PRESENTS YOUR BALDOR GENERATORS 3815 OREGON STREET OSHKOSH WI 54902 PHONE: 920–236–4200 FAX: 920–236–4219 REVISED/EFFECTIVE MAY 1, 2003 FORM#: S–PSG–002–48 C:\ISO9001\FORMS\SPSG–002–48msw
TOWABLES OPERATOR’S MANUAL Table of Contents ACCESSORIES AND EQUIPMENT WITH THIS GENERATOR SET INCLUDES: ITEM PAGE SAFETY RECOMMENDATIONS: These recommendations must be read and followed to safely operate your generator set. 1 VOLTAGE RATINGS: This informational page describes features and specifications for all Towable Units. 7 ELECTRICAL CONNECTION INFORMATION: This information explains how to interface your generator with the AC loads and other standard and optional accessories.
SAFETY WARNINGS z 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. z When cleaning, repairing or inspecting, make sure all moving parts have stopped. z Prior to working on the generator set, disconnect the spark plug and battery to prevent accidental starting. z Use only original equipment or authorized replacement parts.
SAFETY WARNINGS z Never permit anyone to operate the generator set without proper instructions. z Never allow children to operate the generator set. z 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. z Always wear eye protection and Hearing protection when working near the generator set.
SAFETY WARNINGS z Always treat the electrical circuits as if they were energized. z Disconnect all leads plugged into the unit Prior to working on it. z Have the electrical circuits serviced only by qualified technicians. z Inspect wiring frequently and replace frayed, broken or poor leads. z 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.
SAFETY WARNINGS ```` FOR GASOLINE OR DIESEL POWERED GENERATOR SETS ```` z Check all fuel supply piping and their connections on a monthly basis for fuel leaks. z Use only approved piping and componentry in your fuel supply system. z A professional, experienced technician should only install the fuel supply system. z Do not run the fuel line up against any sharp objects. z Comply with NFPA regulations and your local codes in regard to shut–off valves, regulators, etc.
FORWARD This manual contains the information you need to safely and efficiently operate your generator set. During the preparation of this manual every effort was made to ensure the accuracy of its contents. Never operate this generator set without first carefully reading this manual and observing all the safety warnings it presents.
Effective: February 26, 1998 Revised 2/01/02 Form#: S–CSD–003–7 C:\ISO9001\FORMS\SCSD0037.
Features & Specifications Model Standby output– (KVA/KW): G E N E R A T O R TS25 TS45 TS80 TS130 TS175 1500C Rise 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 Continuous Output– 1250C Rise (KVA/KW): 18/18 27/27 45/45 70/70 80/80 3 PH @ 480 Volt 23/18 44/35 75/60 121/97 169/135 3 PH @ 208/240 Volt 23/18 44/35 69/55 119/95 156/125 1 PH @ 240 Volt 18/18 25/25 43/43 66/66 75/75 Voltage – 3 PH A
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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. 2. Voltage is present in 120/240 volt switch position only. Load wires may be brought into receptacle compartment through access door at control station. HARD WIRE LOAD TERMINAL BLOCK 1. 2. 3. 4. 5. Voltage available at load block is outlined in chart below.
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.
CONTROL PANEL OPERATION AND FUNCTION A. MASTER CONTROL SWITCH – This switch controls the starting and stopping of the engine via the engine control logic circuitry. With this switch in the “Manual” mode, the engine will start and run immediately after a 10 – 20 second time delay. CAUTION: Please note that once the engine has been told to start, the gen set should be treated as though it is operational, even though the start delay has not yet allowed the engine to crank.
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. The Hertz Meter monitors and displays the current operating frequency of the generator set.
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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. 4. Secure the generator for operation.
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. Adjust the voltage if necessary by turning the voltage adjustment knob located on 15 the control panel.
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. Initially, the system may be started and operated by placing the operator control in the ”manual/run” position.
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. Clockwise (CW) rotation increases the trip frequency and, thereby, raises the shutdown speed. CRANKING CONTROL 1. Over–crank Protection This feature provides a preset second crank cycle.
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 following instructions will be helpful in tracing the cause and making repairs. SPEED DEVIATIONS: The generator speed should be maintained at rated nameplate speed. The frequency and voltage of the generator output depends on speed.
LOW VOLTAGE (Continued) CAUSE CHECK AND REMEDY High resistance connections– Connections will be warm or hot Make better connection electrically and mechanically. Shorted field. Test field coils for possible short by checking resistance with an ohmmeter or resistance bridge. Return rotor assembly to factory for repair if alternator field coils are shorted. Low power factor Reduce inductive (motor) load. Some AC motors Draw approximately the same current regardless of load.
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 improvement capacitors. Unbalanced load The load on each leg should be as evenly balanced as possible and should not exceed the rated current on any leg. Dry bearing. Replace bearing. MECHANICAL NOISE CAUSE CHECK AND REMEDY Defective bearing. Replace bearing. Rotor scrubbing on stator.
TROUBLESHOOTING – ENGINE CODE LIST OF POSSIBLE CAUSES 1. Battery capacity low. 2. Bad electrical connections. 3. Fault in starter motor. 4. Fault in starter motor. 5. Wrong grade of lubricating oil. 6. Low engine speed from starter motor. 7. Stop control fault. 8. Restriction in fuel lift pipe. 9. Fault in fuel lift pump. 10. Dirty fuel filter element. 11. Restriction in air filter or induction system. 12. Air in fuel system. 13. Fault in fuel injection pump. 14. Fault in atomizers or not correct type.
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MAGNAPLUS GENERATOR 280 -- 430 Frame Installation, Operation and Maintenance Manual Marathon Electric A Subsidiary of Regal-Beloit Corp. 100 East Randolph Street P.O.
TABLE OF CONTENTS SAFETY ..............................................................................................................................................................................................4 4 RECEIVING AND STORAGE .........................................................................................................................................................4 4 UNPACKING AND HANDLING ...........................................................................................
RETURNED GOODS ......................................................................................................................................................................1 16 TROUBLESHOOTING ...................................................................................................................................................................1 16 GENERATOR PRODUCES NO VOLTAGE ................................................................................................................
W hen in doubt, ask. Questions are much easier to handle t h a n m i s t a k e s c a u s e d b y a m i s u n d e rs t a n d i n g o f t h e i n f o rm a t i o n p re s e n t e d i n t h i s m a n u a l . SAFETY PLEASE REMEMBER SAFETY FIRST. If you are not sure o f t h e i n s t ru c t i o n s o r p ro c e d u re s c o n t a i n e d h e re i n , s e e k q u a l i f i e d h e l p b e f o re c o n t i n u i n g .
PRINCIPLES OF OPERATION PMG (optional) PMG Field (rotor) Rotating Assembly Exciter Field (stator) Main Field (rotor) Exciter Armature (rotor) Main Armature (stator) L1 N S (+) (+) DC (in) DC (in) (-) L2 (-) 3 Phase AC (out) 3 Phase AC (out) PMG Armature (stator) Rotating Rectifier Assembly 3 Phase -- Full Bridge Exciter Field Power (DC out) PMG Input Power (optional) (1 phase, 300/250 hertz) Input Power -- Single Phase (shunt powered regulator) Automatic Voltage Regulator Sensing Input --
generators generally supply .3 to .4 horsepower per generator kW in motor starting capability. For specific data contact Marathon Electric. PRINCIPLE OF OPERATION MagnaPLUS generators are a brushless, self excited, and externally voltage regulated, synchronous AC generator. The generator is made up of six major components: main stator (armature), main rotor (field), exciter stator (field), exciter rotor (armature), rectifier assembly, and voltage regulator.
driver and the generator's shaft. Aligning the generator and its driver as accurately as possible will reduce vibration, increases bearing life, and ensure minimum coupling wear. I t m a y b e n e c e s s a ry t o s h i m t h e g e n e ra t o r f e e t f o r p ro p e r support and alignment. Secure the feet of the generator with grade 5 or greater bolts through the holes provided in the m o u n ti n g fe e t.
with the conduit. To minimize the transmission of vibration, it is essential that flexible conduit be used for all electrical entrance to the generator conduit box. ENVIRONMENTAL CONSIDERATIONS All MagnaPLUS generators are equipped with link boards (terminal strips) for both internal and external connections. All connections made to the studs of the link board should be made with high quality ring terminals. Ring terminal sizes are 6 mm (280 Series Frames) and 10 mm (360 and 430 Series Frames).
LOW WYE CONNECTION L1 T7 T1 T10 T4 T12 VOLTAGE (LOW WYE) Hz L-L L-N 60 240 139 230 133 220 127 208 120 190 110 50 208 120 200 115 190 110 L-L T5 T9 T2 T6 T11 L3 T3 L2 T8 L-N HIGH DELTA CONNECTION T12 L1 T1 ` T6 L-L T7 T3 L3 VOLTAGE (HIGH DELTA) Hz L-L L-N 60 277 139 240 120 50 240 120 220 110 200 100 T4 T9 T10 T11 T8 T5 L2 T2 L-N LOW DELTA CONNECTION L1 T12 T1 T9 T3 L3 T4 T10 T11 VOLTAGE (LOW DELTA) Hz L-L L-N 60 120 NA 110 NA 50 110 NA 100 NA L-L T6 T7 T8 T5 T2 L2
DOUBLE DELTA -- SINGLE PHASE CONNECTION T3 T5 T6 L2 T11 T9 T2 T1 T8 T12 T4 VOLTAGE (DOUBLE DELTA) Hz L-L L-N 60 240 120 220 110 50 220 110 T7 T10 L1 L-N L-N Note: Single-phase KW /KVA ratings are approximately e q u a l t o 5 0 % o f t h e g e n e ra t o r’ s t h re e p h a s e ra t i n g s .
DEDICATED SINGLE PHASE CONNECTION L1 T1 T2 T3 T4 VOLTAGE (DEDICATED) Hz L-L L-N 60 240 120 220 110 50 220 110 200 100 L2 L-N L-N L-L 8. Review all prime mover prestart-up instructions, and e n s u re t h a t a l l re c o m m e n d e d s t e p s a n d p ro c e d u re s have been followed. 9. Remove any masking materials affixed during painting.
6. The purpose of this initial test with the regulator out of the circuit is to detect any wiring mistakes without exposing the unit to undue risk. Check all line to line and line to neutral voltages for balanced voltage. If voltages are balanced shut down the set and reconnect the regulator. If voltages are unbalanced, shut down the equipment and check for improper wiring. If the problem persists, consult the factory. 3.
DRYING WINDINGS Generators in service may inadvertently have their windings exposed to splashing or sprayed water. Units that have b e e n i n t ra n s i t o r s t o ra g e f o r l o n g p e ri o d s o f t i m e m a y b e subjected to extreme temperature and moisture changes causing excessive condensation. Regardless of the source of moisture, wet windings should be thoroughly dried out b e f o re o p e ra t i n g t h e u n i t .
W hen the positive test probe is connected to the diode's anode and the negative test probe is connected to the diode's cathode (forward biased), the diode will switch on and conduct electricity (figure 3). This is observed by a low resistance reading when using an ohm meter or the lighting of the bulb when using a battery light continuity tester. Reversing the test leads (reverse biased) will result in the diode switching off and no electricity will be conducted.
Continue to pull the bracket free from the bearing. Visually inspect the bearing bore for damage or wear. If worn or damaged, sleeve or replace prior to reassembly. CAUTION: Failure to remove the exciter field leads from the automatic voltage regulator during flashing procedures may destroy the regulator. Reassembly note: Before the bearing bracket is seated a g a i n s t t h e f ra m e , a t h re a d e d ro d m a y b e u s e d t o h e l p a l i g n the inner bearing cap with the bearing bracket. 2.
430 FRAME 280 / 360 FRAME A - Exciter Rotor Lead, B - Main Rotor Lead, C - Red (+) Suppressor Lead, D - Black (-) Suppressor Lead FIGURE 4: ROTATING RECTIFIER ASSEMBLY checks first and prevent further t ro u b l e s h o o t i n g a d i s a b l e d m a c h i n e . RETURNED GOODS dam age when The first step of troubleshooting is to gather as much i n f o rm a t i o n a s i s p o s s i b l e f ro m o p e ra t i n g p e rs o n n e l a n d individuals present during the failure.
WARNING HIGH VOLTAGES MAY BE PRESENT AT THE GENERATOR’S TERMINALS WHEN THE UNIT IS RUNNING. SOME ACCESSORY EQUIPMENT SUCH AS SPACE HEATERS MAY BE ENERGIZED FROM AN OUTSIDE POWER SOURCE WHEN THE UNIT IS AT REST. TOOLS, EQUIPMENT, CLOTHING AND YOUR BODY MUST BE KEPT CLEAR OF ROTATING PARTS AND ELECTRICAL CONNECTIONS. SPECIAL PRECAUTIONS MUST BE TAKEN DURING TROUBLESHOOTING SINCE PROTECTIVE COVERS AND SAFETY DEVICES MAY BE REMOVED OR DISABLED TO GAIN ACCESS AND PERFORM TESTS. BE CAREFUL.
GENERATOR PRODUCES LOW VOLTAGE WHEN LOAD APPLIED CAUSE CHECK AND REMEDY Excessive load Reduce load. The load on each leg should be evenly balanced, and rated current should not be exceeded on any leg. L a rg e m o t o r s t a rt i n g o r l o w l o a d power factor Motor starting currents are too large for the generator. W hen starting multiple motors, sequence the motors and start the largest motors first. Reduce lagging power factor load. Driver speed droop or belt slip Check driver.
GENERATOR BUILDS VOLTAGE FROM STARTUP, THEN GOES TO LOW (RESIDUAL) VOLTAGE CAUSE Regulator protective circuit operating CHECK AND REMEDY Check indicators on regulator. Correct problems and adjust regulator as is required. Refer t o re g u l a t o r m a n u a l . GENERATOR IS OVERHEATING CAUSE CHECK AND REMEDY Generator is overloaded Reduce load. Check with ammeter and compare with nameplate rating. Clogged ventilating screens Clean air passages.
SPECIFICATIONS MODEL / FRAME SIZE 281, 282, 283, 284 3 6 1 , 3 6 2 , 3 6 3 -- t h re e p h a s e 3 6 1 , 3 6 2 , 3 6 3 -- d e d i c a t e d s i n g l e p h a s e 4 3 1 , 4 3 2 , 4 3 3 -- t h re e p h a s e 4 3 1 , 4 3 2 -- d e d i c a t e d s i n g l e p h a s e EXCITER RESISTANCE STATOR ROTOR 2 3 .0 .1 2 0 2 3 .5 .1 2 0 2 3 .0 .1 3 5 2 0 .3 3 .0 7 6 1 8 .0 .1 0 5 EXCITER FIELD GENERATOR RESISTANCE NO LOAD VOLTS STATOR* ROTOR 480 V / 60 HZ 281PSL1500 4 .2 0 .4 0 0 1 1 .0 281PSL1501 4 .1 5 .4 0 0 1 1 .
PARTS LIST – SINGLE BEARING Typical Generator Cross Section Reference Number 1 2 3 4 5 6 7 8 9 10 Note: Part Name Reference Number 11 12 13 14 15 16 17 18 19 20 End Bracket (under end cover 360 & 430 frames) Bearing O-ring (280 frame only) Rectifier Assembly Air Intake Screen (280 frame only) Exciter Rotor Exciter Stator Link Board (terminal block) Conduit Box Generator Frame Part Name Main Stator Main Rotor Rotor Integral Keyway Fa n Mounting Adapter (SAE) Shaft Drive Hub Drive Disk (SAE) Exhaust Scre
PARTS LIST – DUAL BEARING Typical Generator Cross Section Reference Number 1 2 3 4 5 6 7 8 9 10 Note: Part Name Reference Number 11 12 13 14 15 16 17 18 19 20 End Bracket (under end cover 360 & 430 frames) Bearing (nondrive end) O-ring (280 frame only) Rectifier Assembly Air Intake Screen (280 frame only) Exciter Rotor Exciter Stator Link Board (terminal block) Conduit Box Generator Frame Part Name Main Stator Main Rotor Rotor Integral Keyway Fa n End Bracket (drive end) Bearing (drive end) Shaft Key E
RULES FOR SAFE TRAILER OPERATION CAUTION – Before you start: S S S S S S S 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. It is against the law to carry passengers in the back of any trailer.
ELECTRICAL TRAILER WIRING All trailers must have taillights, brake lights and turn signals connected in with the towing vehicle’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 1. Trailer brakes – In all cases refer to your Vehicle Owner’s Manual and the Trailer Operating Manual to be certain you have an adequate braking system to handle the vehicle/trailer combination.
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. (4) Inspect hitch and ball for damage in every day use.
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. Attach the white ground wire to the vehicle frame. If vehicle has rear turn signals separated from stoplights, you will need an Anderson 5403 electronic converter.
Limited Warranty 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.
Limited Warranty Continued Notes for Warranty Period: 1. Labor coverage for warrantable repairs is provided for the applicable period not to exceed published rates as contained in the Baldor Generators Warranty Policy. Mileage is allowed only for permanent installations not to exceed published rates as contained in the Baldor Generators Warranty Policy. 2. Proof of purchase date is required for all Portable and Towable products to qualify for any warranty consideration.
Owner’s Responsibilities: The owner is obligated to operate and maintain the generator in accordance with the recommendations . The owner is responsible for published by Baldor Generators in the Operator the costs associated with maintenance and any adjustments that may be required. The owner is responsible for payment of any of the following expenses that might be incurred as a result of a failure under the terms of this warranty: 1. 2. 3. 4. 5.
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.