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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:
CALIFORNIA PROPOSITION 65 WARNING:
Battery posts, terminals and related accessories are known to the state of California to cause cancer, birth defects and other reproductive harm.
Table of Contents
Section 1
Product Safety Information
Safety Notice
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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
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Cooling System
Air System
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Radiator Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other Engine Cooling Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Crankcase Ventilation
Transfer Switch
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Battery Starting System
Battery Location
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3
Receiving & Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Receiving & Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting the Generator
Physical Location
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Secure the Generator
Engine Cooling
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Hot Exhaust Gasses
Installation
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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
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
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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
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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.
Continued on next page.
MN2408 Product Safety Information 1-3
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: An open bottom stationary engine generator set must be installed over noncombustible materials and shall be located such that it prevents combustible materials from accumulating under the generator set.
Continued on next page.
1-4 Product Safety Information MN2408
Warning Statements Continued
Maintenance
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: 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: 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: 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: 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.
Continued on next page.
MN2408 Product Safety Information 1-5
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.
1-6 Product Safety Information MN2408
Section 2
General Information
Thank you for purchasing your Baldor Generator Set. This manual contains information you need to safely and efficiently install and operate your generator set. During the preparation of this manual every effort was made to ensure the accuracy of its contents. This manual describes only very basic engine information. A separate owner’s manual for the engine is supplied with this unit for your use. Please refer to the engine manual for 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
1 Year or 1,000 Hours
Whichever comes first
1 Year or 3,000 Hours
Whichever comes first
1 Year or 1,000 Hours
Whichever comes first
1 Year or 1,000 Hours
Whichever comes first
1 Year or 1,000 Hours
Whichever comes first
3 Years
3 Years or 3,000 Hours
Whichever comes first
3 Years or 1,000 Hours
Whichever comes first
3 Years or 3,000 Hours
Whichever comes first
2 Years or 1,000 Hours
Whichever comes first
1 Year or 1,000 Hours
Whichever comes first
1 Year or 1,000 Hours
Whichever comes first
*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.
MN2408 General Information 2-3
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.
2-4 General Information MN2408
Foundation Design
WARNING: An open bottom stationary engine generator set must be installed over noncombustible materials and shall be located such that it prevents combustible materials from accumulating under the generator set.
Foundation Checklist
A. Evaluate if a separate, isolated foundation is required for the application.
B. Observe local codes on soil bearing capacity freezing and thawing.
C. Design the separate foundation for the genset and specify the appropriate concrete mix.
D. Determine if the application requires vibration isolators and if so, order as a factory option.
The foundation must be strong enough to support the weight of the genset and its associated equipment, must prevent any deflection of the genset base and absorb vibration produced by the rotating and reciprocating masses.
Setting The Genset On An Existing Concrete Floor Slab
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
MN2408 General Information 2-5
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
2-6 General Information MN2408
Designing An Isolated Foundation
If the genset cannot be mounted directly on a floor slab, or if it is desirable to isolate it from the floor slab, then a separate foundation slab must be designed.
A massive concrete foundation is not required. Outside dimensions of the foundation should exceed the outside genset dimensions by 12in (300mm).
For single genset installation, the foundation weight should be a minimum of 1.50 times the genset wet weight.
For multiple genset installation, the foundation weight should 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
MN2408 General Information 2-7
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
2-8 General Information MN2408
Exhaust System
Exhaust Checklist
A. Exhaust outlets are not located upwind or near any building air intakes.
B. Flexible piping section is used at engine exhaust outlet.
C. Exhaust piping material is adequate for expected service.
D. Exhaust piping sizing is adequate to prevent back pressure.
E. Exhaust piping components are insulated as necessary to 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.
MN2408 General Information 2-9
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.
2-10 General Information MN2408
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
MN2408 General Information 2-11
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”.
2-12 General Information MN2408
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.
MN2408 General Information 2-13
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
2-16 General Information MN2408
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.
MN2408 General Information 2-17
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.
2-18 General Information MN2408
Transfer Switch
Transfer Switch Checklist
A. Locate transfer switch in a clean, dry place, near the emergency load.
B. Provide a circuit breaker between the genset and the transfer switch.
C. 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.
MN2408 General Information 2-19
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.
2-20 General Information MN2408
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
MN2408 General Information 2-21
2-22 General Information MN2408
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
WARNING: An open bottom stationary engine generator set must be installed over noncombustible materials and shall be located such that it prevents combustible materials from accumulating under the generator set.
Several other factors should be carefully evaluated when selecting a location for installation:
1.
For effective cooling and maintenance, the system should be mounted on a flat, smooth, noncombustible level surface. A concrete pad is ideal and provides a secure installation.
2.
Installation should prevent water levels from reaching the generator. Drainage must be adequate to keep concrete pad free from standing water.
3.
Installation should prevent obstructions by buildup of leaves, grass, sand, snow, etc. If these items pose a problem, consider building a small fence or other break to protect the unit from accumulation of debris.
4.
Installation should place the generator as close as possible to the fuel supply and transfer switch.
5.
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.
MN2408 Receiving & Installation 3-3
Hot Exhaust Gasses
WARNING: Exhaust fumes/gases are extremely dangerous and can cause severe illness or death. Never breath exhaust fumes produced by a running engine. Only run the engine outdoors where ventilation is plentiful. Exhaust gases contain carbon monoxide, a colorless, odorless and extremely dangerous gas that can cause unconsciousness or death. Symptoms of carbon monoxide poisoning include: dizziness, nausea, headaches, sleepiness, vomiting or incoherence. If you or anyone else experiences these symptoms, get out into fresh air immediately. Stop the engine and do not restart the engine until it has been inspected and if necessary repaired or reinstalled in a well ventilated area.
WARNING: Hot exhaust gasses must never be directed toward anything that may catch fire or explode.
It is extremely important to discharge engine exhaust gasses away from the engine and out of the building. If these gasses 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.
3-4 Receiving & Installation MN2408
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.
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.
MN2408 Receiving & Installation 3-5
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
3-6 Receiving & Installation MN2408
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.
3-8 Receiving & Installation MN2408
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.
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.
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.
MN2408 Receiving & Installation 3-9
Figure 3-4 Three Phase WYE and DELTA Connections
3-10 Receiving & Installation MN2408
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
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.
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.
MN2408 Receiving & Installation 3-11
Battery Connections The generator is shipped with no battery installed.
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: 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.
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.
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.
3-12 Receiving & Installation MN2408
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.
MN2408 Receiving & Installation 3-13
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.
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.
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.
3-14 Receiving & Installation MN2408
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
MN2408 Operation 4-3
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
MN2408 Operation 4-5
Figure 4-3 Engine Controller Inputs & Outputs
4-6 Operation MN2408
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
MN2408 Operation 4-7
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.
4-8 Operation MN2408
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
Press ↑ or ↓ key
Press ↑ or ↓ 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.
MN2408 Operation 4-9
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.
4-10 Operation MN2408
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 A to B
1-phase system: LINE TO LINE VOLTAGE--Phases A to B
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
Displays the generator's output voltage:
3-phase system: LINE TO LINE VOLTAGE--Phases C to A
1-phase system: LINE TO NEUTRAL VOLTAGE--Phases B-N
Generator Phase/Neutral Voltage Display
(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
Displays generator load current as follows:
3-phase system: PHASE B CURRENT
1-phase system: PHASE B CURRENT
Displays generator load current as follows:
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.
MN2408 Operation 4-11
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
4-12 Operation MN2408
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.
MN2408 Operation 4-13
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.
4-14 Operation MN2408
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.
MN2408 Operation 4-15
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.
4-16 Operation MN2408
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).
MN2408 Operation 4-17
j j j j j j
Figure 4-4 Configuration Data Sheet j j j
4-18 Operation MN2408
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 Yes/No
Toggle Between Alarm/Shutdown
Toggle Between Yes/No
Toggle Between Yes/No
Common Fail (Factory setting)
Common Fail (Factory setting)
Common Fail (Factory setting)
Common Fail (Factory setting)
Common Fail (Factory setting)
Common Fail (Factory setting)
0–99 Seconds
0–99 Seconds
0–999 Seconds
Access by Master Password Only
Toggle Between Yes/No
MN2408 Operation 4-19
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
4-20 Operation MN2408
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
MN2408 Operation 4-21
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.
2 - Phase 2 current is measured by the Amperage meter.
3 - Phase 3 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.
4-22 Operation MN2408
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
MN2408 Operation 4-23
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
High Water Temperature
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)
High Water Temperature
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
4-24 Operation MN2408
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.
MN2408 Operation 4-25
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
Internal failure of Alternator
Low power factor
Excessive speed (fixed speed mode)
Static charge.
Grounded armature or field coil.
Internal failure of Alternator
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.)
MN2408 Series GLC A-3
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 UCI274E 12/311 Nat Gas
GLC125 UCI274E 12/311 Nat Gas
GLC125 UCI274E 12/311 Nat Gas
GLC125 UCI274F 4/06 Nat Gas
GLC125 UCI274F 12/311 Nat Gas
GLC125 UCI274F 12/311 Nat Gas
GLC125 UCI274F 12/311 Nat Gas
GLC125 UCI274F 12/311 Nat Gas
GLC125 UCI274F 12/311 Nat Gas
GLC125 UCI274F 12/311 Nat Gas
GLC125 UCI274F 12/311 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
A-4 Series GLC MN2408
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 12/311 Nat Gas
GLC100 UCI274E 12/311 Nat Gas
GLC100 UCI274E 12/311 Nat Gas
GLC100 UCI274E 12/311 Nat Gas
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
GLC80 UCI274C 12/311 Nat Gas
GLC80 UCI274C 12/311 Nat Gas
LPG
LPG
LPG
LPG
LPG
LPG
LPG
LPG
GLC80 UCI274C 12/311 Nat Gas
GLC80 UCI274C 12/311 Nat Gas
GLC80 UCI274C 12/311 Nat Gas
GLC80 UCI274C 12/311 Nat Gas
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
MN2408 Series GLC A-5
GLC DATA Continued
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 UCI224E 12/311 Nat Gas
GLC60 UCI224E 12/311 Nat Gas
GLC60 UCI224E 12/311 Nat Gas
GLC60 UCI224E 12/311 Nat Gas
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
GLC50 UCI224D 12/311 Nat Gas
GLC50 UCI224D 12/311 Nat Gas
GLC50 UCI224D 12/311 Nat Gas
LPG
LPG
LPG
LPG
LPG
LPG
LPG
LPG
GLC50 UCI224D 12/311 Nat Gas
GLC50 UCI224D 12/311 Nat Gas
GLC50 UCI224D 12/311 Nat Gas
GLC50 UCI224D 12/311 Nat Gas
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
A-6 Series GLC MN2408
GLC DATA Continued
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 12/311 Nat Gas
GLC45 UCI224D 12/311 Nat Gas
GLC45 UCI224D 12/311 Nat Gas
GLC45 UCI224D 12/311 Nat Gas
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
GLC35 UCI224C 4/06 Nat Gas
GLC35 UCI224C 12/311 Nat Gas
GLC35 UCI224C 12/311 Nat Gas
GLC35 UCI224C 12/311 Nat Gas
LPG
LPG
LPG
LPG
LPG
LPG
LPG
LPG
GLC35 UCI224C 12/311 Nat Gas
GLC35 UCI224C 12/311 Nat Gas
GLC35 UCI224C 12/311 Nat Gas
GLC35 UCI224C 12/311 Nat Gas
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
MN2408 Series GLC A-7
GLC DATA Continued
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 UCI224C 12/311 Nat Gas
GLC30 UCI224C 12/311 Nat Gas
GLC30 UCI224C 12/311 Nat Gas
GLC30 UCI224C 12/311 Nat Gas
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
A-8 Series GLC MN2408
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 - #14 EPDM PER PHASE
1 - #8 EPDM PER PHASE
1 - #8 EPDM PER PHASE
1 - #8 EPDM PER PHASE
1 - #8 EPDM PER PHASE
1 - #8 EPDM PER PHASE
1 - #8 EPDM PER PHASE
1 - #6 EPDM PER PHASE
1 - #6 EPDM PER PHASE
1 - #6 EPDM PER PHASE
1 - #4 EPDM PER PHASE
1 - #4 EPDM PER PHASE
1 - #1 EPDM PER PHASE
1 - #1 EPDM PER PHASE
1 - #1 EPDM PER PHASE
1 - #1/0 EPDM PER PHASE
1 - #2/0 EPDM PER PHASE
1 - #3/0 EPDM PER PHASE
1 - #4/0 EPDM PER PHASE
2 - #1/0 EPDM PER PHASE
2 - #1/0 EPDM PER PHASE
2 - #2/0 EPDM PER PHASE
2 - #3/0 EPDM PER PHASE
2 - #4/0 EPDM PER PHASE
3 - #2/0 EPDM PER PHASE
3 - #3/0 EPDM PER PHASE
3 - #4/0 EPDM PER PHASE
4 - #4/0 EPDM PER PHASE
4 - #4/0 EPDM PER PHASE
5 - #4/0 EPDM PER PHASE
6 - #4/0 EPDM PER PHASE
6 - #250 EPDM PER PHASE
8 - #250 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.
MN2408 Series GLC A-9
MEC20
MEC2
Figure A-2 Customer Interface Connection Diagram
A-10 Series GLC MN2408
Figure A-3 Customer Interface (w/o Breaker) Power Connection Diagram
MN2408 Series GLC A-11
Figure A-4 Single Phase – (w/o Breaker) Connection Diagram
A-12 Series GLC MN2408
Figure A-5 Single Phase – One Breaker Connection Diagram
MN2408 Series GLC A-13
Figure A-6 Single Phase – Two Breaker Connection Diagram
A-14 Series GLC MN2408
Figure A-7 Single Phase Connection Diagram (Wire 1/0 and Larger w/Breaker)
MN2408 Series GLC A-15
Figure A-8 Single Phase Connection Diagram (Wire 1/0 and Smaller w/Breaker)
A-16 Series GLC MN2408
Figure A-9 Single Phase Connection Diagram (Wire 1/0 and Smaller w/o Breaker)
MN2408 Series GLC A-17
Figure A-10 Single Phase Connection Diagram (Wire Larger than 1/0 w/o Breaker)
A-18 Series GLC MN2408
Figure A-11 Three Phase Connection Diagram
MN2408 Series GLC A-19
Figure A-12 Three Phase Connection Diagram with PMG
A-20 Series GLC MN2408
Figure A-13 Three Phase Connection Diagram (Wire 1/0 and larger)
MN2408 Series GLC A-21
Figure A-14 Three Phase Connection Diagram (Wire Larger than 1/0 w/Breaker)
A-22 Series GLC MN2408
Figure A-15 Three Phase Connection Diagram (Wire 1/0 and Smaller w/Breaker)
MN2408 Series GLC A-23
Figure A-16 Three Phase Connection Diagram (Wire Larger than 1/0 w/o Breaker)
A-24 Series GLC MN2408
Figure A-17 Three Phase Connection Diagram (Wire 1/0 and Smaller w/o Breaker)
MN2408 Series GLC A-25
Figure A-18 Control Box Connections with MEC20 Controller
Without Governor
A-26 Series GLC MN2408
Figure A-19 Control Box Connections with MEC20 Controller & Governor
With Governor
MN2408 Series GLC A-27
Figure A-20 Control Box Connections with MEC2 Controller
A-28 Series GLC MN2408
Figure A-21 Engine Wiring, Woodward 4.3L GM
MN2408 Series GLC A-29
Figure A-22 Engine Wiring, Woodward 5.7L GM
A-30 Series GLC MN2408
Figure A-23 Engine Wiring, Woodward 8.1L GM
MN2408 Series GLC A-31
A-32 Series GLC MN2408
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
A-34 Series GLC MN2408
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:
CALIFORNIA PROPOSITION 65 WARNING:
Engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects and other reproductive harm.
WARNING:
CALIFORNIA PROPOSITION 65 WARNING:
Battery posts, terminals and related accessories are known to the state of California to cause cancer, birth defects and other reproductive harm.
© 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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