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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.
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.
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.
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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.
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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.
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Warning Statements Continued Maintenance WARNING: Disconnect the battery’s ground terminal before working in the vicinity of the battery or battery wires. Contact with the battery can result in electrical shock when a tool accidently touches the positive battery terminal or wire. The risk of such shock is reduced when the ground lead is removed during installation and maintenance.
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Caution Statements Caution: Avoid installing the generator set beside heat generating equipment, or directly below water or steam pipes or in the vicinity of corrosive substances or vapors, metal particles and dust. Heat can cause engine problems to develop and unwanted substances can cause rust or generator failure over time.
Limited Warranty Baldor Generators will replace or repair free of charge any part or parts of the generator of their manufacture that are defective in workmanship and materials for a period of time as set forth in the Warranty Period chart below.
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.
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: Maintain the building at a satisfactory temperature year round (to meet applicable codes).
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.
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Steel spring isolators are a very effective and commonly used. Steel spring isolators are typically 95–98% efficient (reduces the transmitted vibration 95–98%) while a pad type can be 75–88% efficient. Spring isolators also level the genset sub–base in the event the foundation pad is not perfectly level. Spring steel isolators offer the highest level of vibration isolation, however higher levels of vibration (although not detrimental) may be seen on some areas of the genset when mounted on steel springs, due to the (almost) total isolation from the foundation.
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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).
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Table 2-1 Approximate Load Bearing Capacities of Various Soil Types Safe Bearing Capacity Soil Type Soil Type lb per ft kilo Pascals Hard Rock – Granite etc. 50,000 – 200,000 2,395 – 9,576 Medium Rock – Shale etc. 20,000 – 30,000 958 –...
Marine and Mining Safety Administration (MSA) codes may require water cooled manifolds in all genset installations. If you are in doubt on your particular application, consult your Baldor Distributor. Exhaust Gas Restriction The maximum allowable back pressure, or system restriction, is 3 inches of mercury. If this back pressure is exceeded, the air–fuel ratio is reduced due to incomplete scavenging of the cylinders,...
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.
Cooling System Cooling System Checklist Have noise considerations been taken into account? Has system piping been properly sized? Has system been properly protected from freeze up and corrosion? Have standby equipment heaters been specified? Have all electrically driven devices been connected to load side of EPS connection points? Have system drain valves and air eliminators been installed? The system consists of the cooling medium which is generally a solution of water and ethylene glycol, a method of rejecting engine produced heat, and a means to transport cooling medium...
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The remote radiator may be mounted either vertically or horizontally. In general, the radiator will have an electric fan to provide cooling air and may be able to utilize the engine mounted coolant pump to provide coolant flow. The piping system friction and head loss between engine and radiator must be calculated and not exceed the capacity of the engine pump.
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A typical example is shown in Figure 2-12. The design of hot well tanks and piping systems is somewhat complex. Your authorized Baldor Distributor has experience in the design and installation of hot well systems. Consult your Baldor Distributor if the static head of the coolant system in your genset application exceeds this criteria and requires a hot well system.
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Figure 2-11 Valves & Fittings and Fluid Flow in Pipe Figure 2-12 Hot Well Installation 2-14 General Information MN2408...
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The heat exchanger cooled system may be used with a cooling tower. Baldor Gensets are available with heat exchangers sized and mounted on the engine by the factory. If a heat exchanger cooled system is required, specify with order.
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A solution can be increased to 65%. Do not exceed 65% as freeze protection begins to diminish at 65%. It is recommended that the consultant specify Baldor supplied DCA and water filters, and Baldor antifreeze.
Air System Air System Checklist A. Air inlet faces the direction of prevailing winds. B. Air outlet does not face noise sensitive areas without noise attenuating devices. C. All heat loads have been taken into consideration in sizing air flow. D.
Figure 2-15 Radiator Cooling with Ducted Air Handling Other Engine Cooling Systems Remote radiator and heat exchanger cooled engine cooling systems will not have an engine driven fan. As a result, the consultant must provide a means of supplying air to the room, and exhausting it.
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...
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.
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.
Section 3 Receiving & Installation Receiving & Inspection When you receive your generator, there are several things you should do immediately. Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered your system. Verify that the part number of the system you received is the same as the part number listed on your purchase order.
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WARNING: An open bottom stationary engine generator set must be installed over noncombustible materials and shall be located such that it prevents combustible materials from accumulating under the generator set. Several other factors should be carefully evaluated when selecting a location for installation: For effective cooling and maintenance, the system should be mounted on a flat, smooth, noncombustible level surface.
Secure the Generator Six (eight for the GLC125) mounting bolts in the base frame secure the generator to the shipping pallet. Remove these bolts, lift the generator and remove the shipping pallet. Secure the ″ anchor hardware (not provided) in the base frame generator to the concrete pad using mounting holes.
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.
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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. Keep all fuel and its associated piping away from all components of the engine exhaust system.
Installation The generator is completely assembled, tested and adjusted at the factory before it is shipped to you. The procedures presented in this manual are suggestions and it is the responsibility of the Owner/Operator to arrange for these procedures to be performed by licensed contractors according to all applicable codes including local codes for your Municipality/City/County and State.
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Example: Determining Pipe Size for Natural Gas A generator has a 16Hp engine 60 feet from the supply. Determine the supply pipe size for Natural Gas fuel. 16 x 10,000 = 160,000 BTU’s / per hour for proper operation. 160, 000 + 146 cubic feet per hour.
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The LPG connections should only be made if your generator is setup to run on LPG. If it is setup to run on Natural Gas, contact your Baldor representative and do not continue with installation. The incoming pressure must be 11 inches water column (6 oz. pressure).
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.
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Figure 3-4 Three Phase WYE and DELTA Connections 3-10 Receiving & Installation MN2408...
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Battery Charger Considerations Mount the battery charger on the generator or as close to the generator as possible. If you mount the battery charger inside the building, mount it near the main breaker box or disconnect box. If you mount the battery charger outside, you must protect it from the environment and the elements.
Battery Connections The generator is shipped with no battery installed. WARNING: Installation and servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries. WARNING: Do not dispose of battery or batteries in a fire. The battery is capable of exploding. If the battery explodes, electrolyte solution will be released in all directions.
Figure 3-6 Battery Installation The + and – terminals of your battery may be different than shown. Be sure that the Positive lead is connected to the positive (+) terminal of your battery. Washers & Nut Battery Hold Down Bar Battery (Install away from terminals) Washers &...
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Verify that the transfer switch is in Utility Power mode. No power must be present at the generator or transfer switch connections. Verify with a voltmeter. Verify that the engine starting battery is disconnected so accidental starting is not possible. Verify that the generator is securely mounted and anchored to its cement pad.
Section 4 Operation Operator Control Panel (Digital Engine Controller Only) The Operator Control Panel is shown in Figure 4-1. WARNING: Never connect this generator to any buildings electrical system unless a licensed electrician has installed an approved transfer switch. The National Electrical Code (NEC) requires that connection of a generator to any electrical circuit normally powered by means of an electric utility must be connected by means of approved transfer switch equipment so as to isolate the electrical circuit from the utility distribution system when the generator is operating.
Operator Control Panel Continued Operating Procedures The engine–generator controller is designed to start and stop an engine from either a local (“Manual”) or remote (“Automatic”) modes. When a start command is issued, the controller issues a run and crank output signal. The controller then monitors engine speed and when crank disconnect speed is reached, the crank signal is terminated.
When the cool down time delay period expires (typically 5 minutes), the controllers RUN output will be immediately terminated which will initiate the engine to stop. Automatic Fault Shutdown When a fault circuit is programmed as a SHUTDOWN, the engine will immediately stop when the fault is activated.
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When the controller is applied in an Auto Mains Failure (AMF) application with a transfer switch, it must be wired as shown in Figure 4-2. Programmable output #3 must be selected for Utility Ready To Load and programmable output #4 must be selected for Gen Ready To Load. After the controller is programmed, the AMF sequence of operation will be as follows: Utility Normal Condition: Remote Start input signal (terminals 16 &...
No Load Test To allow a timed No Load Test of the engine/generator set while using the AMF control application, a digital input contact from an external timer must be programmed for NO LOAD Test The sequence of operation for a No Load Test condition is as follows: With the utility supply normal and the generator stopped, a no load test sequence may be initiated by closing an external exercise timer contact to the programmed digital input for No Load Test.
Output Contacts All output contacts are non–powered (i.e. dry contacts) and are rated 10A/240VAC, 8A/28VDC resistive (3A inductive, 0.4pf). Output contacts are not fused therefore external overcurrent protection (maximum 10A) is required for all control circuits using these contacts. Contacts are shown in a de–energized state and will change state upon activation.
Display Modes The controller is in the display mode at all times except when in the programming mode. The display screens and menus may be selected by pressing the Enter or Exit keys to access Operating Status Display, Fault Display, Timer Countdown, Generator AC Metering or Programming Menus.
Timer Countdown Timer countdown menus are automatically displayed when a specific time delay function occurs during a control sequence. When a time delay begins, the LCD display will show the time delay function name (i.e. Engine Start Delay) and the current time remaining in the countdown sequence.
Generator AC Metering The controller is in the display mode at all times except when in the programming mode. The display screens and menus may be selected by pressing the Enter or Exit keys to access Operating Status Display, Fault Display, Timer Countdown, Generator AC Metering or Programming Menus.
Engine Parameter Display Two engine operating parameter screens are provided. BATTERY 27.0 Vdc SPEED 1800 rpm ENG TEMP 57 Deg C OIL PRESS 200 KPA Program Menus The programming menu is used to change values such as time delays, analog fault settings, digital fault settings.
Navigation Hints Programming parameters are displayed in the same order as the Programming Sheets (see Figures 4-5 to 4-8). To skip over parameters that do not require changes, push and hold the ENTER push–button until the desired parameter is displayed. The EXIT push–button may be used to scroll backwards through the programming parameter loops.
Main Menu Loop Continued Caution: The Programmable Output Contacts selection must agree with the external control wiring prior to energizing the controller. Failure to do so may cause severe equipment damage. Analog Fault Menu Loop The controller’s analog fault settings are described as follows: 4-14 Operation MN2408...
Digital Fault Menu Loop The controller’s digital fault settings are described as follows: Caution: The Digital Fault Label selection must agree with the external control wiring prior to energizing the controller. Failure to do so may cause severe equipment damage. Calibration Menu Loop AC Voltage, AC current and battery voltage analog circuits are factory calibrated and should not require field calibration.
Current Sensing Calibration To accurately calibrate the current sensors, an external test AC ammeter and current clamp is required, with an accuracy of 0.5% or better. CURRENT A ZERO 350A Battery Voltage Calibration To accurately calibrate the MEC 2 battery voltage sensor, an external test DC voltmeter is required, with an accuracy of 0.5% or better.
Engine Temperature & Oil Pressure Calibration To accurately calibrate the controller’s temperature sensor, an external temporary engine mounted temperature gauge is required. The external temperature gauge should be connected as close as possible to the temperature sender. To accurately calibrate the controller’s pressure sensor, an external temporary engine mounted pressure gauge is required.
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Figure 4-4 Configuration Data Sheet 4-18 Operation MN2408...
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Figure 4-5 Main Menu Loop Parameters Parameter Setting Range System Voltage (Line To Line) XXXXX VAC 120–15000VAC System Frequency 50Hz/60Hz Toggle Between 50/60 Hz System Phases 1 Phase/3 Phase Toggle Between 1 & 3 Phase Neutral Connected Toggle Between Yes/No Voltage Sensing Voltage Sensing Pt Ratio Ratio XXX...
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Figure 4-6 Analog Fault Menu Loop Parameters ° ° ° Figure 4-7 Digital Fault Menu Loop Parameters Figure 4-8 Calibration Menu Loop Parameters 4-20 Operation MN2408...
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Figure 4-9 Engine Control Connections 12VDC (24VDC) – GENERATOR STARTING OUTPUT VOLTAGE BATTERY B – (DELETE PHASE VC FOR SINGLE PHASE SYSTEMS) CRANK CRANK PILOT RELAY GENERATOR OUTPUT φA RUN CIRCUIT CURRENT SENSING RUN CIRCUIT (FUEL SOL., GOV.) TRANSFORMERS φB 5 Aac SECONDARY SPEED SENSING (DELETE PHASE C...
Manual Start/Stop To manually Start the Gen–Set, set the Master Control switch to the “Manual Run” position. The following happens: When the “Manual Run” push–button is pressed, an Engine Start Delay timer is initiated. (The start sequence will not be initiated if any shutdown fault condition is present.) When the engine start delay time expires, an engine RUN and CRANK output signal will be initiated.
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Figure 4-12 A121H Analog Engine Controller Connections Display LED’s Lamp Test Overspeed High Water High Water Temperature Temperature Low Oil Low Oil Pressure Pressure Overcrank Cycle Crank Remote Start Contact Alarm Auto Contacts are Fuel Relay shown below * Start Relay Auto Starting Battery...
Garretson Model KN Fuel Valve Considerations General The KN is designed for sensitivity and simple operation. It is used with low–pressure vaporized gaseous fuels, where dependable starting is a requirement. Because of its extreme sensitivity, the KN offers excellent results in most remote starting applications (Standby power generators, etc.).
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Installation The KN should be mounted as close to the carburetor as possible with the arrow on the cover pointing up and the diaphragm in a vertical position. This helps to minimize the effects of gravity on diaphragm travel. This unit should also be placed for easy access to the primer if provided. There are two sets of mounting holes provided.
Section 5 Troubleshooting and Maintenance Maintenance This manual contains only very minimal engine maintenance instructions. Refer to the engine manufacturer’s owner’s manual for specific engine maintenance instructions for your generator set. Any maintenance instructions or recommendations in the engine owner’s manual take precedence over any of the following general recommendations.
It is not an exhaustive “how to” for all types of problems. Procedures that require in depth knowledge or skills (like flashing the field) should be referred to the Baldor Generator Service Department by calling (920) 236–4200. Table 5-1 General Troubleshooting Guide...
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Note: See Engine Controller manual for additional information. Table 5-3 Troubleshooting Guide (Analog Controller Only) Service Service for your generator can be obtained from the service department at Baldor Generators by calling (920) 236–4200. Please have the following information available prior to contacting the factory: The model number and serial number of the generator set.
Appendix A Series GLC Parts & Wiring Diagrams Replacement Parts Replacement parts information is provided in this section of the manual. Engine parts are identified in the engine manual that was provided with your generator set. 10.95030 IMPORTANT: Fuses are installed in the control box to protect the engine controller and associated control circuits.
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Replacement Parts Continued A-2 Series GLC MN2408...
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Replacement Parts Continued Figure A-1 Magnetic Pickup Replacement MN2408 Series GLC A-3...
GLC Wire Size Revision B 5–12–04 Wiring Diagrams Wiring diagrams for these generators are contained on the following pages of this appendix. MN2408 Series GLC A-9...
Start–up Inspection Form It is required that both sides of this form be completed, signed where indicated and returned to Baldor Generators within 30 days of initial Start–up and test. It is your responsibility to deliver copies to: n Baldor Generators Factory...
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Return this completed form to: BALDOR GENERATORS 3815 Oregon Street Oshkosh, WI 54902 A-34 Series GLC MN2408...