Baldor TS25 Operator's Manual
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- Page 1 PRESENTS YOUR BALDOR GENERATORS 3815 OREGON STREET OSHKOSH WI 54902 PHONE: 920–236–4200 FAX: 920–236–4219 REVISED/EFFECTIVE MAY 1, 2003 C:\ISO9001\FORMS\SPSG–002–48msw FORM#: S–PSG–002–48...
- Page 2 AC and Engine Control circuits. These diagrams will also include information for any optional AC or DC powered accessories that are included. PARTS LIST: This is a listing of all parts used by Baldor Generators to build this specific generator set.
- Page 4 SAFETY WARNINGS Place protective covers and guards over the rotating parts, if rotating parts such as the drive shaft, pulley, belt, etc. are left exposed, they are potentially hazardous. When cleaning, repairing or inspecting, make sure all moving parts have stopped. Prior to working on the generator set, disconnect the spark plug and battery to prevent accidental starting.
- Page 5 SAFETY WARNINGS Never permit anyone to operate the generator set without proper instructions. Never allow children to operate the generator set. Children and pets must be kept away from the area of operation due to the possibility of burns from hot engine components or injury from any equipment the generator set is powering.
- Page 6 SAFETY WARNINGS Always treat the electrical circuits as if they were energized. Disconnect all leads plugged into the unit Prior to working on it. Have the electrical circuits serviced only by qualified technicians. Inspect wiring frequently and replace frayed, broken or poor leads. Do not connect this unit to any building’s electrical system unless you utilize an approved transfer switch or the main service entrance switch has been disconnected and locked open.
- Page 7 Operation inside an enclosed compartment or building is a potential fire hazard and should not be done unless approval is obtained from Baldor Generators. Engine/Generator overheating can cause severe damage due to restricted, obstructed or improper air–flow that is necessary for the proper cooling of the unit.
- Page 8 Never operate this generator set without first carefully reading this manual and observing all the safety warnings it presents. While safety is built into every Baldor Pow’R Gard generator set, careless or improper operation could possibly result in mechanical failure, property damage, se- vere injury or death.
- Page 9 Effective: February 26, 1998 Revised 2/01/02 Form#: S–CSD–003–7 C:\ISO9001\FORMS\SCSD0037.MSW...
- Page 10 Features & Specifications Model TS25 TS45 TS80 TS130 TS175 Standby output– C Rise (KVA/KW): 3 PH @ 480 Volt 25/20 48/38 81/65 134/107 175/140 3 PH @ 208/240 Volt 25/20 46/37 72/58 131/105 169/135 1 PH @ 240 Volt 18/18...
- Page 12 SWITCHABLE ELECTRICAL CONNECTION INFORMATION WARNING: High voltage may be present at receptacles and load studs while engine is operating – DANGER of electrical shock is present. Use extreme care. LOAD RECEPTACLES 1. Voltage is present in 120/240 volt switch position only. Load wires may be brought into receptacle compartment through access door at control station.
- Page 13 CONNECTION INFORMATION Your new Baldor Generator has all interconnecting wiring terminated at a junction box. All wiring will be clearly labeled as being load; remote start contacts and AC input terminals and are to be connected as described below. Load – These connections are rated and sized according to the KW of the generator. Proper lead wire from these points to the automatic transfer switch (or load switching device) is mandatory.
- Page 14 This gauge should normally be above 12.5V whenever the unit is running. If you ever notice the gauge is reading below 12V while the engine is running please contact the service department at Baldor Generators. The Temperature Gauge monitors and displays the operating temperature of the engines coolant. The point at which a fault shut–down will occur is approximately 230°F.
- Page 15 E. VOLTAGE ADJUST – The rheostat allows the user to “fine tune” the generator set’s voltage output. It is normally used to adjust output voltage after switching the output of the generator set to a different voltage. F. METERS – These meters monitor and display the current operating parameters of the generator set. The Voltmeter monitors and displays the current operating AC output of the generator set.
- Page 17 OPERATION – PRE–START PROCEDURE 1. Fill system fuel tank with clean, fresh diesel fuel. CAUTION: Wipe up any and all fuel spillage. 2. Fill engine crankcase to full mark with clean, fresh lubricating oil per attached engine operating guide. 3. Radiator coolant should be checked at the beginning of each day and filled in compliance with the engine manufacturer’s guidelines.
- Page 18 OPERATION – STARTING 1. Conduct ‘Pre–start Procedures. 2. Switch the generator set to the applicable voltage setting. 3. Connect the load(s) to the circuit breaker. WARNING: High voltage is present when the generator set is running. 4. Move the ‘Master Control Switch” to the appropriate position. 5.
- Page 19 OPERATION The prime mover utilized in this power generating system is controlled via an engine control module. Starting is accomplished by commanding the control to ”start” the engine. This command can be given by a number of controls. ? The operator control mounted on the front panel. ? The remote controls via the transfer switch or remote start terminal closure.
- Page 20 3. Over–speed Adjustment – (OS) – Over Frequency Over–speed protection is provided by a frequency sensing network within the controller. The trip point of the frequency network is adjustable via a rheostat located on the top of the controller at the right hand side.
- Page 21 TROUBLESHOOTING – GENERATOR As with any machine, trouble may develop in electrical generators. It may be due to long service or neglect of regular maintenance. Servicing, and checking. Should trouble develop, the follow- ing instructions will be helpful in tracing the cause and making repairs. SPEED DEVIATIONS: The generator speed should be maintained at rated nameplate speed.
- Page 22 LOW VOLTAGE (Continued) CAUSE CHECK AND REMEDY High resistance connections– Make better connection electrically and Connections will be warm or hot mechanically. Shorted field. Test field coils for possible short by checking resist- ance with an ohmmeter or resistance bridge. Re- turn rotor assembly to factory for repair if alternator field coils are shorted.
- Page 23 OVERHEATING (continued) CAUSE CHECK AND REMEDY High room temperature. Improve ventilation. Insufficient circulation. Provide cross–ventilation. Low power factory. Reduce inductive loads or install power factor im- provement capacitors. Unbalanced load The load on each leg should be as evenly balanced as possible and should not exceed the rated cur- rent on any leg.
- Page 24 TROUBLESHOOTING – ENGINE CODE LIST OF POSSIBLE CAUSES 1. Battery capacity low. 33. Piston rings not free or are worn or broken. 2. Bad electrical connections. 34. Valve stems and/or guide worn. 3. Fault in starter motor. 35.West type air cleaner too full or wrong oil used. 4.
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Page 27: Table Of Contents
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Page 29: S A F E Ty
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Page 30: P R I N C I P L E S O F O P E R A T I On
PMG (optional) Rotating Assembly PMG Field Exciter Field Exciter Armature Main Field Main Armature (rotor) (stator) (rotor) (rotor) (stator) (in) (in) 3 Phase AC (out) 3 Phase AC (out) Armature (stator) Rotating Rectifier Assembly 3 Phase -- Full Bridge Exciter Field Power Input Power -- Single Phase (DC out) (shunt powered regulator) -
Page 31: O L T A G E R E G U L A T I O N
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Page 33: E N V I R O N M E N T A L C O N S I D E R A T I O Ns
& & ’ ’ VOLTAGE (HIGH WYE) L - L L - N... - Page 34 VOLTAGE (LOW WYE) L - L L - N VOLTAGE (HIGH DELTA) L - L L - N VOLTAGE (LOW DELTA) L - L L - L...
- Page 35 VOLTAGE (DOUBLE DELTA) L - N L - N L - L ’ ’ VOLTAGE (LOW ZIGZAG) L - N L - N ’ ’ L - L VOLTAGE (HIGH ZIGZAG) L - N L - N L - L ’...
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VOLTAGE (DEDICATED) L - N L - N L - L... -
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Page 38: D R Y I N G W I N D I N Gs
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Page 39: I N S U L A T I O N T E S T
’ ’ " " " " " " " " " " " " " " " " " " " " Forward Reverse Terminal End Anode Cathode Stud End Cathode Anode... -
Page 40: B E A R I N G R E M O V A L
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Page 47: Part S L I S T - D U A L B E A R I Ng
– – & &... - Page 48 RULES FOR SAFE TRAILER OPERATION CAUTION – Before you start: Make sure vehicle is capable of towing the load. Be sure hitch capacity is equal to or greater than the load when mounted on the vehicle. See that hitch ball rated capacity is equal to or greater than the load. Make sure your safety chain(s) is rated equal to or greater than twice the maximum gross trailer weight rating of your trailer.
- Page 49 ELECTRICAL TRAILER WIRING All trailers must have taillights, brake lights and turn signals connected in with the towing ve- hicle’s electrical system. It is also recommended that a heavy–duty turn signal flasher be installed since the trailer lights place an extra load on the car flashers. TOWING HEAVY TRAILER LOADS Trailer brakes –...
- Page 50 SAFETY CHECKS The following items should be checked before each use and once every 100 miles of towing: (1) Check lighting to be sure stop, tail and turn signals are working properly. Replace any broken lenses, reflectors or bulbs. (2) Check wires for good connections and possible fraying or wearing of insulation. (3) Check and properly maintain the trailer, hitch, ball and coupler.
- Page 51 TRAILER LIGHT KIT WIRING INSTRUCTIONS Connect the wires of the short trunk connector to the vehicle wiring. Connect the brown wire to the tail light wire, the yellow wire to the left–hand stop and turn, and the green wire to the right–hand stop and turn wire.
- Page 52 Unless otherwise provided, Baldor generators are warranted against defects in Baldor workmanship and materials for a period of time as set forth in the Warranty Period chart below. If a Baldor product is defective due to Baldor workmanship or materials and the defect occurs during the warranty period, then Baldor will either repair the product or replace it with a new one, whichever Baldor believes to be appropriate under the circumstances.
- Page 53 4. The premium costs for overtime labor requested by the owner. 5. All parts transportation costs. All warranty claims must be submitted to a Baldor Generator repair facility prior to the expiration of the warranty period. Baldor Generators shall have no responsibility or liability for any defect, latent or otherwise, discovered after the expiration of the warranty period provided herein.
- Page 54 No person is authorized to give any other warranties or to assume any other liabilities on Baldor Generators’ behalf unless made or assumed in writing by an officer of Baldor Generators and no person is authorized to give any warranties or assume any other liability on behalf of the seller unless made or assumed in writing by the seller.
- Page 55 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: Diesel engine exhaust and some constituents are known to the state of California to cause cancer, birth defects and other reproductive harm.