Baldor TS25 Installation & Operating Manual
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Baldor TS25 Installation & Operating Manual

Baldor TS25 Installation & Operating Manual

Tier 2/3 towable generators (trailer and skid mounted) (diesel liquid cooled)
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See also: Operator's Manual
Tier 2/3 Towable Generators
(Trailer and Skid Mounted)
(Diesel Liquid Cooled)
TS25, 35, 45, 60, 80, 130, 175, 250 and 400
Installation & Operating Manual
8/06
MN2417

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  • Page 1 Tier 2/3 Towable Generators (Trailer and Skid Mounted) (Diesel Liquid Cooled) TS25, 35, 45, 60, 80, 130, 175, 250 and 400 Installation & Operating Manual 8/06 MN2417...
  • Page 2 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.

  • Page 3: Table Of Contents

    Table of Contents Section 1 Product Safety Information ............... Safety Notice .
  • Page 4 ii Table of Contents MN2417...

  • Page 5: Product Safety Information

    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.

  • Page 6: Important Safety Instructions

    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.
  • Page 7 Operation Warning Statements Continued WARNING: Over crank indication can mean a loss of crank disconnect signal during the previous run period. Attempting to restart the engine with no crank disconnect signal can destroy the starter motor, which can cause serious personal injury. WARNING: Hot exhaust gasses must never be directed toward anything that may catch fire or explode.
  • Page 8 Warning Statements Continued 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.
  • Page 9 Warning Statements Continued 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: Never stand under or close to an object that is being hoisted or lift into position. Accidents happen and if the object falls or tips over you or someone else could be crushed by the weight of the object causing severe injury or death to to yourself or others.

  • Page 10: Caution Statements

    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.

  • Page 11: Section 2 General Information

    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.
  • Page 12 2-2 General Information MN2417...

  • Page 13: Section 3 Receiving & Installation

    The lift point is designed only for the weight of the generator and factory trailer. Do not lift by these points if the generator is mounted to a trailer that has been modified from the factory specifications for stock units. Please consult Baldor for custom designs. Figure 3-1 Generator Lifting...

  • Page 14: Secure The Generator

    Maximum Ambient temperature is 122°F (50°C). Figure 3-2 Generator Mounting (Skid) Holes each side TS250 only TA0000C10 (4 Holes) BA0236A00 TS130/175 only (4 Holes) TS25/45/80 only BA0236A02 (3 Holes) TS400 only 10.85401−G10 (6 Holes) Table 3-2 Mounting Dimensions Generator TS25 8.12...

  • Page 15: Hot Exhaust Gasses

    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.

  • Page 16: Electrical Connections

    25 feet of the Genset. Use only copper wires. Table 3-3 Standby Power Ratings Electrical Load Capacity Standby Power Ratings Generator Generator 1 Phase 3 Phase Catalog Catalog Volts Amps * Volts Amps TS25 240/120 75/2x75 25/25/25 20/20/20 208/240/480 69/60/30 TS35 240/120 104/2x104 37/37/37 30/30/30 208/240/480...
  • Page 17 Single Phase Connections Single phase connections are made at load receptacles located by the operator panel, see Figure 3-3. Simply open the rear panel access door and make the connections. When the panel door is closed, the connections are weather tight. Figure 3-3 Receptacle Panel (Single Phase) Circuit Breakers (Single or Double pole) Circuit Breakers provides protection on some...
  • Page 18 Three Phase Connections Three phase connections are made at L1, L2, L3 and N connections shown in Figure 3-4. Figure 3-4 Three Phase and Remote Start Connections RR1 RR2 For power to be applied to these terminals, the Output Voltage Selector Switch must be in the 120/208V, Remote Start Connections 120/240V or 277/480V positions.

  • Page 19: Battery Connections

    Frame Ground Connection WARNING: Be sure the system is properly grounded before applying power. Do not apply AC power before you ensure that grounds are connected. Electrical shock can cause serious or fatal injury. NEC requires that the frame and exposed conductive surfaces (metal parts) be connected to an approved earth ground.
  • Page 20 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: Do not smoke when near batteries.

  • Page 21: Recommended Engine Oil And Battery Type

    Table 3-5 Oil & Battery Recommendations SUMMER SUMMER WINTER WINTER RECOMMENDED RECOMMENDED (AMPS) COLD (AMPS) COLD MODEL MODEL CAPACITY BATTERY CRANKING TS25 SAE. 20W/50 5W/30 8.6 QTS BCI Group 24 TS35 SAE. 20W/50 5W/30 8.5 QTS BCI Group TS45 SAE. 20W/50 5W/30 11.8 QTS...
  • Page 22 Post Installation Checks Continued 16. Place the voltage output selector switch in the appropriate position. 17. Verify all loads are disconnected. 18. Verify the Master Control is in the “Stop” position. Connect the engine starting battery to the starter. Verify it is installed correctly. 19.

  • Page 23: Section 4 Operation

    Section 4 Operation Towing the Generator WARNING: Never allow a person to ride in or on a trailer that is being towed. All states prohibit passengers in towed vehicles. A person can fall off and be struck be another vehicle or run over by the towed trailer.

  • Page 24: Safe Driving Tips

    Selecting the Proper Towing Equipment Continued Electrical Trailer Wiring All trailers must have taillights, brake lights and turn signals connected to the towing vehicle’s electrical system. It is also recommended that a heavy duty turn signal flasher and emergency flasher (if separate) be installed since the trailer lights place an extra load on car flasher units. Towing Heavy Trailer Loads Trailer brakes.

  • Page 25: Safety Checks

    Figure 4-1 Trailer Component Identification Lift Hook Battery Jack Compartment Coupler Handle Coupler Tow Vehicle Mounted Trailer Brake Pintle Hook Pintle Safety Chains Single or Safety Ball Coupler Double Axle Trailer Chains Jack Engine Compartment Caution: Large “Engine Compartment Doors” on each side of enclosure must remain closed during operation.

  • Page 26: Towing Instructions

    Towing Instructions See Figure 4-1 for component identification. Be sure the generator is off. Shut all enclosure doors and latch the locks. Back the tow vehicle to within a few inches of the trailer coupler (Pintle or Ball). Be sure the Coupler Handle is in the “UP” (open) position or the Pintle Hook is Open. Adjust the trailer jack for the height of the hitch on the tow vehicle.

  • Page 27: Trailer Setup

    Trailer Setup See Figure 4-1 for component identification. Carefully read all instructions before starting. Locate a suitable, level location. Also be sure there are no overhead wires or obstructions. The trailer is balanced so the majority of the weight rests on the tow bar (Jack). If on a minor incline, the safest way to position the tailer is to have the tow bar facing down the incline (front of the trailer lower than the rear of the trailer).

  • Page 28: Receptacle Panel (Single Phase)

    Table 4-2 Three/Single Phase Operation Voltage at Terminal Lugs Voltage at Plug Receptacles Alternator Alternator Voltage Voltage 120VAC 240VAC Receptacles Switch Line To Line Voltage Line To Neutral Voltage Winding Adjust Receptacles (Twist Lock) Position Position Connection Connection Position Position L1−L2 L2−L3 L1−L3...
  • Page 29 Meters, switches, lights and other operator control components are located in various places on each panel. Figure 4-5 can be used to identify the function and features of each operator control regardless of where it is located on your panel. Figure 4-5 Operator Control Panel Components Volts Battery...

  • Page 30: Pre−Start Procedure

    Pre−Start Procedure Before attempting to start the generator set, several things must first be verified or performed. These are: Fill system fuel tank with clean, fresh diesel fuel. Fill engine crankcase to full mark with clean, fresh lubricating oil per engine manufacturer operating guide.

  • Page 31: Digital Engine Controller Description

    Digital Engine Controller Description EM0046A21 (MRS17) Figure 4-6 Operator Control Panel Operating Modes and Horn & Fault Reset Manual Display Stop Menu Group LED Indicators LED Indicators 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) −...
  • Page 32 Digital Engine Controller Description EM0046A21 (MRS17) Continued Operating Mode Press Mode A 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 4-7. When the desired Control Mode is highlighted, press Start to begin operation.
  • Page 33 Digital Engine Controller Description EM0046A21 (MRS17) Continued Table 4-4 Manual Mode Sequence Description Action  Menu Status Condition of Transition Next State Start request PRESTART on, PRESTART Prestart time counter started RPM > 2 or Oil pressure detected or Stop (Stop fail) Ready Gen voltage >...

  • Page 34: Alarms

    Alarms Following alarms are available: Sensor fail (FLS) see Table 4-5 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 4-5 When warning comes up, only alarm outputs and common warning output are closed.

  • Page 35: Inputs And Outputs

    Inputs and Outputs Any Binary input or output can be configured to any controller terminal Inputs are BI1 − BI6, Outputs are BO1 − BO6) or changed to different function by LiteEdit software. There is fixed 1 sec delay when any binary input is configured as protection. Table 4-6 Binary Inputs Alarm Alarm type Warning or Shut down...
  • Page 36 Table 4-7 Binary outputs Continued GenParamsOK The output is same as generator status LED on panel. Output is closed if genset is running and all genset electric values are in limits. CommonWrnSd Output is closed if : Any warning or shutdown are active or the gen−set malfunctions The output opens if: FAULT RESET is pressed.
  • Page 37 Table 4-7 Binary outputs Continued Common Wrn Output closes when any warning alarm appears. The output opens, if alarm is not active and FAULT RESET is pressed. Common Sd Output closes when any shut−down alarm appears. The output opens, if alarm is not active and FAULT RESET is pressed. Sd OilPress Output closes if the oil pressure shutdown alarm activates.

  • Page 38: Analog Inputs

    Analog Inputs Three analog inputs for resistive sensor 0 to 2400 Ù measuring are available on IL controller. Use LiteEdit software to modify configuration. The Analog inputs values assignment (AI1 = Oil press, AI2 = Water temp, AI3 = Fuel level) is fix. It is possible to configure on each Analog input: Reading from IL Analog inputs or from Engine Control Unit via CAN bus (J1939) Sensor characteristics...
  • Page 39 Table 4-9 Setpoints Continued Start RPM “Firing” speed when iL controller stops cranking (starter goes OFF). Step: 1% of nominal RPM; Range: 5 − 50 % Starting POil 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).
  • Page 40 Table 4-9 Setpoints Continued GCB CloseDelay 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 Stabil time Generator Nominal voltage is detected during genset start after starter is switched off and Idle time elapses.
  • Page 41 Table 4-9 Setpoints Continued Overload Threshold for generator overload (in % of Nominal power) Step: 1% of Nominal power; Range: 0 − 200% Overload Wrn Threshold for generator overload warning (in % of Nominal power) Step: 1% of Nominal power; Range: 0 − 200% Overload del Delay for generator overload alarm.
  • Page 42 Table 4-9 Setpoints Continued AnlInIOM1 lev1 The level for IOM ANALOG INPUT 1 alarm detection. Step: 1; Range: −100 to +10000 AnlInIOM1 lev2 The level for IOM ANALOG INPUT 1 alarm detection. Step: 1; Range: −100 to+10000 AnlInIOM1 del Delay for IOM ANALOG INPUT 1 alarm. Step: 1 s; Range: 0 − 180 s AnlInIOM2 lev1 The level for IOM ANALOG INPUT 2 alarm detection.
  • Page 43 Digital Engine Controller Description EM0046A21 (MRS17) Continued Figure 4-9 Controller Connection Diagram LOA D Generator C.B. DIESEL/GAS ENGINE GENERATOR − BATTERY STARTER GENERATOR GENERATOR BINARY INPUTS BINARY INPUTS CURRENT VOLTAGE BOOT JUMPER ANALOG INPUTS BINARY OUTPUTS POWER 8− 36 V DC Ground MN2417 Operation 4-21...
  • Page 44 Digital Engine Controller Description EM0046A21 (MRS17) Continued Figure 4-10 Controller Connection Diagram LOAD Ge n er at o r C.B. DI ESE L /GAS ENGIN E GENERATOR 8− Pole Connector − 87654321 BATTERY START ER CONTROL C O NT RO L SIGNALS SI GNALS CHRG...

  • Page 45: Section 5 Troubleshooting And Maintenance

    Section 5 Troubleshooting and Maintenance 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.

  • Page 46: Problems And Solutions

    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 an authorized service department.
  • Page 47 Table 5-1 Troubleshooting Guide Continued Problem Possible Cause Remedy Genset will not pull load Incorrect Engine Speed Remove electrical load, output should be 61−62 Hertz adjust engine speed if necessary. Load not connected properly Verify voltage at the load and the connections to the proper receptacle or load terminal block.
  • Page 48 5-4 Troubleshooting and Maintenance MN2417...

  • Page 49: Appendix A Wiring Diagrams

    Appendix A Wiring Diagrams Replacement Parts Replacement parts information is provided in Replacement Parts Catalog CA2401. Engine parts are identified in the engine manual that was provided with your generator set. IMPORTANT: Fuses are installed in the control box to protect the engine controller and associated control circuits.
  • Page 50 Figure A-1 TS25 Connection Diagram A-2 Wiring Diagrams MN2417...
  • Page 51 Figure A-2 TS25 Connection Diagram Wiring Diagrams A-3 MN2417...
  • Page 52 Figure A-3 TS25 Connection Diagram A-4 Wiring Diagrams MN2417...
  • Page 53 Figure A-4 TS25 Connection Diagram Wiring Diagrams A-5 MN2417...
  • Page 54 Figure A-5 TS25 Connection Diagram A-6 Wiring Diagrams MN2417...
  • Page 55 Figure A-6 TS25 Connection Diagram Wiring Diagrams A-7 MN2417...
  • Page 56 Figure A-7 TS35 Connection Diagram A-8 Wiring Diagrams MN2417...
  • Page 57 Figure A-8 TS35 Connection Diagram Wiring Diagrams A-9 MN2417...
  • Page 58 Figure A-9 TS35 Connection Diagram A-10 Wiring Diagrams MN2417...
  • Page 59 Figure A-10 TS35 Connection Diagram Wiring Diagrams A-11 MN2417...
  • Page 60 Figure A-11 TS35 Connection Diagram A-12 Wiring Diagrams MN2417...
  • Page 61 Figure A-12 TS35 Connection Diagram Wiring Diagrams A-13 MN2417...
  • Page 62 Figure A-13 TS35 Power Connection Diagram A-14 Wiring Diagrams MN2417...
  • Page 63 Figure A-14 TS60 Connection Diagram Wiring Diagrams A-15 MN2417...
  • Page 64 Figure A-15 TS60 Connection Diagram A-16 Wiring Diagrams MN2417...
  • Page 65 Figure A-16 TS60 Connection Diagram Wiring Diagrams A-17 MN2417...
  • Page 66 Figure A-17 TS60 Connection Diagram A-18 Wiring Diagrams MN2417...
  • Page 67 Figure A-18 TS60 Connection Diagram Wiring Diagrams A-19 MN2417...
  • Page 68 Figure A-19 TS60 Connection Diagram A-20 Wiring Diagrams MN2417...
  • Page 69 Figure A-20 TS60 Connection Diagram Wiring Diagrams A-21 MN2417...
  • Page 70 Figure A-21 TS80 Connection Diagram A-22 Wiring Diagrams MN2417...
  • Page 71 Figure A-22 TS80 Connection Diagram Wiring Diagrams A-23 MN2417...
  • Page 72 Figure A-23 TS80 Connection Diagram A-24 Wiring Diagrams MN2417...
  • Page 73 Figure A-24 TS80 Connection Diagram Wiring Diagrams A-25 MN2417...
  • Page 74 Figure A-25 TS80 Connection Diagram A-26 Wiring Diagrams MN2417...
  • Page 75 Figure A-26 TS80 Connection Diagram Wiring Diagrams A-27 MN2417...
  • Page 76 Figure A-27 TS80 Connection Diagram A-28 Wiring Diagrams MN2417...
  • Page 77 Figure A-28 TS80 Connection Diagram Wiring Diagrams A-29 MN2417...
  • Page 78 Figure A-29 TS80 Connection Diagram A-30 Wiring Diagrams MN2417...
  • Page 79 Figure A-30 TS80 Connection Diagram Wiring Diagrams A-31 MN2417...
  • Page 80 Figure A-31 TS400 Connection Diagram A-32 Wiring Diagrams MN2417...
  • Page 81 Figure A-32 TS400 Connection Diagram Wiring Diagrams A-33 MN2417...
  • Page 82 Figure A-33 TS400 Connection Diagram A-34 Wiring Diagrams MN2417...
  • Page 83 Figure A-34 TS400 Connection Diagram Wiring Diagrams A-35 MN2417...
  • Page 84 Figure A-35 TS400 Connection Diagram A-36 Wiring Diagrams MN2417...
  • Page 85 Figure A-36 TS400 Connection Diagram Wiring Diagrams A-37 MN2417...
  • Page 86 Figure A-37 TS400 Connection Diagram A-38 Wiring Diagrams MN2417...
  • Page 87 Figure A-38 TS400 Connection Diagram Wiring Diagrams A-39 MN2417...
  • Page 88 Figure A-39 TS400 Connection Diagram A-40 Wiring Diagrams MN2417...
  • Page 89 Baldor District Offices...
  • Page 90 Battery posts, terminals and related accessories are known to the state of California to cause cancer, birth defects and other reproductive harm. BALDOR ELECTRIC COMPANY P.O. Box 2400 Ft. Smith, AR 72902−2400 (479) 646−4711 Fax (479) 648−5792 www.baldor.com © Baldor Electric Company Printed in USA MN2417 8/06...

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