

105

110

110

110

110

105

3

3

3

3

1

3

3

3

3

3

3

3

1

3

3

3

3

3

Series

WYE

Series

// WYE

// WYE

Series/

Delta

// WYE

Series

WYE

Series

// WYE

// WYE

Series/

Delta

// WYE

Series

WYE

Voltage

Config

Series

// WYE

// WYE

Series/

Delta

// WYE

Series

WYE

VAC

(L - L)

240

208

220

240

VAC

(L - N)

120

120

127

120

Output

FLA

479

434

410

376

115%

FLA

551

499

472

432

240

380

139

220

391

237

450

273

416

480 277 195 225

240

208

220

240

240

380

120

120

127

120

139

220

521

451

426

391

391

237

450

273

599

519

490

450

416

480 277 195 225

240

208

220

240

240

380

120

120

127

120

139

220

438

382

361

331

331

199

380

229

503

439

415

380

Circuit

Breaker

600

500

500

450

450

300

225

600

600

500

450

450

300

225

500

450

450

400

400

250

110

105

1

3

3

3

3

3

3

3

Series

WYE

Series

// WYE

// WYE

Series/

Delta

// WYE

Series

WYE

416

480

240

208

220

240

240

380

277

120

120

127

120

139

220

165

438

382

361

331

331

199

190

503

439

415

380

380

229

400

250

200

500

450

450

400

110

3

3 Series

WYE

416

480 277 165 190 200

250:5

500:5

500:5

400:5

400:5

400:5

250:5

C.T.

Ratio

600:5

500:5

500:5

500:5

500:5

300:5

250:5

600:5

600:5

500:5

500:5

500:5

300:5

200:5

500:5

500:5

400:5

400:5

400:5

250:5

200:5

Wire Size

(QTY) AWG

(2) #2/0

(2) #1/0

(2) #1/0

(2) #1/0

(2) #1/0

(1) #2/0

(1) #1

(1) #1

(2) #1/0

(2) #1/0

(2) #1/0

(2) #4/0

(2) #4/0

(2) #1/0

(1) #1

(2) #2/0

(2) #2/0

(2) #1/0

(2) #1/0

(2) #1/0

(1) #2/0

(1) #1

(2) #1/0

(2) #1/0

(2) #1/0

(2) #4/0

(2) #4/0

(2) #1/0


GLC DATA Continued

GLC100

GLC100

GLC100

GLC100

Alternator

Model

UCI274E

UCI274E

UCI274E

UCI274E

Leads/

Winding

4/06

12/311

12/311

12/311

Fuel

Type

Nat Gas

Engine

Nat Gas

Nat Gas

Nat Gas

Size

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L





GLC100 UCI274E 4/06

GLC100 UCI274E 12/311

GLC100 UCI274E 12/311

GLC100 UCI274E 12/311

GLC100 UCI274E 12/311

GLC100 UCI274E 12/311

GLC100 UCI274E 12/311

GLC100 UCI274E 12/311

GLC80 UCI224G 4/06 Nat Gas

GLC80 UCI274C 12/311 Nat Gas



LPG

LPG

LPG

LPG

LPG

LPG

LPG

LPG





GLC80 UCI224G 4/06

GLC80 UCI274C 12/311

GLC80 UCI274C 12/311

GLC80 UCI274C 12/311

LPG

LPG

LPG

LPG

GLC80 UCI274C 12/311

GLC80 UCI274C 12/311

GLC80 UCI274C 12/311

GLC80 UCI274C 12/311

LPG

LPG

LPG

LPG GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

GM/8.1L

80

75

80

80

80

80

80

75

80

99

99

97

99

KW

Rated Phase

84 1

86

86

86

3

3

3

87

86

3

3

Voltage

Config

Series

// WYE

// WYE

Series/

Delta

// WYE

Series

Wye

87

3

3

100

98

1

3

3

3

3

3

Series

Wye

Series

// WYE

// WYE

Series/

Delta

// WYE

Series

Wye

100

3

3

80

80

1

3

3

3

3

3

Series

Wye

Series

// WYE

// WYE

Series/

Delta

// WYE

VAC

(L - L)

240

208

220

240

VAC

(L - N)

120

120

127

120

Output

FLA

350

298

282

259

115%

FLA

403

343

324

297

Circuit

Breaker

400

350

350

300

240

380

416

480

240

208

220

240

240

380

416

480

240

208

220

240

240

380

139

220

277

120

120

127

120

139

220

277

120

120

127

120

139

220

262

163

0

131

404

344

325

298

301

186

150

313

278

262

241

241

152

301

188

0

150

465

395

373

342

346

214

173

359

319

302

277

277

175

300

200

150

500

400

400

350

350

225

175

400

350

300

300

300

175

80

80

1

3

3

3

3

3

3

3

Series

Wye

Series

// WYE

// WYE

Series/

Delta

// WYE

Series

Wye

416

480

240

208

220

240

240

380

277

120

120

127

120

139

220

120

313

278

262

241

241

152

138

359

319

302

277

277

175

300

175

150

400

350

300

300

80

3

3 Series

Wye

416

480 277 120

0

138 150

200:5

400:5

400:5

300:5

300:5

300:5

200:5

C.T.

Ratio

400:5

400:5

400:5

300:5

300:5

200:5

150:5

400:5

400:5

300:5

300:5

300:5

200:5

150:5

500:5

400:5

400:5

400:5

400:5

250:5

150:5

Wire Size

(QTY) AWG

(2) #4/0

(1) #3/0

(1) #3/0

(1) #2/0

(1) #2/0

(1) #1

(1) #4

(1) #1

(2) #4/0

(1) #3/0

(1) #2/0

(1) #2/0

(1) #2/0

(1) #1

(1) #4

(2) #4/0

(1) #3/0

(1) #2/0

(1) #2/0

(1) #2/0

(1) #1

(1) #4

(2) #1/0

(2) #4/0

(2) #4/0

(1) #3/0

(1) #3/0

(1) #1



GLC60

GLC60

GLC60

GLC60

Alternator

Model

UCI224F

UCI224E

UCI224E

UCI224E

Leads/

Winding

4/06

12/311

12/311

12/311

Fuel

Type

Nat Gas

Engine

Nat Gas

Nat Gas

Nat Gas

Size

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L





GLC60 UCI224F 4/06

GLC60 UCI224E 12/311

GLC60 UCI224E 12/311

GLC60 UCI224E 12/311

GLC60 UCI224E 12/311

GLC60 UCI224E 12/311

GLC60 UCI224E 12/311

GLC60 UCI224E 12/311

GLC50 UCI224D 4/06 Nat Gas




LPG

LPG

LPG

LPG

LPG

LPG

LPG

LPG





GLC50 UCI224D 4/06

GLC50 UCI224D 12/311

GLC50 UCI224D 12/311

GLC50 UCI224D 12/311

LPG

LPG

LPG

LPG

GLC50 UCI224D 12/311

GLC50 UCI224D 12/311

GLC50 UCI224D 12/311

GLC50 UCI224D 12/311

LPG

LPG

LPG

LPG GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

GM/5.7L

50

44

48

50

48

KW

Rated Phase

54 1

53

54

54

3

3

3

55

49

55

56

54

60

54

60

49

60

50

48

44

48

50

43

3

3

3

3

1

3

3

3

3

3

3

3

1

3

3

3

3

3

Series

Wye

Series

// WYE

// WYE

Series/

Delta

// WYE

Series

Wye

Series

// WYE

// WYE

Series/

Delta

// WYE

Series

Wye

Voltage

Config

Series

// WYE

// WYE

Series/

Delta

// WYE

Series

Wye

VAC

(L - L)

240

208

220

240

VAC

(L - N)

120

120

127

120

Output

FLA

225

184

177

162

115%

FLA

259

211

204

187

240

380

139

220

165

93

190

107

416

480 277 83

0

95

240

208

220

240

240

380

120

120

127

120

139

220

250

187

184

162

180

93

207

107

288

215

211

187

416

480 277 90

0

104

240

208

220

240

240

380

120

120

127

120

139

220

183

167

164

144

150

82

173

94

211

192

189

166

Circuit

Breaker

300

225

225

200

200

110

100

300

225

225

200

225

110

110

225

200

200

175

175

100

50

43

1

3

3

3

3

3

3

3

Series

Wye

Series

// WYE

// WYE

Series/

Delta

// WYE

Series

Wye

416

480

240

208

220

240

240

380

277

120

120

127

120

139

220

75

183

167

164

144

150

82

0

86

211

192

189

166

173

94

175

100

90

225

200

200

175

50

3

3 Series

Wye

416

480 277 75

0

86 90

125:5

250:5

200:5

200:5

200:5

200:5

100:5

C.T.

Ratio

300:5

250:5

200:5

200:5

200:5

125:5

100:5

250:5

200:5

200:5

200:5

200:5

100:5

100:5

300:5

250:5

250:5

200:5

200:5

125:5

100:5

Wire Size

(QTY) AWG

(1) #2/0

(1) #1

(1) #1

(1) #1

(1) #1

(1) #6

(1) #6

(1) #6

(1) #1

(1) #1

(1) #1

(1) #1

(1) #1

(1) #6

(1) #6

(1) #1

(1) #1

(1) #1

(1) #1

(1) #1

(1) #6

(1) #6

(1) #2/0

(1) #1

(1) #1

(1) #1

(1) #1

(1) #6



GLC45

GLC45

GLC45

GLC45

Alternator

Model

UCI224D

UCI224D

UCI224D

UCI224D

Leads/

Winding

4/06

12/311

12/311

12/311

Fuel

Type

Nat Gas

Engine

Nat Gas

Nat Gas

Nat Gas

Size

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L





GLC45 UCI224D 4/06

GLC45 UCI224D 12/311

GLC45 UCI224D 12/311

GLC45 UCI224D 12/311

GLC45 UCI224D 12/311

GLC45 UCI224D 12/311

GLC45 UCI224D 12/311

GLC45 UCI224D 12/311





LPG

LPG

LPG

LPG

LPG

LPG

LPG

LPG





GLC35 UCI224C 4/06

GLC35 UCI224C 12/311

GLC35 UCI224C 12/311

GLC35 UCI224C 12/311

LPG

LPG

LPG

LPG

GLC35 UCI224C 12/311

GLC35 UCI224C 12/311

GLC35 UCI224C 12/311

GLC35 UCI224C 12/311

LPG

LPG

LPG

LPG GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

35

35

35

35

35

35

35

35

35

44

44

41

44

KW

Rated Phase

37 1

39

39

39

3

3

3

40

40

3

3

Voltage

Config

Series

// WYE

// WYE

Series/

Delta

// WYE

Series

Wye

40

3

3

45

45

1

3

3

3

3

3

Series

Wye

Series

// WYE

// WYE

Series/

Delta

// WYE

Series

Wye

45

3

3

35

35

1

3

3

3

3

3

Series

Wye

Series

// WYE

// WYE

Series/

Delta

// WYE

VAC

(L - L)

240

208

220

240

VAC

(L - N)

120

120

127

120

Output

FLA

154

135

128

117

115%

FLA

177

156

147

135

Circuit

Breaker

175

175

150

150

240

380

416

480

240

208

220

240

240

380

416

480

240

208

220

240

240

380

139

220

277

120

120

127

120

139

220

277

120

120

127

120

139

220

120

76

60

171

153

144

132

135

85

68

146

121

115

105

105

66

138

87

0

69

196

176

166

152

156

98

0

78

168

140

132

121

121

76

150

90

70

200

175

175

175

175

100

80

175

150

150

125

125

80

35

35

1

3

3

3

3

3

3

3

Series

Wye

Series

// WYE

// WYE

Series/

Delta

// WYE

Series

Wye

416

480

240

208

220

240

240

380

277

120

120

127

120

139

220

53

146

121

115

105

105

66

0

61

168

140

132

121

121

76

125

80

60

175

150

150

125

35

3

3 Series

Wye

416

480 277 53

0

61 60

75:5

200:5

150:5

150:5

125:5

125:5

75:5

C.T.

Ratio

200:5

150:5

150:5

150:5

150:5

100:5

60:5

200:5

150:5

150:5

125:5

125:5

75:5

75:5

200:5

200:5

200:5

150:5

150:5

100:5

60:5

Wire Size

(QTY) AWG

(1) #1

(1) #1

(1) #4

(1) #4

(1) #4

(1) #6

(1) #8

(1) #8

(1) #1

(1) #4

(1) #4

(1) #4

(1) #4

(1) #8

(1) #8

(1) #1

(1) #4

(1) #4

(1) #4

(1) #4

(1) #8

(1) #8

(1) #1

(1) #1

(1) #1

(1) #1

(1) #1

(1) #6



GLC30

GLC30

GLC30

GLC30

Alternator

Model

BCI184G

UCI224C

UCI224C

UCI224C

Leads/

Winding

4/06

12/311

12/311

12/311

Fuel

Type

Nat Gas

Engine

Nat Gas

Nat Gas

Nat Gas

Size

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L





GLC30 BCI184G 4/06

GLC30 UCI224C 12/311

GLC30 UCI224C 12/311

GLC30 UCI224C 12/311

GLC30 UCI224C 12/311

GLC30 UCI224C 12/311

GLC30 UCI224C 12/311

GLC30 UCI224C 12/311

LPG

LPG

LPG

LPG

LPG

LPG

LPG

LPG

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

GM/4.3L

KW

Rated Phase

30 1

30

30

30

3

3

3

30

30

30

30

30

30

30

30

30

30

3

3

3

3

1

3

3

3

3

3

3

3

Series

Wye

Series

// WYE

// WYE

Series/

Delta

// WYE

Series

Wye

Voltage

Config

Series

// WYE

// WYE

Series/

Delta

// WYE

Series

Wye

VAC

(L - L)

240

208

220

240

VAC

(L - N)

120

120

127

120

Output

FLA

125

104

98

90

115%

FLA

144

120

113

104

240

380

139

220

90

57

104

66

416

480 277 45

0

52

240

208

220

240

240

380

120

120

127

120

139

220

125

104

98

90

90

57

104

66

144

120

113

104

Series

Wye

416

480 277 45

0

52

Circuit

Breaker

150

125

125

110

110

70

60

150

125

125

110

110

70

60

C.T.

Ratio

150:5

125:5

125:5

125:5

125:5

75:5

60:5

150:5

125:5

125:5

125:5

125:5

75:5

60:5

Wire Size

(QTY) AWG

(1) #4

(1) #4

(1) #4

(1) #6

(1) #6

(1) #8

(1) #8

(1) #8

(1) #4

(1) #4

(1) #4

(1) #6

(1) #6

(1) #8


GLC Wire Size

Revision B 5–12–04

500

600

700

800

900

1000

1200

1400

1600

2000

2500

3000

4000

300

350

400

450

175

200

225

250

100

110

125

150

60

70

80

90

20

30

40

50

Circuit

Breaker

Size

15

Quantity per

Phase

Minimum

Wire Gauge

5

6

4

4

7

8

3

3

3

3

2

2

2

2

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

4/0

250

250

250

2/0

3/0

3/0

250

250

300

1/0

1/0

3/0

4/0

2/0

4/0

4/0

#1

#2

#2

#1

1/0

#6

#6

#6

#4

#10

#8

#8

#6

#16

#16

#14

#12

EDI Plant

1 - #14 EPDM PER PHASE
















1 - #1/0 EPDM PER PHASE


















Ampacity @125C

950

1065

1230

1425

1900

1900

2375

2850

3180

4240

610

610

710

820

305

355

410

475

170

265

265

265

125

125

125

170

90

90

90

90

40

40

90

90

Wiring Diagrams Wiring diagrams for these generators are contained on the following pages of this appendix.


MEC20

MEC2

Figure A-2 Customer Interface Connection Diagram


Figure A-3 Customer Interface (w/o Breaker) Power Connection Diagram


Figure A-4 Single Phase – (w/o Breaker) Connection Diagram


Figure A-5 Single Phase – One Breaker Connection Diagram


Figure A-6 Single Phase – Two Breaker Connection Diagram


Figure A-7 Single Phase Connection Diagram (Wire 1/0 and Larger w/Breaker)


Figure A-8 Single Phase Connection Diagram (Wire 1/0 and Smaller w/Breaker)


Figure A-9 Single Phase Connection Diagram (Wire 1/0 and Smaller w/o Breaker)


Figure A-10 Single Phase Connection Diagram (Wire Larger than 1/0 w/o Breaker)


Figure A-11 Three Phase Connection Diagram


Figure A-12 Three Phase Connection Diagram with PMG


Figure A-13 Three Phase Connection Diagram (Wire 1/0 and larger)


Figure A-14 Three Phase Connection Diagram (Wire Larger than 1/0 w/Breaker)


Figure A-15 Three Phase Connection Diagram (Wire 1/0 and Smaller w/Breaker)


Figure A-16 Three Phase Connection Diagram (Wire Larger than 1/0 w/o Breaker)


Figure A-17 Three Phase Connection Diagram (Wire 1/0 and Smaller w/o Breaker)


Figure A-18 Control Box Connections with MEC20 Controller

Without Governor


Figure A-19 Control Box Connections with MEC20 Controller & Governor

With Governor


Figure A-20 Control Box Connections with MEC2 Controller


Figure A-21 Engine Wiring, Woodward 4.3L GM







Start–up Inspection Form It is required that both sides of this form be completed, signed where indicated and returned to Baldor Generators within 30 days of initial Start–up and test.

It is your responsibility to deliver copies to: n Baldor Generators Factory n Baldor Distributor n Customer

For Standby, Automatic Emergency and Prime Power Generators

Distributor Information

Name:

Address:

Name:

Address:

Phone:

Model Number:

_______ RPM _______ Hz _______ P.F.

_______ kW _______ Volts

Engine Model #:

Engine Serial #:

List Items Installed by Distributor:

End User / Owner Information

Phone:

Job Number:

Standby Continuous

_______ KVA _______ Amps.

Generator Model #:

Generator Serial #:

List Items Installed by Others:

Engine Hour

Meter

Power

Output kW

No Load

Voltage (Phase-to-Phase)

1-2 2-3 3-1 1 2

Current

3 Hz

Oil Temp.

Oil

Pressure

Water

Temp.

Ambient

Temp.

Start-up Performed by:

Address:

Phone:

MN2408

Date:

Technician:

Customer Signature:

Series GLC A-33

n Pre Start-up Check List

No freight damage (Components tight, straight, etc.).

Proper belt alignment and tensions.

Flex fuel lines installed between engine and tank.

Fluid levels (Oil, Antifreeze, Battery, Governor, etc.) Check for leaks, tighten as necessary.

Correct fuel and exhaust plumbing.

Adequate air flow.

Correct AC wire sizes and connections.

Correct DC wire sizes and connections (route separate from AC).

Block heater is operational.

Bleed and prime the fuel system; check for leaks.

Correct as necessary.

On natural gas fueled sets, gas pressure of 4-6 oz. of pressure with adequate volume is available.

Gas solenoid valve is properly functioning.

Exhaust line and flexible connections are properly installed without excessive bends and restrictions.

Exhaust system termination properly located to prevent entry of exhaust gas into building.

Batteries properly filled with electrolyte & properly connected to the engine.

Battery charger must be properly installed & connected to the battery. Battery must be fully charged prior to start-up.

Generator load connectors of proper ampacity are connected to either the circuit breaker or the emergency side of the transfer switch.

The nameplate voltage & frequency of the Genset matches that of

ATS & normal source.

n Start-up Procedure

Check that all applicable warning decals are in their proper place and are legible.

The ATS engine start wires and other DC wires, if any, must be properly connected.

All wiring connections are tight.

The equipment room is clean & all unrelated materials removed.

The equipment is protected from possible fire damage by fire extinguisher system.

Earthquake protection (when applicable) is adequate for the equipment.

Open generator mainline breaker or remove fuses.

Turn down speed potentiometer (electronic governor) or speed screw (mechanical governor).

Move switch to "manual". Let the engine start & run.

After a few minutes, check oil pressure & check for leaks.

Adjust the speed to 60/50Hz if equipped with electronic governor or

63/53 Hz with mechanical governor.

If speed is unstable, adjust per engine or governor manual.

Adjust the AC voltage to match the normal source.

Let the unit run until engine reaches proper water temp.

Close generator mainline breaker or replace fuses.

Manually over-speed the unit until engine shutdown (68-70 Hz for

60 Hz generators ; 58-60 Hz for 50 Hz generator sets).

Test automatic shut-downs (low oil pressure, low coolant level, high coolant temperature, Overspeed set to ______Hz Other______)

*** Instruct End User On Functions Of Unit ***.

Set Times to Customer's Request and Run a Simulated Power

Outage.

Instruct the customer in proper operation & maintenance of the system and make sure they have correct manuals.

Return this completed form to:

BALDOR GENERATORS

3815 Oregon Street

Oshkosh, WI 54902


UNITED STATES

ARIZONA

PHOENIX

4211 S 43RD PLACE

PHOENIX, AZ 85040

PHONE: 602-470-0407

FAX: 602-470-0464

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

2520 W BARBERRY PLACE

DENVER, CO 80204

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

795 MITTEL DRIVE

WOOD DALE, IL 60191

PHONE: 630-787-9600

FAX: 630-787-0434

INDIANA

INDIANAPOLIS

5525 W. MINNESOTA ST.

INDIANAPOLIS, IN 46241

PHONE: 317-246-5100

FAX: 317-246-5110

800-428-4141

IOWA

DES MOINES

1901 BELL AVE., SUITE 7

DES MOINES, IA 50315

PHONE: 515-244-9996

FAX: 515-244-6124

MARYLAND

BALTIMORE

6660 SANTA BARBARA RD

SUITE 22-24

ELKRIDGE, MD. 21075

PHONE: 410-579-2135

FAX: 410-579-2677

MASSACHUSETTS

BOSTON

317 BROOKS ST.

WORCESTER, MA 01606

PHONE: 508-854-0708

FAX: 508-854-0291

Baldor District Offices

MICHIGAN

DETROIT

33782 STERLING PONDS BLVD.

STERLING HEIGHTS, MI 48312

PHONE: 586-978-9800

FAX: 586-978-9969

TENNESSEE

MEMPHIS

4000 WINCHESTER ROAD

MEMPHIS, TN 38118

PHONE: 901-365-2020

FAX: 901-365-3914

GRAND RAPIDS

668 3 MILE ROAD NW

GRAND RAPIDS, MI 49504

PHONE: 616-785-1784

FAX: 616-785-1788

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

915 N W PLATTE VALLEY DR

RIVERSIDE, MO 64150

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

P O BOX 16500

GREENSBORO, NC 27416

PHONE: 336-272-6104

FAX: 336-273-6628

OHIO

CINCINNATI

2900 EARHART COURT

SUITE 200

HEBRON, KY 41048

PHONE: 859-586-0222

FAX: 859-586-0779

CLEVELAND

8929 FREEWAY DRIVE

MACEDONIA, OH 44056

PHONE: 330-468-4777

FAX: 330-468-4778

OKLAHOMA

TULSA

2 EAST DAWES

BIXBY, OK 74008

PHONE: 918-366-9320

FAX: 918-366-9338

OREGON

PORTLAND

20393 SW AVERY COURT

TUALATIN, OR 97062

PHONE: 503-691-9010

FAX: 503-691-9012

PENNSYLVANIA

PHILADELPHIA

1035 THOMAS BUSCH

MEMORIAL HIGHWAY

PENNSAUKEN, NJ 08110

PHONE: 856-661-1442

FAX: 856-663-6363

PITTSBURGH

616H BEATTY ROAD

MONROEVILLE, PA 15146

PHONE: 412-380-7244

FAX: 412-380-7250

TEXAS

HOUSTON

4647 PINE TIMBERS

SUITE # 135

HOUSTON, TX 77041

PHONE: 713-895-7062

FAX: 713-690-4540

DALLAS

3040 QUEBEC

DALLAS, TX 75247

PHONE: 214-634-7271

FAX: 214-634-8874

ODESSA

6968 EAST COMMERCE

ODESSA, TX 79762

PHONE: 432-367-2707

FAX: 432-367-9877

UTAH

SALT LAKE CITY

2230 SOUTH MAIN STREET

SALT LAKE CITY, UT 84115

PHONE: 801-832-0127

FAX: 801-832-8911

WISCONSIN

MILWAUKEE

2725 SOUTH 163RD STREET

NEW BERLIN, WI 53151

PHONE: 262-784-5940

FAX: 262-784-1215

INTERNATIONAL SALES

FORT SMITH, AR

BALDOR ELECTRIC CO

FORT SMITH, AR 72902

PHONE: 479-646-4711

FAX: 479-648-5895

CANADA

EDMONTON, ALBERTA

4053-92 STREET

EDMONTON, ALBERTA T6E6R8

PHONE: 780-434-4900

FAX: 780-438-2600

OAKVILLE, ONTARIO

2750 COVENTRY ROAD

OAKVILLE, ONTARIO L6H6R1

PHONE: 905-829-3301

FAX: 905-829-3302

MONTREAL, QUEBEC

1844 WILLIAM STREET

MONTREAL, QUEBEC H3J1R5

PHONE: 514-933-2711

FAX: 514-933-8639

VANCOUVER,

BRITISH COLUMBIA

1538 KEBET WAY

PORT COQUITLAM, BC V3C 5M5

PHONE 604-421-2822

FAX: 604-421-3113

WINNIPEG, MANITOBA

54 PRINCESS STREET

WINNIPEG, MANITOBA R3B1K2

PHONE: 204-942-5205

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 KELLETTS ROAD

ROWVILLE, VICTORIA, 3178

AUSTRALIA

PHONE: (03) 9753 4355

FAX: (03) 9753 4366

CHINA

SHANGHAI JIAHUA BUSINESS CENTER

ROOM NO. C-203

808 HONG QIAO ROAD

SHANGHAI 200021

PHONE: 86-21-64473060

FAX: 86-21-64078620

EL SALVADOR

BALDOR CENTROAMERICA

RESIDENCIAL PINARES DE SUIZA

POL. 15 #44, NVA. SAN SALVADOR

EL SALVADOR, CENTRO AMERICA

PHONE: (503) 288-1519

FAX: (503) 288-1518

FRANCE

2, RUE DU VALLON

94440 MAROLLES EN BRIE

PHONE: 33 145 10 7902

FAX: 33 145 99 0864

GERMANY

DIESELSTRASSE 22

D-85551 KIRCHHEIM

MUNICH, GERMANY

PHONE: (49) (89) 90508 - 0

FAX: (49) (89) 90508 - 491

ITALY

Baldor ASR AG

Mendrisio Office

Via Borromini, 20A

6850 Mendrisio

Switzerland

PHONE: 0041 91 640 99 50

FAX: 0041 91 630 26 33

JAPAN

NEO MIME 501

2-5 DAIMACHI,

KANAGAWA-KU

YOKOHAMA, 221-0834, JAPAN

PHONE: 81-45-412-4506

FAX: 81-45-412-4507

MÉXICO

BLVD. AL AEROPUERTO, KM. 2

LEÓN 37545, GUANAJUATO,

MÉXICO

PHONE: 52-477-761-2030

FAX: 52-477-761-2010

PANAMA

BALDOR SUDAMERICA

9109 0818, ZONA 6 BETHANIA

PANAMÁ CITY, REP. DE PANAMÁ

PHONE: (507) 261-5347

FAX: (507) 261-5355

SINGAPORE

51 KAKI BUKIT ROAD 2

K B WAREHOUSE COMPLEX

SINGAPORE 417863

PHONE: (65) 6 744 2572

FAX: (65) 6 747 1708

SWITZERLAND

POSTFACH 73

SCHUTZENSTRASSE 59

CH-8245 FEUERTHALEN

SWITZERLAND

PHONE: (41) (52) 6474700

FAX: (41) (52) 6592394

TAIWAN

ROOM R, 2F, NO. 124

CHUNG CHENG ROAD, SHIHLIN DIST.

TAIPEI 11141

PHONE: 886-2-2835-1666 EXT. 802

FAX: 886-2-2835-1717

UNITED KINGDOM

6 BRISTOL DISTRIBUTION PARK

HAWKLEY DRIVE

BRISTOL BS32 0BF U.K.

PHONE: 44 1454 850000

FAX: 44 1454 859001

WARNING:


Engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects and other reproductive harm.

WARNING:


Battery posts, terminals and related accessories are known to the state of California to cause cancer, birth defects and other reproductive harm.

© Baldor Electric Company

MN2408

BALDOR GENERATORS

3815 Oregon Street

Oshkosh, WI 54902

(920) 236–4200 or (800) 872–7697

Fax (920) 236–4219 www.baldor.com

Printed in USA

5/04 FAR200

Baldor GLC60 Installation & Operating Manual

GLC Generator

(Gaseous Liquid Cooled)

5/04

Installation & Operating Manual

MN2408

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.

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

Symbols

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

Section 2

General Information

Section 3

Receiving & Installation

Receiving & Inspection

Lifting the Generator

Physical Location

Section 4

Operation

Display Modes

Section 5

Troubleshooting and Maintenance

Appendix A

Series GLC Parts & Wiring Diagrams

Distributor Information

End User / Owner Information

BALDOR GENERATORS

3815 Oregon Street

Oshkosh, WI 54902

Baldor District Offices

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.

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.

© Baldor Electric Company

MN2408

BALDOR GENERATORS

3815 Oregon Street

Oshkosh, WI 54902

(920) 236–4200 or (800) 872–7697

Fax (920) 236–4219 www.baldor.com

Printed in USA

5/04 FAR200

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