GLC Generator
(Gaseous Liquid Cooled)
GLC10, 15, 20, 25 35, 45, 55, 75, 105 and 130
Installation & Operating Manual
1/10
MN2408
Any trademarks used in this manual are the property of their respective owners.
WARNING:
CALIFORNIA PROPOSITION 65 WARNING:
Engine exhaust from this product contains chemicals known
to the state of California to cause cancer, birth defects and
other reproductive harm.
WARNING:
CALIFORNIA PROPOSITION 65 WARNING:
Battery posts, terminals and related accessories are known to
the state of California to cause cancer, birth defects and other
reproductive harm.
Table of Contents
Section 1
Product Safety Information
Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caution Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 2
General Information
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Site Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Room Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Room Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Utility Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foundation Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Level Of Attenuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multi−Engine Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Gas Restriction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rain Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Formulas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 3
Receiving & Installation
Receiving & Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Physical Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secure the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot Exhaust Gasses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single Phase Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Engine Oil and Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Post Installation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MN2408
1-1
1-1
1-2
1-6
2-1
2-2
2-2
2-2
2-3
2-4
2-4
2-6
2-6
2-7
2-7
2-7
2-8
2-8
2-9
2-10
2-10
2-10
2-10
2-11
2-12
3-1
3-1
3-1
3-2
3-2
3-6
3-7
3-7
3-10
3-11
3-14
3-15
3-15
3-15
Table of Contents i
Section 4
Operation
Digital Engine Controller Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Set points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 5
Troubleshooting and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Problems and Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix A
Options & Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Block Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Silencers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flexible Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E−Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Annunciators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiator Duct Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix B
Series GLC Information & Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GLC Circuit Breaker & Wire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii Table of Contents
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4-4
4-5
4-6
4-6
5-1
5-1
5-2
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A-1
A-2
A-2
A-3
A-4
A-4
A-5
A-6
B-1
B-1
B-1
MN2408
Section 1
Product Safety Information
Safety Notice
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.
Responsibility
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.
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
Battery Safety
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.
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.
Continued on next page.
MN2408
Product Safety Information 1-5
Warning Statements Continued
Maintenance
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.
Caution Statements
Caution:
Caution:
Caution:
Caution:
Caution:
Caution:
Caution:
Avoid installing the generator set beside heat generating equipment, or directly below water
or steam pipes or in the vicinity of corrosive substances or vapors, metal particles and dust.
Heat can cause engine problems to develop and unwanted substances can cause rust or
generator failure over time.
Do not apply high voltage to windings (do not start the generator) in a moisture−saturated
condition. Moisture can cause insulation breakdown, making it necessary to return the
generator for repair.
Use only original equipment or authorized replacement parts. Using the correct parts will
assure continued safe operation as designed.
Do not support the generator from the top of the frame or enclosure.
Do not tamper with or change the engine speed. Engine speed is factory set to produce the
correct voltage and output frequency.
Never operate the engine without a muffler. The engine is designed to have the correct
exhaust components installed and operating without these components can present a fire
hazard, cause excessive exhaust gases and cause damage to engine. Inspect muffler
periodically and replace if necessary.
The Programmable Output Contacts selection must agree with the external control wiring
prior to energizing the controller. Failure to do so may cause severe equipment damage.
1-6 Product Safety Information
MN2408
Section 2
General Information
Thank you for purchasing your Baldor Generator Set. This manual contains information you need to safely and efficiently
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 2009. All rights reserved.
This manual is copyrighted and all rights are reserved. This document may not, in whole or in part, be copied or
reproduced in any form without the prior written consent of Baldor Electric Company, Inc.
Baldor Generators have earned the reputation of being high quality and dependable. We take pride in this fact and
continue to keep our quality standards high on our list of priorities. We are also constantly researching new technological
ideas to determine if they could be used to make our generator sets even better.
Baldor makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied
warranties of fitness for any particular purpose. The information in this document is subject to change without notice.
Baldor assumes no responsibility for any errors that may appear in this document.
Limited Warranty
Baldor will replace or repair free of charge any part or parts of the generator of their manufacture that are defective in
workmanship and materials for a period of time as set forth in the Warranty Period chart below. All Baldor products
requiring warranty service shall be transported or shipped freight pre−paid to a Baldor Generator repair facility.
Notification of the defect or problem, a description of the manner in which the Baldor generator is used, and the name,
address and telephone number of the customer requiring warranty service must be included. Baldor is not responsible for
removal and shipment of the Baldor product to the service center or for the reinstallation of the Baldor product upon its
return to the customer, or any incidental or consequential damages resulting from the defect, removal, reinstallation,
shipment or otherwise. Problems with Baldor products can be due to improper maintenance, faulty installation,
non−Baldor additions or modifications, or other problems not due to defects in Baldor workmanship or materials. If a
Baldor Generator repair facility determines that the problem with a Baldor product is not due to defects in Baldor
workmanship or materials, then the customer will be responsible for the cost of any necessary repairs. Genset engines
are covered under the engine manufacturers warranty. Proper engine maintenance is required. Any request for engine
warranty or repair should be made directly with the engine manufacturers warranty center. See engine manufacturers
data for applicable engine warranty periods and location of repair centers. This Limited Warranty and Service Policy
represents Baldor’s sole and exclusive warranty obligation with respect to Baldor products. Baldor’s liability to a customer
or any other person shall not exceed Baldor’s sales price of the applicable Baldor product. BALDOR DISCLAIMS ALL
OTHER EXPRESSED AND IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF FITNESS FOR A
PARTICULAR PURPOSE AND MERCHANTABILITY.
Warranty Period
Generator Series
Labor*
Parts
Portable Products (Premier, Powerchief,
DG Series)
Towable Products (TS)
POW’R LITE Light Towers
1 Year
3 Years
1 Year or 3,000 Hours
1 Year or 3,000 Hours
1 Year or 1,000 Hours
3 Years or 3,000 Hours
3 Years or 3,000 Hours
Light Fixture, Lamps and Ballasts are excluded
from any warranty coverage
3 Years or 1,000 Hours
1 Year or 3,000 Hours
3 Years or 3,000 Hours
1 Year or 1,000 Hours
1 Year or 1,000 Hours
1 Year or 1,000 Hours
2 Years or 1,000 Hours
1 Year or 1,000 Hours
1 Year or 1,000 Hours
3600 RPM Standby Systems
(Some AE Models)
1800 RPM Standby Systems
(Some AE Models, DLC, GLC)
Industrial Standby Systems
Industrial Prime Power Systems
International
*For products covered under labor coverage, travel expenses will be allowed up to 7 hours straight labor or 300 miles,
whichever occurs first, and only applies to permanently wired and mounted products (AE, DLC, GLC, IDLC).
You must save the purchase receipt. Proof of purchase, date, serial number and model number will be required for all
portable and Towable products to qualify for any warranty consideration.
A start−up inspection form/warranty registration must be completed in its entirety and submitted to Baldor Generators
within 30 days of start−up to qualify for any warranty consideration, excluding: Portables, Towables and Light Towers.
MN2408
General Information 2-1
Important
Be sure you are completely familiar with all Safety Instructions detailed in Section 1 of this
manual. Do not proceed if you are unsure of any detail. Contact your Baldor Distributor, they are
experienced and are happy to assist you and to answer your questions.
Installation Guidelines
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 3 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.
2-2 General Information
MN2408
Room Location Often a separate building located on the site away from the main building is the most simple and
cost effective. Major considerations when housing the genset in a separate building are:
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. 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
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.
MN2408
General Information 2-3
Utility Power
During periods when the generator is not running, utility power must be provided to power critical
components. Battery chargers, block heaters, space heaters and other devices must have power
to maintain the generator set components and allow fast easy starting.
Foundation Design
WARNING: An open bottom stationary engine Generator Set must be installed over noncombustible
materials and shall be located such that it prevents combustible materials from accumulating
under the Generator Set.
Foundation Checklist
A. Evaluate if a separate, isolated foundation is required for the application.
B. Observe local codes on soil bearing capacity freezing and thawing.
C. Design the separate foundation for the Genset and specify the appropriate concrete mix.
D. Determine if the application requires vibration isolators and if so, order as a factory option.
The foundation must be strong enough to support the weight of the Genset and its associated
equipment, must prevent any deflection of the Genset base and absorb vibration produced by the
rotating and reciprocating masses.
Setting The Genset On An Existing Concrete Floor Slab
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
Vibration isolators are commonly used to mount the Genset to a concrete pad, Figure
2-1. The purpose of vibration isolators is to reduce the noise and vibration which would
be transmitted from the Genset to the foundation or supporting structure.
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 is determined by the rating of the pads and the Gensets weight.
Figure 2-1 Typical Installation J−Bolt or Spring Type Isolator
Generator Base
Spring Type Isolator
Generator Base
J-Bolt
Fill with Grout
3” (76mm) Pipe
Use of expansion
bolts also acceptable
2-4 General Information
Foundation
“J” or “L” Bolt
“J” or “L” Bolt
MN2408
S
Caution:
Caution:
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. 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 for cleaning around the
Genset and to provide a more level base. When using this method, floor strength must
support the pad and the Genset. The pad should be at least 6in (150mm) thick and
extend beyond the Genset in all directions 12in (300mm).
Weight of the Genset
The dry weight of the entire Genset is shown on the Generator Set Specification Sheet. The wet
weight includes the fluids (coolant and oil).
Designing an Isolated Foundation
If the Genset cannot be mounted directly on a floor slab, or if it is desirable to isolate it from the
floor slab, then a separate foundation slab must be designed.
A massive concrete foundation is not required. Outside dimensions of the foundation should
exceed the outside Genset dimensions by 12in (300mm).
For single Genset installation, the foundation weight should be a minimum of 1.50 times the
Genset wet weight.
For multiple Genset installation, the foundation weight should be a minimum of 2.0 times the
Genset wet weight.
Figure 2-2 shows a method to calculate foundation thickness and the soil bearing load of the
foundation and Generator Set. The soil load bearing capacity under the foundation must equal or
exceed the load from the foundation and Genset. If it does not, then a footing must be added to
spread the load over a larger area.
Check the local building codes for load bearing capacity requirements.
If the soil is subject to freezing and thawing, the foundation must be extended below the frost
line. Check the local building codes.
Figure 2-2 Calculate Soil Bearing Load (SBL) Capacity
T +
WT
145 x L x W
T
Where:
T = Foundation depth in feet (m)
WT = Wet weight of Geneset in lbs (kg)
145 = Density of concrete in lbs/ft3
(kg/m3)
L = Foundation length in feet (m)
W = Foundation width in feet (m)
Foundation
L
SBL +
W
TW
WxL
Where:
SBL
= Soil bearing load in
lbs/ft2 (kPa)
TW = Total weight (foundation load)
Genset (wet) and all other
equipment to be supported
in lbs (kg)
L = Foundation length in feet (m)
W = Foundation width in feet (m)
Table 2-1 shows approximate load bearing capacities for various types of soil if the actual load
bearing capacity of the soil under the foundation is not known.
MN2408
General Information 2-5
Table 2-1 Approximate Load Bearing Capacities of Various Soil Types
Soil Type
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
S
S
S
S
S
Safe Bearing Capacity
lb per ft2
kilo Pascals
50,000 − 200,000
2,395 − 9,576
20,000 − 30,000
958 − 1,436
16,000 − 20,000
766 − 958
10,000 − 20,000
479 − 958
10,000 − 12,000
479 − 575
8,000 − 10,000
383 − 479
8,000 − 10,000
383 − 479
8,000 − 10,000
383 − 479
6,000 − 8,000
287 − 383
4,000 − 8,000
192 − 383
2,000 − 4,000
96 − 192
2,000
96
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).
Suggested concrete mixture by volume is 1 part cement, 2 parts sand, and 3 parts
aggregate. Maximum slump of 4in (100mm) and a 28−day compressive strength of
3000 psi (20,600 kPa).
The size of the bolts holding the sub−base to the foundation should be sized to fit the
mounting holes shown on the installation diagram.
Three−inch (76mm) iron pipe sleeves should be placed around the bolts in the
foundation to allow for any mislocation of the bolts after the foundation hardens.
“J” or “L” type bolts are recommended for the foundation bolts.
After the foundation is cured and the Genset is located, the sleeves are filled with grout.
Exhaust System Exhaust Checklist
A.
B.
C.
D.
E.
F.
G.
Exhaust outlets are not located upwind or near any building air intakes.
Flexible piping section is used at engine exhaust outlet.
Exhaust piping material is adequate for expected service.
Exhaust piping sizing is adequate to prevent back pressure.
Exhaust piping components are insulated as necessary to prevent operator burns and
reduce pipe radiant heat losses.
Pipe sleeves or fire proof materials are used where exhaust pipe passes through building
materials as per local and state codes.
Exhaust pipe includes rain cap or is horizontal.
The purpose of the exhaust system is to safely discharge the engine combustion products into
the atmosphere outside the building. A silencer should be installed in the exhaust system to
reduce noise levels. Compliance with local noise codes is always required.
WARNING: Never allow the exhaust outlet to be positioned so that the exhaust gases are directed
towards any openings or air entry routes (doors, windows, vents, etc.) of an occupied
building. When discharging the hot exhaust gases out of the building do not direct them
towards anything that could catch fire or explode.
For aesthetic reasons, consider exhaust placement in relation to the building. Over a period of
time, exhaust gas carbon deposits will tend to accumulate on any nearby wall or structure.
Attention must also be given to exhaust noise in selecting placement of the exhaust system.
Level Of Attenuation
In general, manufacturers offer multiple grades of silencers: industrial, residential, and critical.
Select the silencer to assure the desired level of silencing is met.
2-6 General Information
MN2408
Multi−Engine Installations
Caution: 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. Do not use check valves in the exhaust system because they can “stick”.
Exhaust Manifold
There are two exhaust manifold types. Dry type which is standard and the optional water cooled.
The dry type is simply exposed to the surrounding air and becomes very hot. Shields, insulating
wraps, or other types of guards can be used to limit operator contact with the hot surfaces. This
practice is common where engine room size is small, creating cramped conditions.
Water cooled exhaust manifolds are not available on all engine models. This type manifold has
passages through which engine coolant is circulated to remove heat from the manifold surface. It
also will help protect the operator from contact with the hot manifold surface. This will reduce the
amount of heat that is radiated by the engine to the surrounding air by approximately 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.
Note: If you are using a remote muffler a flexible coupling of 12” or more must be installed between the
exhaust line and the manifold to absorb the engine’s vibration. However, a short, solid section of pipe
between 6” and 8” long should be placed between the connection of the manifold and the flexible
coupling. This nipple will reduce the possibility of the hot gases burning up the flexible coupling.
Exhaust Gas Restriction
The maximum allowable back pressure, or system restriction, is stated in the product
specifications data (inches Hg). If this back pressure is exceeded, the air−fuel ratio is reduced
due to incomplete scavenging of the cylinders, fuel economy and power output is reduced,
engine life is reduced and exhaust temperatures and smoke levels increase. Any restriction of
the exhaust gas reduces horsepower. Take every precaution to reduce restriction. Proper design
and installation will provide safe Genset operation.
It is essential that engine exhaust systems have the least possible restriction to exhaust gas flow.
This can be calculated as shown in Figure 2-3.
Figure 2-3 Exhaust System Calculations
S (lb/ft 3) +
S (kg/m 3) +
39.6
Exhaust Temperature ) 460 oF
352.05
Exhaust Temperature ) 273.16 oC
To obtain equivalent length of straight pipe for
each long radius 90° bend:
L (ft) + 15 x D
15 x D
L (in) +
12
Note:
L (m) + 15 x D
15 x D
L (mm) +
1000
For 90° bends, radii of 1.5 times pipe diameter
helps reduce resistance and backpressure.
MN2408
Q (cfm or ft3/min)
10000
9000
8000
7000
6000
5000
4500
4000
3500
3000
P (in Hg per ft)
1.0
0.5
0.1
0.05
1500
1000
900
800
4
5
6
0.01
0.005
2500
2000
D (in) x 25.4 = D (mm)
Where:
P = Backpressure in psi (kPa)
psi = 0.4912 x in Hg
kPa= 0.1333 x in Hg
L = Length of pipe in ft (m)
Q = Exhaust gas flow ft3/min (m3/min)
D = Inside diameter of pipe in (mm)
S = Specific weight of gas lb/ft3 (kg/m3)
D (in)
3
P (in Hg) x 25.4 = P (mm Hg)
L x SL x Q 2
5,184 x D 5
cfm (ft3/min) x 0.472 = l/s
P (psi) +
0.001
0.0005
7
8
9
10
0.0001
0.00005
0.00001
13
General Information 2-7
Exhaust Piping
Caution: The weight of the exhaust system must never be imposed on the turbo−charger outlet.
Damage to the turbo−charger and other components may result.
An exhaust system must withstand the vibration and thermal expansion that they are subjected
to, yet supported well enough to remain independent of the engine.
The most common method of providing flexibility is with the use of bellows type flexible piping.
This piping component allows lateral and linear movement of the piping system without
subjecting fixed components to excessive stress. A minimum of 12 inches of flexible connection
must be provided at the engine exhaust manifold to allow for thermal expansion and vibration. If
the engine is to be mounted on spring type vibration 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 2-4.
Note: Water is one of the by−products of combustion. This water must be kept from draining back into the
engine. Slanting the horizontal section of the exhaust system piping downward slightly, away from the
engine can do this. A water trap (tee extension with a drain cock) should also be used. The water
trap should be located between the flex coupling and the muffler, but as close to the engine as
possible on a horizontal section of the exhaust piping.
Figure 2-4 Exhaust Pipe Thimble Installation
Wind blowing against air exhaust or intake openings of the Genset room must be considered,
especially where the radiator and fan are located on the engine. Wind blowing against an
exhaust opening creates restriction to the fan. Wind blowing against intake openings can blow
open gravity louvers causing low temperature and moisture problems in bad weather. A turning
vane may be required to prevent exhaust air recirculation between the exhaust louvers and the
barrier surface. This will route the exhaust upward into the atmosphere.
Rain Protection
Moisture entering the engine through an exhaust system can cause extensive damage. Exhaust
outlets must have a rain cap or be horizontal to prevent such damage, see Figure 2-4.
Wind Barrier
2-8 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 2-5.
Figure 2-5 Typical Emergency Power System Installations
Utility
Main
Disconnect
Utility
G
Genset
Branch
Protection
G
Gensets
Main
Disconnect
Branch
Protection
Generator Paralleling Control Panel Priority Control
Branch
Protection
Transfer
Switch
TS-1
TS-2
Transfer
Switch1
Non-Emergency
Loads
G
Transfer
Switch2
Emergency
Loads
Non-Emergency
Loads
Level -1
Loads
Level -2
Loads
Multiple Gensets can be arranged either in parallel or separately connected to dedicated
emergency loads. Figure 2-5 also shows a typical arrangement of two Gensets in parallel with
transfer switches for loads that have different levels of priority. A typical multiple Genset
installation is shown for NFPA 110 Level 1 and Level 2 emergency power circuits and a priority
control to select the appropriate transfer switch.
Wattmeters should be installed on each Genset so load sharing can be checked. The control
system should include an automatic paralleling control. Paralleling identical Gensets is not
difficult, but paralleling dissimilar sets can cause load sharing problems. When designing an
installation that 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. The circuit breaker can be separately mounted. In the
case of very large circuit breakers, a separate floor mounted circuit breaker may be
easier to wire up than a wall mounted breaker.
4. Install power and control wires in separate solid conduit with flexible sections at the
Genset. The flexible sections prevent vibration from damaging the conduit. All power
conduits from the Genset must contain all three phases.
5. Never install control wires in the same conduit as power conductors.
6. Conduit, wire, circuit protective 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.
MN2408
General Information 2-9
Battery Starting System
This section describes the battery starting system (nominal 12 or 24 volt rating of the battery
supply) for the engine, battery charger, and precautions to take if the ambient temperature is
expected to be below 70 °F (20°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 2-6. 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 2-6 Battery Starting System
The ability to start the engine depends upon battery capacity, ambient temperature and coolant
and oil temperatures. The Engine/Generator Set Data Sheet lists minimum recommended battery
capacity at various ambient temperatures. The recommended battery capacities are listed in the
Electric Systems section of the Engine Data Sheet, cold cranking amps (CCA) at 0 °F (−18 °C).
Battery capacities decrease as ambient temperatures decrease so it is important to specify
batteries with the appropriate CCA rating at a temperature no higher than the minimum ambient
temperature for the application.
Battery Charger An engine mounted alternator to charge the batteries during operation is an available option.
Standby Gensets require a solid state battery charger that is connected to utility power so the
battery is charged continuously while the Genset is not running. The battery charger should be
connected to the emergency circuit. The batteries on prime power Gensets are charged by the
engine mounted alternator, if equipped.
Harmonic wave forms from solid state battery charges and belt driven alternators can cause the
electronic governor on the engine to act erratically. To avoid this, the output of the battery charger
or the belt driven alternator must be connected directly to the battery or to 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 Size
2-10 General Information
MN2408
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 2-7. For purposes of calculating cranking circuit
resistance to select cable size, the resistance of each connection can be taken as .00001 ohms
and the resistance of each relay, solenoid, and switch can be taken as .0002 ohms. Figure 2-7
illustrates an example of a typical cranking circuit resistance calculation.
Figure 2-7 Typical Battery Cable Calculations
#4
0.00400
#3
#2
#1
#0
#00
#000
Resistance in Ohms at 77°F (25°C)
0.00380
0.00360
0.00340
0.00320
0.00300
0.00280
0.00260
0.00240
0.00220
2-#0
2-#00
0.00200
0.00180
Maximum allowable resistance of . . . . . . 0.002 Ohms (24V Systems)
the cranking circuit . . . . . . . . . . . . . . . . 0.0012 Ohms (12V Systems)
0.00160
0.00140
0.00120
0.00100
System Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24V
Resistance of 6 connections . . . . . . . . . . . . . . . . . . . 0.00006 Ohms
Resistance of 100' of #1 Cable . . . . . . . . . . . . . . . . . 0.00100 Ohms
Total resistance of cranking circuit
0.00106 Ohms
0.00080
0.00060
0.00040
0.00020
0
MN2408
100
(2.54)
200
300
400
(5.08)
(7.62) (10.16)
Cable Length inches(meters)
500
(12.70)
600
(15.24)
700
(17.78)
General Information 2-11
Formulas
Single Phase − Electric
Single Phase Power Factor is typically 1.0
1 kW = 1 kilo Watt = 1,000 Watts
Watts + Volts x Amps x Power Factor
Amps +
Three Phase − Electric
Watts
Volts x Power Factor
Three Phase Power Factor is typically 0.8
1 kW = 1 kilo Watt = 1,000 Watts
Watts + (Volts x Amps x Power Factor) x 1.732
Amps +
Watts
Volts x Power Factor x 1.732
Length
inches x 25.40 = mm
feet x 0.305 = m
yard x 0.914 = m
mm x 0.03937 = inches
m x 3.280 = feet
m x 1.094 = yard
Area
inches2 x 6.451 = cm2
feet2 x 0.0929 = m2
cm2 x 0.394 = inches2
m2 x 10.764 = feet2
Pressure
pounds/ft2 x 0.006944 = pounds/in2
psi x 6.8948 = kPa
psi = 0.4912 inches Hg
pounds/in2 x 144 = pounds/ft2
kPa x 0.1450 = psi
kPa = 0.1333 x inches Hg
Temperature
°C = (°F−32) x 0.55555
°F = (°C x 1.8) + 32
Torque
oz−in x 0.007062 = Nm
lb−in x 0.11296 = Nm
lb−ft x 1.356 = Nm
Nm x 141.6029 = oz−in
Nm x 8.8495 = lb−in
Nm x 0.7376 = lb−ft
Velocity
ft/sec x 0.3048 = m/sec
miles/hr x 1.6093 = km/hr
miles/hr x 0.44704 = m/sec
m/sec x 3.2808 = ft/sec
km/hr x 0.6214 = miles/hr
m/sec x 3.2808 = ft/sec
m/sec x 2.2369 = miles/hr
Volume
inches3 x 16.388 = mm3
feet3 x 0.0283 = m3
gallons x 3.785 = liter
gallons x 0.13337 = ft3
cm3 x 0.06102 = inches3
m3 x 35.315 = feet3
liter x 0.2642 = gallon
Miscellaneous
Watt x 0.00134 = hp or 746 watts = hp
BTU/hr x 0.293 = Watts
Watts x 3.4122 = BTU/hr
BTU/hr x 0.0003929 = hp
hp x 2,545 = BTU/hr
Approximate fuel Higher Heating Values (HHV):
Natural Gas = 1015 BTU/ ft3, Liquid Propane = 2650 BTU/ ft3
Effect of engine efficiency on fuel consumption:
hp x 2545 BTU/hr per hp
+ 10, 180BTUńhr
0.25 efficiency
2-12 General Information
MN2408
Section 3
Receiving & Installation
Receiving & Inspection When you receive your Genset, there are several things you should do immediately.
1.
Observe the condition of the shipping container and report any damage immediately to
the commercial carrier that delivered your system.
2. Verify that the part number of the system you received is the same as the part number
listed on your purchase order.
3. If the system is to be stored for several weeks before use, be sure that it is stored in a
location that conforms to published storage temperature and humidity specifications.
Lifting the Genset When lift or hoist equipment is used to lift the Genset and move it to position, be careful not to
contact overhead wires or other obstacles. 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 Genset. If the shipping pallet has been removed, use two steel pipes through the
“Lift Point” holes to lift the Genset. See Figure 3-1.
Figure 3-1 Genset Lifting
To lift the Genset, always use spreader bars,
chains, eyehooks and other hardware that is of
sufficient strength to lift at least three times the
weight of the Genset.
Width
Spreader Bar Method
Length
Height
Maximum Lift
angle = 30°
Lift
Point
Lift
Point
2 Point Lift Method
WARNING: An open bottom stationary engine Genset must be installed over noncombustible materials
and shall be located such that it prevents combustible materials from accumulating under the
Genset.
Physical Location The mounting location of the system is important. It should be installed in an area that is
protected from direct harmful gases or liquids, dust, metallic particles, shock and vibration.
It should be installed in an outdoor location so the exhaust fumes are vented to the atmosphere.
When the Genset is installed outdoors
The factory installed enclosure is designed to keep out undesirable weather elements while
providing cooling and ventilation.
When the Genset is installed in a building it is essential to provide:
1. Adequate control and exhausting of the heated air.
2. An adequate and constant supply of incoming cooling air.
3. Adequate control and discharge of the engine’s hot exhaust gases.
4. Adequate ventilation of the building when the engine shuts down.
MN2408
Receiving & Installation 3-1
Several other factors should be carefully evaluated when selecting a location for installation:
1. For effective cooling and maintenance, the system is mounted on a flat, smooth,
noncombustible level surface. A concrete pad is ideal.
2. Installation should prevent water levels from reaching the Genset. Drainage must be
adequate to keep concrete pad free from standing water.
3. Installation should prevent obstructions by buildup of leaves, grass, sand, snow, etc.
If these items pose a problem, consider building a small fence or other break to protect
the unit from accumulation of debris.
4. Installation should place the Genset as close as possible to the fuel supply and transfer
switch.
5. At least thirty−six (36) inches clearance must be provided on all sides for air flow.
6. Access must be provided to allow the enclosure covers to be opened or removed for
service and maintenance.
7. Maximum Ambient temperature is 122°F (50°C).
Secure the Genset
Mounting bolts in the base frame secure the Genset to the shipping pallet. Remove these bolts,
lift the Genset and remove the shipping pallet.
Secure the Genset to the concrete pad using 3/8″ anchor hardware (not provided) in the base
frame mounting holes. See Figure 3-2.
Anchor bolts must be long enough to extend through the Genset mounting frame.
Engine Cooling A sufficient flow of clean, cool air is required for combustion and to dissipate the heat produced
by the engine. Approximately 60% of the heat value of the fuel used is given off as heat (cooling
air and exhaust).
The air that will cool the engine must be brought in from outside the building. A sufficient air−flow
of rate “Cubic Feet per Minute” (CFM) will allow the incoming fresh air to cool the engine. This
requires a power ventilation system of sufficient CFM to be located at the highest possible point
of the building to exhaust hot air and draw in cool fresh air.
Note: The exhaust fan must not be located where it could easily become blocked by leaves,
snow, water, debris, etc.
It is recommended that the cool air intake have at least three (3) times the cross−sectional area
of the power ventilation system. It is also recommended that the cool air intake be located as
close as possible to the top of the Genset.
The exhaust fan must be connected to the AC power terminals of the Genset so that when the
Genset starts it will provide immediate cooling air flow. The fan will operate until the Genset
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 Genset. This may result in overheating,
fire, or explosion.
3-2 Receiving & Installation
MN2408
Figure 3-2 Genset Mounting 10−25kW
MN2408
Receiving & Installation 3-3
Table 3-2 Mounting Dimensions 35−130kW
3-4 Receiving & Installation
MN2408
Table 3-3 Mounting Dimensions 35−130kW Continued
MN2408
Receiving & Installation 3-5
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 or adjacent structures. In extreme cases this
extremely hot air could cause dried grass or other debris to ignite.
Exhaust lines should be as short and straight as possible. Long pipe lengths and elbows tend to
resist the flow of gases and accumulate carbon deposits. Each pipe fitting and elbow will further
restrict the exhaust flow.
Guidelines for Exhaust System
1. If you are using a remote muffler it should be mounted as close to the engine as
possible, since it will clog with carbon if it’s operating temperature is too low.
2. If you are using a remote muffler a flexible coupling of 12” or more must be installed
between the exhaust line and the manifold to absorb the engine’s vibration. However,
a short, solid section of pipe between 6” and 8” long should be placed between the
connection of the manifold and the flexible coupling. This nipple will reduce the
possibility of the hot gases burning up the flexible coupling.
3. It is extremely important that you do not allow the hot exhaust gases to re−circulate into
the engine’s cooling air intake.
4. Water is one by−product of combustion and is present in the exhaust pipes or muffler.
This water must be kept from draining back into the engine. This can be done by
slanting the horizontal section of the exhaust system piping downward slightly, away
from the engine. A water trap consisting of a tee extension with a drain cock should
also be provided. This water trap should be located between the flex coupling and the
muffler, but as close to the engine as possible on a horizontal section of the exhaust
piping.
5. It is also recommended that an exhaust rain cap be used whenever it is possible that
rain could get into the system. This will help to prevent corrosion and damage to the
exhaust system and engine.
6. The exhaust system is subject to the engine’s vibration and it must therefore be solidly
secured to reduce mechanical stress and the potential for breakage.
7. The engine’s exhaust system is the hottest component of the installation and extreme
care and considerations must be given to it.
8. As much of the exhaust piping as possible should be located near the power ventilation
exhaust. This will reduce the radiant exhaust heat inside the building.
9. Keep all fuel and its associated piping away from all components of the engine exhaust
system.
10. After the exhaust system is installed it should be inspected on a regular basis to assure
there are no toxic exhaust gas leaks. In some areas this inspection may be provided by
your local public service.
11. A carbon monoxide tester may be installed to detect the presence of the deadly gas
during times when you are in the building with the engine running (during testing or
maintenance).
3-6 Receiving & Installation
MN2408
WARNING: Never allow the exhaust outlet to be positioned so that the exhaust gases are directed
towards any openings or air entry routes (doors, windows, vents, etc...) of an occupied
building. When discharging the hot exhaust gases out of the 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.
Installation
The Genset is completely assembled, tested and adjusted at the factory before it is shipped to
you. The procedures presented in this manual are suggestions and it is the responsibility of the
Owner/Operator to arrange for these procedures to be performed by licensed contractors
according to all applicable codes including local codes for your Municipality/City/County and
State. External connections required at the time of installation are:
1. Fuel System.
2. Electrical Connections − power wiring (optional transfer switch) and control wiring.
3. Starting Battery.
4. Ground Connection.
After installation, the post installation checks must be performed prior to starting the engine.
After these checks have been performed and the system operation is verified to be good, refer to
Section 5 Maintenance for periodic checks that must be performed at scheduled intervals to
ensure continued operation with minimal problems.
Fuel Connections
Fuel selection is Natural Gas or LPV (Liquid Propane Vapor). A fuel selection jumper is located
at customer terminal block TB1. The jumper must be correctly set for the type of fuel being used
by the genset.
If natural gas supply is used, follow the “Natural Gas Connections” procedure.
If LPV supply is used, follow the “LP Vapor Connections” procedure.
Table 3-4 defines the flow rate required for each fuel type.
Table 3-4 Fuel Consumption Natural and LPV
Catalog Number
Model Number
GLC10M240LS
GLC15M240LS
GLC20M240LS
GLC25M240LS
GLC30M240LS
GLC43M240LS
GLC55M240LS
IGLC25-2GU
IGLC25-2GU
IGLC25-2GU
IGLC25-2GU
IGLC35-2GU
IGLC45-2GU
IGLC55-2GU
MN2408
Fuel Consumption at 100% load
cubic ft/Hr (cubic m/Hr)
Natural Gas
LP Vapor
203(5.8)
86(2.4)
247(7.0)
108(3.1)
300(8.5
131(3.7)
365(10.3)
154(4.4)
430(12.2)
175(5.0)
585(16.5)
246(7.0)
744(21.1)
295(8.4)
Catalog Number
Model Number
GLC72M240LS
GLC32M208MS
GLC44M208MS
GLC54M208MS
GLC73M208MS
GLC105M208MS
GLC128M208MS
IGLC75-2GU
IGLC35-2GU
IGLC45-2GU
IGLC55-2GU
IGLC75-2GU
IGLC105-2GU
IGLC130-2GU
Fuel Consumption at 100% load
cubic ft/Hr (cubic m/Hr)
Natural Gas
LP Vapor
790(22.4)
330(9.3)
430(12.2)
175(5.0)
584(16.5)
246(7.0)
744(21.1)
295(8.4)
790(22.4)
330(9.3)
1164(33.0)
511(14.5)
1650(46.7)
580(16.4)
Receiving & Installation 3-7
The following pamphlets are available from:
National Fire Protection Association (NFPA) P.O. Box 9101 Quincy, MA 02269
No. 37 − Combustion Engines
No. 54 − Gaseous Appliances and piping
No. 58 − Storage and handling LPV
Example: Determining Pipe Size for Natural Gas
A Genset has a 16Hp engine 60 feet from the supply. An engine needs 10,000 BTU/hr per hp to
run efficiently. For Natural Gas fuel there are 1015 BTU/ft3
Determine the supply pipe size for Natural Gas fuel.
16hp x 10,000 BTU/Hr per hp = 160,000 BTU’s / per hour for proper operation.
160, 000
+ 158 cubic feet per hour.
1, 015
From Table 3-5, a 60 foot run requires a minimum 1” pipe at full engine load.
Natural Gas Connections
The incoming pressure must be 11 inches water column (6 oz. pressure).
Table 3-5 Natural Gas Flow Rate (Cubic Feet per Hour) per Pipe Length
Pipe
Length
(Feet)
15
30
45
60
75
90
105
120
150
180
210
240
270
300
Iron Pipe Size
1/
2″
73
50
41
37
3/
4″
165
115
95
83
74
67
63
1″
1−1/4″
1−1/2″
2″
2−1/2″
3″
4″
6″
8″
332
232
191
166
149
137
126
115
105
96
89
722
515
418
366
332
298
274
260
233
216
197
183
171
164
1174
818
673
587
524
433
415
404
366
337
308
289
274
260
2386
1712
1419
1241
1077
962
885
827
750
693
635
596
558
524
3704
2646
2213
1924
1684
1501
1376
1289
1174
1077
991
933
875
827
6253
4521
3752
3319
2886
2597
2357
2213
2011
1876
1712
1616
1520
1433
13352
9331
7600
6542
5772
5291
4906
4618
4185
3848
3559
3357
3127
2886
37229
26330
22462
18595
16652
15200
14064
13160
11775
10736
9937
9235
8658
8177
53728
43867
37999
33959
31025
28715
26859
24050
21934
20298
18990
17903
16998
Note: Almost all operation problems are related to the installation techniques used. Do Not
guess, be sure pipe size is adequate for required flow rate.
1. Connect the proper size gas pipe at the Inlet Connection to the Fuel Lock Solenoid.
Connect the Natural Gas pipe line shown in Figure 3-3 using the correct size pipe for
the required flow rate and length of pipe. Refer to Table 3-5 for pipe size. Be certain
that all connections are sealed and no leaks are present. The installer must ensure
that all gas connections comply with all building codes.
2. Verify Fuel Supply Pressure
Prior to initial operation of Genset, verify that fuel system pressure is 11″ Water Column
(6 oz. pressure) and fuel pipe sizes comply with Table 3-5.
3. To run on NG fuel, install jumper on TB1 terminals 12 and NG.
4. Proceed to Electrical Connections.
Example: Determining Pipe Size for LPV
A Genset has a 16Hp engine 60 feet from the supply. An engine needs 10,000 BTU’s per hp to
run efficiently. For LP fuel there are 2,650 BTU/ft3. Determine the supply pipe size for LP fuel.
16hp x 10,000BTU/Hr per hp = 160,000 BTU’s / per hour for proper operation.
160, 000
+ 60.4 cubic feet per hour.
2, 650
From Table 3-6, a 60 foot run requires a minimum 1” pipe at full engine load.
3-8 Receiving & Installation
MN2408
Figure 3-3 Gas Line Connections
Air Cleaner
Carburetor
(Typical piping as shown)
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 Genset.
Solenoid, Fuel Lock
Inlet Connection
Supply Piping
To Inlet
Connection
Mounting Bracket
Additional Regulator
(11 - 14" water column pressure)
Additional Valve
(Safety Shutoff Valve)
LP Vapor Connections (vapor withdrawal only)
The LPV connections should only be made if your Genset is setup to run on LPV. If it is setup to
run on Natural Gas, contact your Baldor representative and do not continue with installation.
To run on LP Vapor fuel remove the jumper on TB1 terminals 12 and FS.
The incoming pressure must be 11 inches water column (6 oz. pressure).
Table 3-6 LP Vapor Flow Rate (Cubic Feet per Hour) per Pipe Length
Pipe
Length
(Feet)
15
30
45
60
75
90
105
120
150
180
210
240
270
300
Iron Pipe Size
1/
2″
48
33
27
24
3/
4″
109
76
63
54
49
44
41
1″
218
153
126
110
98
89
83
76
69
63
58
1−1/
4″
475
339
275
241
218
196
180
171
153
142
130
120
113
108
1−1/
2″
772
538
443
386
345
310
285
266
241
222
202
190
180
171
2″
2−1/2″
3″
4″
6″
8″
1570
1127
934
817
709
633
582
544
494
456
418
393
367
345
2437
1741
1456
1266
1108
987
905
848
772
709
652
614
576
544
4115
2975
2469
2184
1899
1709
1551
1456
1323
1234
1127
1063
1000
943
8786
6140
5001
4304
3798
3482
3228
3038
2754
2532
2342
2209
2057
1899
24497
17325
14781
12236
10957
10001
9254
8659
7748
7064
6439
6077
5697
5381
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 inlet connection to the Fuel Lock Solenoid.
Connect the LPV pipe line shown in Figure 3-3 using the correct size pipe for the
required flow rate and length of pipe. Refer to Table 3-6 for pipe size. Be certain that all
connections are sealed and no leaks are present. The installer must ensure that all
gas connections comply with all building codes.
2. Verify Fuel Supply Pressure
Prior to initial operation of Genset, verify that fuel system pressure is 11″ Water Column
(6 oz. pressure) and fuel pipe sizes comply with Table 3-6.
3. To run on LPV fuel, install jumper on TB1 terminals 12 and FS.
4. Proceed to Electrical Connections.
MN2408
Receiving & Installation 3-9
Electrical Connections Class 1 wiring methods must be used for field wiring connections to terminals of a class
2 circuit. It is the responsibility of the owner/operator to arrange for these procedures to be
performed by a licensed electrical contractor and ensure conformance to all applicable codes
including local codes peculiar to your municipality/city/county and state. Wire size and insulation
type should be as required by NEC (National Electrical Code) and local codes.
Warning: Never connect this Genset to the electrical system of any building unless a licensed
electrician has installed an approved transfer switch. The national electrical code (NEC)
requires that connection of a Genset to any electrical circuit normally powered by means of
an electric utility must be connected by means of approved transfer switch equipment to
isolate the electrical circuit from the utility distribution system when the Genset is operating.
Failure to isolate the electrical circuits by such means may result in injury or death to utility
power workers due to backfeed of electrical energy onto the utility lines.
Warning: Incorrect installation of this Genset could result in property damage, injury or death.
Connection of the Genset to its fuel source must be done by a qualified professional
technician or contractor.
WARNING: Be sure the system is properly grounded before applying power. Do not apply AC power
before you ensure that grounds are connected. Electrical shock can cause serious or fatal
injury. NEC requires that the frame and exposed conductive surfaces (metal parts) be
connected to an approved earth ground. Local codes may also require proper grounding of
Genset systems.
Intended Use The intended purpose of this Genset is to provide emergency power when the main utility power
supply is interrupted. Therefore, it is important that all the wiring that connects the Genset with your
house, transfer switch, distribution box, battery charger, etc. be properly installed.
Circuit Protection Circuit Breaker protection is provided within the Genset. The breaker box is mounted to the
Genset prior to shipment (see Genset Mounting diagrams). See “GLC Circuit Breaker & Wire
Size” in Appendix B for recommendations.
Wire Size
Proper lead wire from the circuit breaker to the automatic transfer switch (or load switching
device) is mandatory. See transfer switch information for connection information. When
connecting the Genset output to an electrical load, a UL listed circuit breaker with the appropriate
ratings must be provided within 25 feet of the Genset. Use only copper wires.
Genset ratings are given in Table 3-7.
Table 3-7 Genset Ratings
Catalog Number
Model Number
Alternator
Voltage
Voltage
L-L/L-N
PH
GLC10M240LS
GLC15M240LS
GLC20M240LS
GLC25M240LS
GLC30M240LS
GLC43M240LS
GLC55M240LS
GLC72M240LS
GLC32M208MS
GLC44M208MS
GLC54M208MS
GLC73M208MS
GLC105M208MS
GLC128M208MS
IGLC25-2GU
IGLC25-2GU
IGLC25-2GU
IGLC25-2GU
IGLC35-2GU
IGLC45-2GU
IGLC55-2GU
IGLC75-2GU
IGLC35-2GU
IGLC45-2GU
IGLC55-2GU
IGLC75-2GU
IGLC105-2GU
IGLC130-2GU
282PSL1714
282PSL1715
282PSL1716
283PSL1717
UCI224C-06
UCI224E-06
UCI224F-06
UCI224G-06
PI144J-311
UCI224D-311
UCI24E-311
UCI224G-311
UCI274D-311
UCI274E-311
240
240
240
240
240
240
240
240
208
208
208
208
208
208
240/120
240/120
240/120
240/120
240/120
240/120
240/120
240/120
208/120
208/120
208/120
208/120
208/120
208/120
1
1
1
1
1
1
1
1
3
3
3
3
3
3
3-10 Receiving & Installation
125° Rise Alternator Standby
Rating - LP Fuel
kW/kVA
Amps
10/10
42
15/15
63
20/20
83
25/25
104
30/30
125
43/43
179
55/55
229
72/72
300
32/40
111
44/55
153
54/67.5
187
73/91
253
105/131
364
114/142.5
396
125° Rise Alternator Standby
Rating - NG Fuel
kW/kVA
Amps
10/10
42
15/15
63
20/20
83
25/25
104
30/30
125
40/40
167
52/52
217
67/67
279
31/39
108
41/51
142
52/65
180
67/84
232
99/124
344
128/160
444
MN2408
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 Genset.
5. Do not mount the transfer switch where flammable liquids or vapors are present.
Figure 3-4 Basic Power Transfer System
Utility Power
L1
Main Panel
Transfer
Switch
L2
Genset Power
L1
N
L2
N
Remote Start
Contact
Ground
Fuses or
Circuit
Breakers
Fuses or
Circuit
Breakers
Earth
Ground
Mechanical
Interlock
Ground
L1
L2
N
Power To Load
Remote Start
Connect the remote start start contact (from transfer switch) to GLC Remote Start terminals.
Single Phase Power Connections
Output power connections must be fused within 25 feet of the Genset. If the wires to the transfer
switch are shorter than 25 feet, connect L1, L2 and N to the transfer switch being sure to follow
NEC and local codes. If the wires to the transfer switch are longer than 25 feet, UL requires that
branch circuit protection be provided.
Power connections are made at L1, L2, Neutral and Ground points indicated in the Customer
Connections area shown in Figure 3-5.
MN2408
Receiving & Installation 3-11
Figure 3-5 Single Phase Connections
From Alternator
(Factory Wired)
Bond Jumper
Note: Remove the Bonding
jumper to meet local
codes if required.
NEUTRAL
L1
LOAD
L2
Neutral
Connections
AC Power Connections
Customer Connections
GROUND
Ground
Connections
Figure 3-6 Three Phase WYE and DELTA Connections
N
N
L3
L2
L1
L1
L2
L3
N
L1
L2
L3
N
3-12 Receiving & Installation
MN2408
Frame Ground Connection
It is important for safety reasons that the Genset, transfer switch and battery charger share a
common Ground and neutral.
The NEC requires that the frame and exposed metal surfaces be at local ground reference
potential to avoid electrical shock hazard. A local ground reference may require a driven earth
ground conductor at the Genset installation site. Make the ground connection as shown in Figure
3-7. Use the appropriate size wire as required by NEC and local codes.
Figure 3-7 Frame Ground Connection
Nut
Washer
Ground Wire Lug
Washer
Stud
Frame
1.
Determine ground stud location and connect the ground wire to the “earth ground”
terminal shown in Figure 3-7. This ground is the local reference ground to ground the
Genset frame only.
Battery Charger Considerations
1. Mount the battery charger on the Genset or as close to the Genset 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 (Genset, transfer switch, battery charger,
etc.) share a common hard wired ground.
3. Check with your local building inspector to determine what you must do to comply with
the local regulations for grounding of this type of permanent installation.
WARNING: Be sure the system is properly grounded before applying power. Do not apply AC power
before you ensure that grounds are connected. Electrical shock can cause serious or fatal
injury. NEC requires that the frame and exposed conductive surfaces (metal parts) be
connected to an approved earth ground. Local codes may also require proper grounding of
Genset.
MN2408
Receiving & Installation 3-13
Caution:
This Genset must have a battery installed for operation. The battery is used during starting
and during operation. If engine operation is attempted while the battery is removed, damage
to the engine’s electrical components may result.
Battery Connections
WARNING: Installation and servicing of batteries is to be performed or supervised by personnel
knowledgeable of batteries and the required precautions. Keep unauthorized personnel away
from 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 accidentally
touches the positive battery terminal or wire. The risk of such shock is reduced when the
ground lead is removed during installation and maintenance.
Procedure:
The correct type battery must be installed in the battery compartment provided, see Table 3-8.
Installation and servicing of batteries is to be performed or supervised by personnel
knowledgeable of batteries and the required precautions.
Keep unauthorized personnel away from batteries.
1. Open access doors and locate battery tray.
2. Place the correct battery (see Table 3-8) on the tray.
3. 10−25kW ONLY. Install the Battery Hold Down Bar and Rods as shown in Figure 3-8.
a. Place the bent end of the Battery Hold Down Rod through the hole in the Battery
Tray.
b. Place the threaded end of the Battery Hold Down Rod through the hole in the
Battery Hold Down Bar and secure with flat washer, lock washer and nut.
c. Repeat steps a and b for the other Battery Hold Down Rod.
3-14 Receiving & Installation
MN2408
Figure 3-8 Battery Installation (10−25kW only)
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 Bar
(Install away from terminals)
Washers & Nut
Battery Hold Down Rod
Battery Tray
4.
5.
6.
7.
8.
Connect the positive lead to the positive (+) battery terminal.
Connect the negative lead to the negative (−) battery terminal.
Do not lay tools or metal parts on top of batteries.
Connect charging source to the battery terminals.
Disconnect the battery’s ground terminal before working in the vicinity of the battery or
battery wires. Contact with the battery can result in electrical shock when a tool
accidentally touches the positive battery terminal or wire. The risk of such shock is
reduced when the ground lead is removed during installation and maintenance.
Recommended Engine Coolant
Refer to the Engine manual for coolant type. Normally a 50/50 mix of coolant and water is
required. Coolant system capacity is shown in Table 3-8.
Recommended Engine Oil and Battery Type
When replacing batteries, use only the recommended battery for your Genset, see Table 3-8.
Table 3-8
MODEL
IGLC25-2G
IGLC35-2G
IGLC45-2G
IGLC55-2G
IGLC75-2G
IGLC105-2G
IGLC130-2G
COOLANT CAPACITY
qt (L)
20.0(18.9)
20.0(18.9)
20.8(19.7)
21.2(20.1)
22.0(20.8)
27.2(25.7)
25.6(24.2)
SUMMER
OIL
SAE. 15W40
SAE. 15W40
SAE. 15W40
SAE. 15W40
SAE. 15W40
SAE. 15W40
SAE. 15W40
WINTER OIL
(less than 0°F)
5W/30
5W/30
5W/30
5W/30
5W/30
5W/30
5W/30
OIL
CAPACITY
5.0 QTS
5.0 QTS
5.0 QTS
5.0 QTS
5.0 QTS
9.0 QTS
9.0 QTS
RECOMMENDED
BATTERY
BCI Group 24
BCI Group 24
BCI Group 31
BCI Group 31
BCI Group 31
BCI Group 31
BCI Group 31
(AMPS) COLD
CRANKING
675
675
925
925
925
925
925
Post Installation Checks
Caution:
MN2408
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. Gensets that have been in transit or storage for long periods may be subjected to
extreme temperature and moisture changes. This can cause excessive condensation,
and the generator windings should be thoroughly dried before bringing the Genset up
to full nameplate voltage. If this precaution is not taken, serious damage to the Genset
can result.
Do not apply high voltage to windings (do not start the Genset) in a moisture−saturated
condition. Moisture can cause insulation breakdown, making it necessary to return the
Genset for repair.
Note: These precautions are especially necessary in locations such as seaboard installations
and other high humidity areas. Some installations will be in atmospheres that are much
more corrosive than others.
2. Verify that the transfer switch is in Utility Power mode. No power must be present at
the Genset or transfer switch connections. Verify with a voltmeter.
3. Verify that the engine starting battery is disconnected so accidental starting is not
possible.
4. Verify that the Genset is securely mounted and anchored to its cement pad.
Receiving & Installation 3-15
Post Installation Checks Continued
5. Verify that proper clearance exists on all sides and top of enclosure.
6. Verify that Genset power is properly connected to the transfer switch.
7. Verify that Genset and transfer switch are properly grounded.
8. Assure that Genset is a safe distance from any flammable or combustible material.
9. Verify that the Genset 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 Genset 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 select source jumper is set to select operation on the correct fuel type.
18. Verify the fuel source is ON and the pressure and flow rate are correct.
19. Remove all tools, rags, etc. from inside the Genset enclosure. Close all enclosure
doors and be sure no hands are inside the Genset enclosure when it starts.
20. Verify all loads are disconnected.
21. Start the Genset. (Refer to Section 4 Operation for details).
22. 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.
23. With the engine running, several checks must be made:
a. Verify there are no fuel leaks. If a fuel leak is detected, stop the engine
immediately (move the Master Control Switch to the “Stop” position) and
repair the leak before proceeding.
b. Verify there are no coolant or oil leaks. If a leak is detected, stop the engine
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 immediately and repair before proceeding.
d. Verify that the correct voltage exists (line−to−line and line−to−neutral) at the
Genset and at the transfer switch.
e. Minor adjustment of the output voltage is made using the “Voltage Adjust”
potentiometer on the control panel.
WARNING: Engine coolant is under pressure and is near the boiling point of water when engine is hot.
Do not open the coolant system until the engine has completely cooled. Hot coolant can
cause severe burns and other injuries. When engine is cool, coolant level can be checked.
24. 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.
25. Close all enclosure covers. The post installation checks are now complete.
3-16 Receiving & Installation
MN2408
Section 4
Operation
Digital Engine Controller Description EM0046A45 (MRS19)
Figure 4-1 Operator Control Panel
Operating Modes and
Horn & Fault Reset
Manual
Run
Display
Stop
Menu
Group
LED Indicators
LED Indicators
Note: The operator control panel is equipped with a heater element that allows the LCD display
to operate to −40°C (not the entire generator set, see generator specifications). This
heater operates from the main battery power.
Alarm (red) − Alarm (shutdown) condition occurred. Annunciates & shuts down generator.
Not In Auto (red) − Control is not in auto mode and cannot provide standby power.
Running (green) − Generator is running, no alarms or warnings.
Warning (yellow) − A warning condition has occurred. Annunciates only.
Ready/Auto (green) − Control is in Auto mode and ready to provide standby power.
Supplying Load (green) − Generator is providing output voltage to load.
Table 4-1 Alarm & Warning Conditions
Alarm
X
X
X
X
X
X
Warning
X
X
X
X
X
X
X
High Coolant temperature
Low Oil pressure
Generator Under/Over Voltage
Generator Under/Over Frequency
Generator Over Current
Generator Overspeed
Coolant temperature Low
Starting battery Under/Over Voltage
Immediately begins the crank cycle to start engine and produce power (MAN mode only).
Start generator set operation (MAN mode only).
Stops the Engine and generator set (MAN mode only).
Displays setpoints, adjustments, Alarms and Warning conditions and Operating Mode selections.
Changes menu displayed − Measurement, Adjustment or History.
Allows selection of OFF − MAN − AUTO mode choices.
Deactivates the Horn output.
Reset Alarms and Warnings.
Selects the menu choice, select the setpoint or select the menu or increase/decrease the
setpoint value.
Enter
Confirm and accept changed setpoint value.
Enter + Y and B Adjusts display contrast.
Enter+ Fault Reset Clears engine ECU faults.
Manual Run
Start
Stop
Display
Page
Mode A and "
Horn Reset
Fault Reset
Y and B
MN2408
Operation 4-1
Digital Engine Controller Description EM0046A45 (MRS19) Continued
Operating Mode Press Mode or to scroll though the list of operating modes: Off, Manual and Automatic.
The control mode is shown in the highlighted area at the top of the display, Figure 4-2.
When the desired Control Mode is highlighted, press Start to begin operation.
Press Stop to terminate operation.
OFF − Generator set operation is not allowed.
MAN − Press Start to manually start the generator set immediately.
Press Stop to stop the generator set immediately.
AUT − Start and Stop buttons are ignored.
The binary input terminal conditions start and stop the generator set.
Display Menus
Three display menus are available: Measurement, Adjustment and history.
Press the Page button repeatedly to display each menu. Use and Enter keys to change
and accept setpoint values or press the Page button to cancel changes.
Measurement Menu
The measurement menu, shown in Figure 4-2 displays the operating mode, and operating
parameters such as kW, engine RPM etc.
Figure 4-2 Measurement Menu
Control Mode
Operating Modes and
Horn & Fault Reset
OFF MAN AUT
OFF MAN AUT = Control operating mode (highlighted)
! = Alarm indication is active
!
Ready
0
kW
PF
RPM
Timer
0.00
0
0
Ready = Status
kW = Active power produced by generator
PF = Power Factor
RPM = Engine speed in revolutions per minute
Timer = Event counting time (e.g. prestart, cooling etc.)
OFF Mode
Starting of the generator set is not possible. Outputs STARTER (BO1) and FUEL SOLENOID
(BO2) are not active. No action if buttons START and STOP are pressed.
MAN Mode
START button starts the generator set.
STOP stops the generator set.
This operation is further defined in Table 4-2.
AUT Mode
No action if Start button is pressed. The controller can be programmed so the Stop Button is
either active or inactive when controller is in the AUT mode.
Engine Start/Stop request is given by binary input REM Start/Stop (BI1).
4-2 Operation
MN2408
Digital Engine Controller Description EM0046A45 (MRS19) Continued
Table 4-2 Manual Mode Sequence Description
Menu
Status
Condition of Transition
Start request
Ready
Prestart
RPM > 2 or Oil pressure detected or
Gen voltage > 10V
OFF mode selected or Shut down alarm active
RPM < 2, Oil pressure not detected, Vgen < 10V,
no shutdown alarm active, other than OFF mode
selected
Prestart time elapsed
Cranking
RPM> Start RPM
D+ input activated or oil pressure detected or
Gen voltage > 25% Vgnom
MaxCrank time elapsed, 1st attempt
Crank Pause
MaxCrank time elapsed, last attempt
CrankFail pause elapsed
Starting
30% Nominal speed reached
Not Ready
Main
Measurement
Stop request
Running
Loaded
RPM = 0 or any other shutdown condition
RPM = 0 or any other shutdown condition
Cooling time elapsed
Cooling
Stop
RPM = 0 or any other shutdown condition
Action PRESTART on,
Prestart time counter started
Next State
PRESTART
Stop (Stop fail)
Not Ready
Ready
STARTER on, FUEL SOLENOID on,
MaxCrank time counter started
STARTER off, PRESTART off
STARTER off, PRESTART off
Cranking
STARTER off, FUEL SOLENOID off,
STOP SOLENOID on,
CrankFail pause timer started
STARTER off, PRESTART off
STARTER on, FUEL SOLENOID on,
STOP SOLENOID off,
MaxCrank time counter started
READY TO LOAD on,
MaxStabTime counter started
READY TO LOAD off,
Cooling time timer started
READY TO LOAD off,
FUEL SOLENOID off
FUEL SOLENOID off, STOP SOLENOID
on, READY TO LOAD off
FUEL SOLENOID off,
STOP SOLENOID on
FUEL SOLENOID off,
STOP SOLENOID on
READY TO LOAD on
Crank pause
Starting
Cranking
Shutdown (Start fail)
Cranking
Running
Cooling
Shutdown
Shutdown
Stop
Shutdown
Start request
Running
RPM = 0, Oil pressure not detected, Vgen < 10V
Ready
60 sec. Elapsed
Stop (Stop fail)
Some output conditions are optional and may require additional programming of field connection.
See appropriate wiring diagram.
Adjustment Menu
The adjustment menu, Figure 4-3 allows setting engine and generator values such as
Passwords, Pre−Start Time, Crank Time, Cool Down Time, Alarm Conditions and values,
Shutdown Conditions and values, power transfer settings, etc.
Figure 4-3 Adjustment Menu
> ENGINE BASIC
ENGINE PROT
GEN BASIC
GEN PROTECT
Use and to move the cursor to the desired parameter.
Press ENTER to select the parameter group.
Press PAGE to move to the next page of menu items.
Alarm List
Shows the active alarms and warnings. Press fault reset to clear the list.
ECU Alarm List
Shows the active ECU (engine control unit) fault codes. Press ENTER + fault reset to clear the
list.
MN2408
Operation 4-3
Alarms
Following alarms are available:
Sensor fail (FLS) see Table 4-3
Sensor fail is detected when measured value is 6% out of selected sensor characteristic.
Sensor fail is indicated by ##### symbol instead measured value.
Warning (WRN) see Table 4-3
When warning comes up, only alarm outputs and common warning output are closed.
Shut down (SD) see Table 4-3
When the shut−down alarm comes up, InteliLite opens outputs GCB CLOSE/OPEN, FUEL
SOLENOID, STARTER and PRESTART to stop the engine immediately. Alarm outputs and
common shutdown output are closed. Active or not reset protection disables start.
Table 4-3 Possible Warnings
Events specification
Wrn Oil press
Sd Oil press
Wrn Water temp
Sd Water temp
Wrn Wtemp Low
Battery voltage <, >
Battery flat
Start fail
Vgen <, >
Vgen unbl
Fgen <, >
Igen unbl
Overload
RPM over
RPM under
PickupFault
Stop fail
WrnServiceTime
Emergency Stop
ECU Common Warning
ECU Shutdown
4-4 Operation
Protection type
WRN
SD
WRN
SD
WRN
WRN
SD
SD
SD
SD
SD
SD
SD
SD
SD
SD
SD
WRN
SD
WRN
SD
MN2408
Inputs and Outputs
Any Binary input or output can be configured to any controller terminal Inputs are BI1 − BI7,
Outputs are BO1 − BO7) or changed to different function by LiteEdit software.
There is fixed 1 sec delay when any binary input is configured as protection.
Table 4-4 Binary Inputs
Alarm
Alarm type Warning or Shut down
Alarm active All the time, or Engine running only
External request for engine run. AUT mode only.
If the input is opened, shut down is immediately activated. Input is
inverted (normally closed).
External request for engine run. AUT mode only.
Rem start/stop
Emergency stop
Rem start/stop
Table 4-5 Binary outputs
Starter (relay output)
Fuel solenoid (relay output)
Prestart
Common Sd
MN2408
The closed relay energizes the starter motor.
The relay opens if:
The firing speed is reached or
Maximum time of cranking is exceeded or
Request to stop occurs
Closed output opens the fuel solenoid and enables the engine start.
The output opens if:
Emergency stop occurs or
Cooled gen−set is stopped or
In pause between repeated starts
Output is closed prior to the engine start (Prestart) and opens when
START RPM speed is reached.
During repeated crank attempts the output is closed too.
The output could be used for pre−glow, pre−heat or prelubrication.
Output closes when any shut−down alarm appears.
The output opens, if alarm is not active and FAULT RESET is
pressed.
Used for shunt trip.
Operation 4-5
Analog Inputs
Three analog inputs for resistive sensor 0 to 2400 ohms measuring are available on the
controller. Use LiteEdit software to modify configuration.
The Analog inputs values assignment (AI1 = Oil press, AI2 = Water temp, AI3 = Fuel level) is
fixed. It is possible to configure on each Analog input:
Reading from Analog inputs or from Engine Control Unit via CAN bus (J1939)
Sensor characteristics − from the list,
Value dimension (e.g. psi − bars, °F − °C, % − l)
Number of decimal points (0, 1, 2, ...).
Note: Corresponding Analog input terminal is dead when reading is switched to ECU.
All values from ECU shall show ####, but no alarm is displayed when CAN communication
is interrupted.
Warning and shut−down limits are adjusted in Engine protection group.
Table 4-6 Analog Inputs
AI1 Oil press
AI2 Water temp
AI3 Fuel level
Oil pressure analog input. Default VDO sensor in range 0 to 145 psi.
Water temperature analog input. Default VDO sensor in range 32 to 212°F
Fuel level analog input. Default VDO sensor 0−180R = 0−100%.
Set points
Table 4-7 Basic Setpoints
EnterPassword
ChangePassword
Gen−set name
Nomin power(3ph)
Nomin power(1ph)
CT Ratio
PT ratio
Nominal freq
Gear teeth
Nominal RPM
FLTRESGOTOMAN
DispBackLightTO
Mode IL [ OFF, MAN, AUT ]
RS232 mode
[Standard/Modbus ]
Num rings AA
4-6 Operation
Password is a four−digit number. Password enables change of relevant
protected set points Use ⇑ or ⇓ keys to set and ENTER key to enter the
password.
Use ⇑ or ⇓ keys to set and ENTER key to change the password.
User defined name, used for identification at remote phone or mobile
connection. Gen−set name is max 14 characters long and have to be
entered using LiteEdit software.
Nominal power of the generator in three phases connection.
Step: 1 kW; Range: 1 − 3000 kW
Nominal power of the generator in single−phase connection.
Step: 1 kW; Range: 1 − 3000 kW
Gen−set phases current transformers ratio.
Step: 1 A; Range: 1 − 5000 A / 5A
Gen−set potential transformers ratio.
Step: 0,1 V / V; Range: 0,1 − 500,0 V / V
Nominal generator frequency (usually 50 or 60 Hz )
Step: 1Hz; Range: 45 − 65 Hz
Number of teeth on the engine gear for the pick−up. Set to zero, if no
pick−up is used. Engine speed is counted from the generator frequency.
Step: 1; Range: 0 − 500
Note: Generator frequency can be used only when generator voltage
(min 5V) is present before reaching of the firing speed
(Starting RPM) after start.
Nominal engine speed. Step: 1RPM; Range: 100 − 4000 RPM.
DISABLED: Controller stays in AUT mode after Fault reset .
ENABLED: Automatic switch from AUT (or TEST) to MAN mode after
Fault reset to avoid automatic engine start. This function is active for Shut
down protection only.
Timeout after which the display backlight is switched off.
Step: 1 min Range: 0 − 60 min
Default value: 0 = the display lights all the time
Equivalent to Controller mode changes by MODE or MODE buttons.
Note: Controller Mode change can be separately password protected.
Communication protocol switch.
Standard: LiteEdit communication protocol. Modbus: Modbus protocol.
Note: For detail description see chapter Modbus protocol.
Number of rings prior to open modem connection. Step: 1; Range: 1 − 30
Note: NumberRings AA change is not activated immediately. It is activated
after controller is switched on or when modem is connected to controller.
MN2408
Table 4-8 Engine Setpoints
Start RPM
Starting POil
Prestart time
MaxCrank time
CrnkFail pause
Crank attemps
Idle time
GCB CloseDelay
Stabil time
MinStpValvTime
“Firing” speed when iL controller stops cranking (starter goes OFF).
Step: 1% of nominal RPM; Range: 5 − 50 %
When reached controller stops cranking (starter goes OFF).
Step: 0,1 psi; Range: −100 − 10000
Note: There are three conditions for stop cranking: Starting RPM,
StartingPOil and D+ (when enabled). Starter goes off when any
of these conditions is valid.
Time of closing of the PRE−START output prior to the engine start.
Set to zero if you want to leave the output PRE−START open.
Step: 1s; Range: 0 − 600 s
Maximum time limit of cranking. Step: 1s; Range: 1 − 60 s
Pause between crank attempts. Step: 1s; Range: 5 − 60 s
Max number of crank attempts. Step: 1; Range: 1 − 10
Idle time delay starts when RPM exceeds Start RPM . Start fail is
detected when during Idle state RPM decreases below 2.
During the Idle time timer running the binary output IDLE/NOMINAL is
opened, when it elapses the IDLE/NOMINAL output closes.
Binary output IDLE/NOMINAL opens during Cooling period again.
Step: 1 s; Range: 0 − 600 s
Note: If the IDLE function not supported on the governor, set the Idle time
nevertheless to minimum 5s to avoid Underspeed possibly
caused by instability of the engine short after start.
GCB can be closed earliest GCB CloseDelay after Stabil time when all
electric values are in overunder voltage and over−under frequency limits.
Step: 1 s; Range: 0 − 300 s
Generator Nominal voltage is detected during genset start after starter is
switched off and Idle time elapses. Electric generator protections are
active since detection. Step: 1 s; Range: 0 − 300 s
Binary output Stop solenoid closes when stop sequence begins and
closes at least for MinStpValvTime. Example MinStpValvTime = 20 sec.
a) When engine stops (RPM=0) in 10 seconds, Binary output Stop
solenoid still stays closed for 10 sec.
b) When engine stops in 30 seconds, Binary output Stop solenoid opens
10 seconds after RPM=0 and Vg =0 and Oil pressure = 0. Those 10 sec is
fix time for safe stop. Step: 1s; Range: 0 − 180 s
Note: Stop of engine is detected when all following conditions are met:
RPM =0, Oil pressure < StartingPOil and Generator voltage < 10 VAC.
Stop fail is detected when is difference between those conditions, e.g
RPM=O and Generator voltage > 10V.
Start RPM
RPM
RPM = 2
Idle Function
RPM
B O S tarter
B O IDLE /RA T E D
Idle tim e
Start Fail
M in stab tim e
Electric protections
activ e
Stabil Time
MN2408
Operation 4-7
Table 4-8 Engine Setpoints Continued
Cooling time
AfterCoolTime
CoolingSpeed
D+ function
Runtime of the unloaded gen−set to cool the engine before stop.
Step: 1s; Range: 0 − 3600 s
Runtime of engine after cooling pump. Binary output Cooling pump is
closed when the engine starts and opens AfterCool time delayed after
gen−set stops. Step: 1s Range: 0 − 3600s
Selects the function of the Binary output IDLE/NOMINAL during engine
Cooling state.
NOMINAL : Cooling is executed at Nominal speed and generator
protections are active.
IDLE: Cooling is executed at Idle speed and generator protections are
switched off.
Hint: Binary output IDLE/NOMINAL must be configured and connected to
speed governor. Engine Idle speed must be adjusted on speed governor.
ENABLED: The D+ terminal is used for both functions “running engine”
detection and charge fail detection.
CHRGFAIL: The D+ terminal is used for charge fail detection only
DISABLED: The D+ terminal is not used.
Note: Magnetization current is independent of this setpoint value.
Table 4-9 Engine Protect Setpoints
ECUFreqSelect
ECU Speed Adjust
WTBF Accept RPM
Eng prot del
Horn timeout
Overspeed
Wrn Oil press
Sd Oil press
Oil press del
Sd Water temp
Wrn Water temp
Wrn Wtemp low
Water temp Low del
Water temp del
Batt overvolt
Batt undervolt
Batt volt del
NextServTime
4-8 Operation
This setpoint should be used only for Volvo and Scania engines.
Adjusts engine speed using CAN bus. Nominal speed=50%.
The WtBfAcceptRPM delay setpoint will start to count down since
cranking. Controller waits before communicating with the ECU for this
time. This is because the JD engine passes some erroneous RPM signals
during the first 500ms. Step: 0,1s Range: 0 − 3s
During the start of the gen−set, some engine protections have to be
blocked (e.g. Oil pressure). The protections are unblocked after the
Protection del time. The time starts after reaching Start RPM.
Step: 1s; Range: 0 − 300 s
Max time limit of horn sounding. Set to zero if you want to leave the output
HORN open. Step: 1s; Range: 0 − 600 s
Threshold for over speed protection.
Step: 1% of nominal RPM; Range: 100 − 150%
Warning threshold level for ANALOG INPUT 1.
Step: 1 psi; Range: Sd Oil press − 10000
Shutdown threshold level for ANALOG INPUT 1.
Step: 1 psi; Range: −100 − Wrn Oil press
Delay for ANALOG INPUT 1. Step: 1 s; Range: 0 − 180
Warning threshold level for ANALOG INPUT 2.
Step: 1 °C; Range: Wrn Wtemp − 10000
Warning threshold level for ANALOG INPUT 2.
Step: 1 °F; Range: Wrn Wtemp low − Sd Water temp
Warning threshold level for low value on ANALOG INPUT 2.
Step: 1 °F; Range: −100 − Wrn Water temp
Delay for ANALOG INPUT 2 Wrn Wtemp low. Step: 1 s; Range:1−180 s
Delay for ANALOG INPUT 2 alarm. Step: 1 s; Range: 0 − 180 s
Warning threshold for high battery voltage.
Step: 0,1 V; Range: Batt undervolt − 40V
Warning threshold for low battery voltage.
Step: 0,1 V; Range: 8V − Batt overvolt
Delay for low battery voltage alarm. Step: 1s; Range: 0 − 600 s
Counts down when engine running. If reaches zero, an alarm appears.
Step: 1h; Range: 0 −65535h
MN2408
Table 4-10 Generator Protect Setpoints
Overload
Overload Wrn
Overload del
Ishort
2Inom del
Curr unbal
Curr unbal del
Gen >V
Gen >V Wrn
Gen <V Wrn
Gen <V
Gen V del
Volt unbal
Volt unbal del
Gen >f
Gen >f Wrn
Gen <f
Gen <f Wrn
Gen f del
MN2408
Threshold for generator overload (in % of Nominal power)
Step: 1% of Nominal power; Range: 0 − 200%
Threshold for generator overload warning (in % of Nominal power)
Step: 1% of Nominal power; Range: 0 − 200%
Delay for generator overload alarm. Step: 0.1s; Range: 0 − 60.0 s
Shutdown occurs when short circuit limit Ishort limit is reached.
Step: 1 % of Nominal current; Range: 100 − 500 %
IDMT curve shape selection. 2Inom del is Reaction time of IDMT
protection for 200% overcurrent Igen = 2* Nominal current.
Step: 0,1 s; Range: 0,1 − 20 s
IDMT is “very inverse” generator over current protection. Reaction time is
not constant but depends on generator over current level according
following formula. Reaction time is limited up to 900 sec = 15 minutes.
IDMT protection is not active for Reaction time values longer than 15
minutes.
2lnom del * Nomin current
Reaction Time +
lgen * Nomin current
Threshold for generator current asymmetry (unbalance).
Step: 1% of Nominal current; Range: 1 − 100% of Nominal current
Delay for generator current asymmetry. Step: 0.1 s; Range: 0 − 60.0 s
Shutdown level for generator overvoltage. All three phases are checked.
Maximum out of three is used.
Step: 1% of Nominal voltage; Range: Gen >V Wrn −200%
Warning level for generator overvoltage. All three phases are checked.
Maximum out of three is used.
Step: 1% of Nominal voltage; Range: Gen <V Wrn − Gen >V
Warning level for generator under voltage. All three phases are checked.
Minimum out of three is used.
Step: 1% of Nominal voltage; Range: Gen <V − Gen >V Wrn
Shutdown level for generator under voltage. All three phases are checked.
Minimum out of three is used.
Step: 1% of Nominal voltage; Range: 0% − Gen <V Wrn
Delay for generator under voltage and over voltage alarm
Step: 0.1s; Range: 0 − 60 s
Threshold for generator voltage unbalance alarm.
Step: 1% of Nominal voltage; Range: 0 − 100% of Nominal voltage
Delay for generator voltage unbalance alarm.
Step: 0.1s; Range: 0 − 60.0 s
Shutdown level for generator over frequency.
Step: 0.1% of Nominal frequency; Range: Gen > Wrn − 200.0%
Warning level for generator over frequency.
Step: 0.1% of Nominal frequency; Range: Gen <f Wrn − Gen >V
Shutdown level for generator under frequency.
Step: 0.1% of Nominal frequency; Range: 0.0 − Gen <f Wrn
Warning level for generator under frequency.
Step: 0.1% of Nominal frequency; Range: Gen <f − Gen >f Wrn
Delay for generator under frequency and over frequency alarm.
Step: 0.1s; Range: 0 − 60.0 s
Operation 4-9
Table 4-11 Sensor Spec Setpoints
Calibr AI1,AI2, AI3
AnOut−kW/20mA
Calibrating constant to adjust the measured value of IL analog inputs.
Physical dimension of calibrating constant is corresponding to Analog
input. Step: 1; Range: −1000 to +1000
Conversion coefficient from gen−set power to iG−IOM or PTM analog
output. Step: 1; Range: 1 to 32000
Table 4-12 IOM/PTM Module Setpoints
AnlInIOM1 lev1
AnlInIOM1 lev2
AnlInIOM1 del
AnlInIOM2 lev1
AnlInIOM2 lev2
AnlInIOM2 del
AnlInIOM3 lev1
AnlInIOM3 lev2
AnlInIOM3 del
AnlInIOM4 lev1
AnlInIOM4 lev2
AnlInIOM4 del
Calibr AInIOM 1..4
4-10 Operation
The level for IOM ANALOG INPUT 1 alarm detection.
Step: 1; Range: −100 to +10000
The level for IOM ANALOG INPUT 1 alarm detection.
Step: 1; Range: −100 to+10000
Delay for IOM ANALOG INPUT 1 alarm. Step: 1 s; Range: 0 − 180 s
The level for IOM ANALOG INPUT 2 alarm detection.
Step: 1; Range: −100 to +10000
The level for IOM ANALOG INPUT 2 alarm detection.
Step: 1; Range: −100 to +10000
Delay for IOM ANALOG INPUT 2 alarm. Step: 1 s; Range: 0 − 180 s
The level for IOM ANALOG INPUT 3 alarm detection.
Step: 1; Range: −100 to +10000
The level for IOM ANALOG INPUT 3 alarm detection.
Step: 1; Range: −100 to +10000
Delay for IOM ANALOG INPUT 3 alarm.
Step: 1 s; Range: 0 − 180 s
The level for IOM ANALOG INPUT 4 alarm detection.
Step: 1; Range: −100 to +10000
The level for IOM ANALOG INPUT 4 alarm detection.
Step: 1; Range: −100 to +10000
Delay for IOM ANALOG INPUT 4 alarm. Step: 1 s; Range: 0 − 180 s
The protection of IOM/PTM inputs is activated by over crossing the limits.
Calibrating constant to adjust the measured value of IOM/PTM analog
inputs. Physical dimension of calibrating constant is corresponding to
Analog input. Step: 1; Range: −1000 to +1000
MN2408
Digital Engine Controller Description EM0046A45 (MRS19) Continued
Figure 4-4 Controller Connection Diagram
LOAD
GENERATOR
ENGINE
L1
G
L3
N
FUEL SOLENOID
PE
REMOTE SSTART/STOP
−
Remote
Start
+
BATTERY
START ER
EMERGENCY STOP
EC
U
L2
MN2408
ALARM
PRESTART
FUEL SO LENOID
STARTER
GENSET Control
Operation 4-11
4-12 Operation
MN2408
Section 5
Troubleshooting and Maintenance
Maintenance
MN2408
This manual contains only very minimal engine maintenance instructions. Refer to the engine
manufacturer’s owner’s manual for specific engine maintenance instructions for your generator
set. Any maintenance 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.
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 may not
keep perfect time when powered by a generator.
1. Clean the generator set and remove any and all dust, dirt, or other foreign material.
2. Inspect and clean the cooling air intake and exhaust louvers of the generator end.
Make sure they are clean. Remove dirt or any buildup that may restrict the cooling air
flow.
3. Clean the generator set and its components with a damp cloth or sponge.
Never use a water hose or pressure washer as this may damage electrical
components.
4. Inspect and replace any control panel components that are broken or not working
properly (receptacles, circuit breakers, switches, etc.)
Troubleshooting and Maintenance 5-1
Problems and Solutions
Some of the more common problems are listed in Table 5-1. This information is intended to be a
check or verification that simple causes can be located and fixed. It is not an exhaustive “how to”
for all types of problems. Procedures that require in depth knowledge or skills (like flashing the
field) should be referred to a qualified generator service center.
Table 5-1 General Troubleshooting Guide
Problem
Engine cranks but will not start
Possible Cause
No fuel.
Low Oil Level
Restricted air flow.
No spark.
Engine will not crank (electric start)
Dead battery.
Engine starts but will not run smoothly
Emergency Stop LED is ON
Fuel or ignition problem
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.
Remove battery and trickle charge or replace with new battery.
Never Jump Start.
Reset controller after an Emergency Stop.
Refer to engine manual. Verify fuel selection jumper setting.
Engine overheats
Excessive load
Debris or dirt buildup on engine
Remove one or more electrical loads.
Remove debris. Clean engine surfaces to allow cooling.
No output voltage
Ciruit Breaker tripped or failed.
Internal failure of Alternator
Reset circuit breaker or replace if required.
Contact service.
Output voltage varies
Irregular speed (fixed speed mode)
Fluctuating speed (fixed speed mode)
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.
Loose terminal or load connections
Low output voltage
Low engine speed
Excessive load
High resistance connections connections will be warm or hot
Internal failure of Alternator
Low power factor
Verify engine RPM.
Check engine for malfunction or system for overload. Reduce load.
Verify all connections and terminal tighness.
High output voltage
Excessive speed (fixed speed mode)
Check engine for malfunction. Verify engine RPM.
Electrical shock when frame is touched
Static charge.
Grounded armature or field coil.
Ground generator frame at local reference ground (see Section 3).
Contact service.
Mechanical noise
Internal failure of Alternator
Loose or misaligned coupling
Contact service.
Tighten; align coupling and alternator shaft to engine shaft.
5-2 Troubleshooting and Maintenance
Contact service.
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.
MN2408
Table 5-2 Troubleshooting Guide (Digital Controller Only)
Problem
Possible Cause
Remedy
Controller does not power up even with
correct DC power applied
Wiring Mistake
Check that there are no wiring errors/short circuits connected to the
controller.
Check breaker on the Control Panel.
Check Fuses on Control Panel.
Overload Condition
LCD Display cannot be viewed
Improper Supply Voltage
Improper contrast adjustment
Check DC supply voltage at terminals B+ & B- (10-30VDC).
Adjust LCD contrast for best display (see Section 4).
Controller cannot be “Reset"
Engine not stopped
Controller not in OFF mode
Verify the engine is at a complete stop before trying to reset.
Set the controller to the OFF mode before trying to reset.
No “RUN" output signal
“Shutdown Faults" not reset
Engine speed not detected at cranking
All shutdown faults must be reset (red shutdown LED must be off).
Engine speed signal must be detected (speed signal green LED on)
during cranking if the “run-output fail safe" feature is enabled. Verify
correct magnetic pickup signal at cranking (2.0VAC min. during
cranking).
Overspeed shutdown occurs at normal
speed
Controller programmed values are wrong
or controller has failed.
Verify the controller programmed values are correct for the number
of flywheel teeth, nominal RPM, and overspeed setpoint
percentage. Replace controller if failed.
Voltage or current metering is incorrect
Controller programmed values are wrong
Verify the controller programmed values are correct for the voltage
sensing PT ratio and/or current sensing CT ratio.
Verify that the battery supply DC negative conductor is properly
grounded to the engine block (i.e. to a common ground point).
Verify that the controller's analog input is properly calibrated.
Verify the voltage sensing wiring connection to the controller
matches power distribution type.
Note: standard direct voltage connection requires that the
generators neutral is solidly grounded.
Ground is missing
Analog input needs to be calibrated
Voltage sensing wiring mistake
Engine temperature or oil pressure
display is incorrect
Analog input needs to be calibrated
Failed engine sensor
Ground is missing
Engine temperature or oil pressure
displays 9999
OR
Engine alarms are ON for high engine
temperature or low oil pressure when
engine is operating properly
Sending unit is disconnected (open
circuit)
Defective sending unit
Keypad Buttons (switches) do not
operate.
Keypad not connected to controller
MN2408
Wrong Temp or pressure calibration
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 AI1 and AI2
(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.
Troubleshooting and Maintenance 5-3
Note: See Engine Controller manual for additional information.
Table 5-3 Troubleshooting Guide (Analog Controller Only)
Problem
Controller cannot be “Reset"
Possible Cause
Engine not stopped
Controller not in OFF mode
Remedy
Verify the engine is at a complete stop before trying to reset.
Set the controller to the OFF mode before trying to reset.
Engine alarms are ON for high engine
temperature or low oil pressure when
engine is operating properly
Sending unit is disconnected (open
circuit)
Defective sending unit
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.
Overspeed shutdown occurs at normal
speed
Controller has failed or input from
Magnetic pickup is incorrect.
Verify the adjustments. Replace controller if failed.
Service
Service for your generator can be obtained from to a qualified generator service center.
Please have the following information available and ready:
The model number and serial number of the generator set.
A complete and accurate description of the problem.
Parts
Parts for your generator can be obtained from to a qualified generator service center.
Please have the following information available and ready:
The model number and serial number of the generator set.
A complete and accurate description of the part (part number if known).
Note: Engine parts can usually be obtained from a local distributor by using the information in the
engine manufacturer’s owner’s manual.
5-4 Troubleshooting and Maintenance
MN2408
Appendix A
Options & Accessories
Battery Charger BTCGR10A Battery Charger − 12 Volt /10 Amp Float. Includes terminal strip for AC input power
and DC output. UL Listed.
Figure A-1 Recommended Mounting Locations
GLC35 Battery Charger
GLC45−105 Battery Charger
Mounting Location
Mounting Location
Frame
Frame
Battery
Tray
BTCGR10A
BTCGR10A
Battery
Tray
Installation Considerations:
Shore power must be available (120VAC or 240VAC) to power the battery charger and other
components that may be installed). Shore power outlets or wiring must be located close to
Battery Charger.
BTCGR10A Charger (refer to charger manual for specific details)
1. Mount charger, refer to Figure A-1 to determine suggested location.
2. Connect charger negative wire (Black) to battery “−” negative terminal.
3. Connect charger positive wire (Red) to battery “+” positive terminal.
4. Connect charger AC power cord to shore power outlet.
MN2408
Options & Accessories A-1
Battery Heaters Battery Heater (BTHTR81) − 120 Volt / 80 Watt. Includes 6 ft power cord.
Installation Considerations:
Shore power must be available (120VAC or 240VAC) to power the battery heater and other
components that may be installed). Shore power outlets or wiring must be located close to
battery heater.
Figure A-2 Battery Heating Pad Installation
BTHTR81 Heater
1. Carefully disconnect the Negative battery terminal from the battery.
2. Carefully disconnect the Positive battery terminal from the battery.
3. Remove battery hold down bracket.
4. Remove battery.
5. Install Heating Pad in battery tray, refer to Figure A-2. The ”A” and ”B” dimensions
should match the battery tray.
6. Install battery on top of Heating Pad.
7. Install battery hold down bracket.
8. Carefully install the Positive battery terminal to the battery.
9. Carefully install the Negative battery terminal to the battery.
10. Connect the AC power cord to shore power outlet.
Engine Block Heater
Installation Considerations:
Shore power must be available (120VAC or 240VAC) to power the block heater and other
components that may be installed). Shore power or wiring must be located close to block heater.
Figure A-3
Block Heater (refer to block heater manual for specific details)
1. The block heater is mounted as shown in Figure A-3.
2. Connect the AC power cord to shore power outlet.
A-2 Series GLC
MN2408
Silencers
Refer to enclosure procedure to install silencer when enclosure is present.
Industrial Silencer for Open Skid Mount Units − Provides silenced exhaust for up to 11 dBA
sound attenuation. Kit includes engine adapters, flex pipe, clamps, silencer, and rain cap.
Critical Silencer for Open Skid Mount Units − Provides silenced exhaust for up to 18 dBA sound
attenuation. Kit includes engine adapters, flex pipe, clamps, silencer, and rain cap.
Figure A-4
Straight Pipe
Rain Cap
Clamp
Exhaust Flex
Straight Pipe
90° Elbow
Clamp
Clamp
Straight Pipe
Muffler
10-35kW
Muffler
45° Elbow
90° Elbow
Rain Cap
45° Elbow
90° Elbow
Exhaust Flex
Muffler
45-75kW
Muffler
Clamp
Reducer
Clamp
90° Elbow
Gasket
Gasket
Rain Cap
Catalyst
Exhaust Flex
105-130kW
Silencer (refer to Figure A-4 for specific details)
1. Attach the Silencer to the Exhaust Output of the engine, refer to Figure B−4.
2. Use correct size clamp to attach extension pipe to Exhaust Output pipe from engine.
3. Be sure the Extension pipe fits securely over Exhaust Output pipe so that no exhaust
leaks can occur.
MN2408
Options & Accessories A-3
Flexible Fuel Lines
A flexible fuel line can be installed at the fuel pressure regulator to make connection to the fuel
main shutoff valve easier. Either 1−1/4” or 2” fittings may be specified.
Figure A-5 Fuel Strainer and Flex Fuel Line Connections
Fuel Solenoid Valve
GLCFFL1 3/4" NPT Male fittings, 12" long
GLCFFL2 1 - 1/4" NPT Male fittings, 18" long
GLCFFL3 2" NPT Male fittings, 12" long
GLCFS1 3/4" NPT Fuel Strainer female Inlet, male outlet.
GLCFS3 2" NPT Fuel Strainer female Inlet, male outlet.
Fuel Flex Line
Fuel Strainer
Installation: Use appropriate thread sealer as required by plumbing codes.
1. Thread Fuel strainer onto NPT close pipe nipple.
3. Thread Flex Fuel Line into Fuel Strainer input.
4. Connect other end of Flex Fuel Line to site fuel supply pipe as required by plumbing
codes.
E−Stop
E−Stop Switch Kit − Mounts to an Enclosure remote from the Genset to provide easy access to
shut down engine with the press of a button. Connects to Remote Run Terminals on genset.
Must be adapted for remote mounting when used with open skid mount units.
Figure A-6
Installation:
1.
2.
3.
4.
A-4 Series GLC
Locate and drill 4 holes shown in Figure A-6.
Mount the E−Stop Switch box to the enclosure,
Install the E−Stop assembly into the E−Stop Switch box enclosure.
Connect the E−Stop Switch cable into the connections for GLCESS.
MN2408
Remote Annunciators
Remote Annunciator provides remote annunciation of faults and generator status. Individual fault
conditions are remotely monitored using both visual LED lights & audible alarm annunciation.
Lamp test and alarm horn silence pushbuttons are provided. Each fault is individually
programmable for audible horn operation and alarm labels are field configurable.
Requires 12VDC 100mA power supply to operate (engine starting battery can be power supply).”
Maximum distance from the controller is 656ft(200m).
For GLC all CAN Address jumpers are removed to select address #1.
Figure A-7 Intelilite Remote Annunciator
AB
DC power
120R *
+ supply
CAN bus Connection (200m Maximum)
* Only one 120R resistor can be connected
to the CAN bus (If it is the last device on the
network (termination).
MN2408
Options & Accessories A-5
Radiator Duct Flange
Radiator Duct Flange for Open Skid Mount − Provides easy connection to air ducting to carry
away hot air from engine radiator. Duct flange mounts to front of engine radiator.
Add 3” to length.
Figure A-8
Frame
B
Optional Radiator
Duct Flange
Radiator/Fan As­
sembly
Optional Radiator
Duct Flange
A
C
Frame
Frame
Table A-1 Mounting Dimensions
Generator
IGLC25
IGLC35
IGLC45-75
IGLC105
IGLC130
A-6 Series GLC
A
3.00
3.00
3.00
3.00
3.00
B
22.00
26.00
26.38
26.38
26.63
C
20.00
26.70
29.50
29.50
29.50
MN2408
Appendix B
Series GLC Information & Wiring Diagrams
GLC Circuit Breaker Wire Size (Line Side)
Circuit Breaker Size
Wire Size AWG or kcmil
Qty /Phase
Type of Conductor
Ampacity @ 600VAC
20
30
40
50
60
70
80
90
100
110
125
150
175
200
225
250
300
350
400
450
500
600
700
800
10
10
8
8
6
6
4
4
2
2
1
1
2/0
4/0
4/0
4/0
300
400
500
4/0
4/0
300
400
500
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
THHN, THWN, XHHW
40
40
55
55
75
75
95
95
130
130
150
150
195
260
260
260
320
380
430
520
520
640
760
860
Wiring Diagrams Wiring diagrams for these generators are contained on the following pages of this appendix.
MN2408
Series GLC B-1
Figure B-9 Enclosure Grounding
B-2 Series GLC
MN2408
Figure B-10 Customer Interface Connection Diagram
MN2408
Series GLC B-3
Figure B-11 Single Phase Diagram
B-4 Series GLC
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Figure B-12 Three Phase Diagram
MN2408
Series GLC B-5
Figure B-13 DC Schematic for 10−25kW
MUST USE UL APPROVED WIRE
B-6 Series GLC
MN2408
Figure B-14 DC Schematic for 10−25kW Continued
MN2408
Series GLC B-7
Figure B-15 DC Schematic for 35−130kW
MUST USE UL APPROVED WIRE
B-8 Series GLC
MN2408
Figure B-16 DC Schematic for 35−130kW Continued
MN2408
Series GLC B-9
Figure B-17
B-10 Series GLC
MN2408
Figure B-18
MN2408
Series GLC B-11
Figure B-19
B-12 Series GLC
MN2408
Figure B-20
MN2408
Series GLC B-13
Figure B-21
B-14 Series GLC
MN2408
Figure B-22
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Series GLC B-15
Figure B-23
B-16 Series GLC
MN2408
Baldor District Offices
WARNING:
CALIFORNIA PROPOSITION 65 WARNING:
Engine exhaust from this product contains chemicals known
to the state of California to cause cancer, birth defects and
other reproductive harm.
WARNING:
CALIFORNIA PROPOSITION 65 WARNING:
Battery posts, terminals and related accessories are known to
the state of California to cause cancer, birth defects and other
reproductive harm.
World Headquarters
P.O. Box 2400 Fort Smith, AR 72902−2400 USA Ph: (1) 479.646.4711, Fax: (1) 479.648.5792
www.baldor.com
© Baldor Electric Company
MN2408
All Rights Reserved. Printed in USA
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