GLC Generator (Gaseous Liquid Cooled) GLC30, 35, 45, 50, 60, 80, 100 and 125 Installation & Operating Manual 5/04 MN2408
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Control Panel (Digital Engine Controller Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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.
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 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.
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.
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. Caution: Do not apply high voltage to windings (do not start the generator) in a moisture–saturated condition.
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.
2-2 General Information MN2408
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.
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.
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.
S 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.
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.
Table 2-1 Approximate Load Bearing Capacities of Various Soil Types Soil Type Hard Rock – Granite etc. Medium Rock – Shale etc.
Exhaust System Exhaust Checklist A. Exhaust outlets are not located upwind or near any building air intakes. B. Flexible piping section is used at engine exhaust outlet. C. Exhaust piping material is adequate for expected service. D. Exhaust piping sizing is adequate to prevent back pressure. E. Exhaust piping components are insulated as necessary to prevent operator burns and reduce pipe radiant heat losses. F.
Figure 2-6 Exhaust System Calculations 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.
Cooling System Cooling System Checklist A. Have noise considerations been taken into account? B. Has system piping been properly sized? C. Has system been properly protected from freeze up and corrosion? D. Have standby equipment heaters been specified? E. Have all electrically driven devices been connected to load side of EPS connection points? F.
Caution: 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. If the maximum coolant friction head loss external to the engine is exceeded, a hot well system must be used.
Remote Radiator Cooling Remote Radiator Airflow generally assumed there will be no external restrictions to airflow. If this is not true, restriction must be considered in sizing and selection of a cooling fan and drive motor. Typical examples of restrictions include landscaping, nearby buildings, air turbulence created by buildings or other structures, and sight or noise “screens”. See Figure 2-9. Remote Radiator Fan Motor. Remote radiator cooling systems require the use of an electrically driven fan.
Figure 2-11 Valves & Fittings and Fluid Flow in Pipe Figure 2-12 Hot Well Installation 2-14 General Information MN2408
Other Considerations General: 1. Deaeration of the coolant. This can be accomplished through the use of the system deaerators in very large systems, or simply ensuring the radiator top tank or surge tank is at the highest point in the piping system. Unvented piping systems can create air pockets which reduce coolant flow and can lead to engine overheating. Baldor furnished radiators are equipped with deaerating top tanks. 2.
Coolant Treatment: See Figure 2-13. 1. Engine coolant should be treated with a Diesel Coolant Additive (DCA) to minimize corrosion of the engine and cooling system components. A 50/50 ethylene glycol antifreeze solution is recommended for all genset engines. This will provide freeze protection and increase the boiling point of the engine coolant. A solution can be increased to 65%. Do not exceed 65% as freeze protection begins to diminish at 65%. 2.
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. Gravity louvers face inward for air intake and outward for discharge. E. Where electrically operated ventilation devices are used, power must be present under all operating situations. Be certain these devices are on the emergency circuit.
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. The air movement must be provided by an electrically driven fan. This fan may be located in the air inlet or exhaust opening.
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.
6. 7. Conduit, wire, circuit protective device sizes, insulation etc. must conform to applicable local and national codes and regulations. 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.
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.
2-22 General Information MN2408
Section 3 Receiving & Installation Receiving & Inspection When you receive your generator, 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.
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: 1. For effective cooling and maintenance, the system should be mounted on a flat, smooth, noncombustible level surface. A concrete pad is ideal and provides a secure installation. 2.
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 generator 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 generator mounting frame.
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.
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.
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. External connections required at the time of installation are: 1. Fuel System. 2.
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. 1, 096 From Table 3-6, 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).
Example: Determining Pipe Size for LPG 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 + 63.5 cubic feet per hour. 2, 516 From Table 3-6, a 60 foot run requires a minimum 1” pipe at full engine load. LP Gas Connections (vapor withdrawal only) The LPG connections should only be made if your generator is setup to run on LPG.
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.
Figure 3-4 Three Phase WYE and DELTA Connections 3-10 Receiving & Installation MN2408
Battery Charger Considerations 1. Mount the battery charger on the generator or as close to the generator 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.
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 (Install away from terminals) Battery 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.
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 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. Verify that proper clearance exists on all sides and top of enclosure.
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.
Operator Control Panel Continued Auto Switch Auto LEDLoad Test Switch - Load Test LED - When pushed, initiates automatic operation of the engine (generator set). Starting and stopping of the engine is controlled by a remote contact (transfer switch). When the remote start signal is removed the engine will continue to run for the cool down period (if selected) then stop. Pushing the Off switch will stop the engine immediately, even if the cool down period is not complete.
5. 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. A specific shutdown fault can be programmed with a definite time transient delay period that must expire before the shutdown is activated.
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: 1. Remote Start input signal (terminals 16 & 17) is not activated (i.e. normal). 2.
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: 1. 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. 2.
Figure 4-3 Engine Controller Inputs & Outputs 4-6 Operation MN2408
Analog Faults Eight analog fault inputs are user programmable for 12 fault conditions. Each analog fault input requires a specific analog signal type.
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. Run The Run contact is a Form A" dry contact to control the engines Run" circuit.
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. The LCD display shows the status of the generator output: Operating Status The controller will power–up into an Emergency Stop failure mode, preventing possible engine operation.
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. When the timing function has expired, the LCD display will automatically change to either the next timing sequence countdown display or return to the original system status menu.
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 Voltage/Engine Speed (Tachometer) Battery Speed Program Menus Program Menu 27.0 Vdc 1800 rpm Displays battery voltage in DC volts. The voltage is displayed with a resolution of 1/10 of a volt. Displays engine speed in revolutions per minute (RPM).
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 Loss Of Speed Signal Select the desired action (i.e. alarm or shutdown) when a loss of speed signal is detected during operation. Note: A loss of speed signal must be detected for longer than 2 seconds to initiate the desired action. Common Fail For Not In Auto" Function Selects if a common fail alarm condition is to be activated during manual operation. Horn For Not In Auto The Horn may be programmed to sound when the controllers operating mode is switched from the Auto position.
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. Digital Fault Label Select the desired fault label, these are stored in non-volatile memory.
Span Calibration Energize the generator supply voltage to the controller at nominal level. Note: It may be necessary to program the optional under and over voltage shutdowns as alarms to ensure the generator will continue to operate during calibration. Caution must be taken to ensure the generator output voltage is set within nominal limits. In the programming mode, scroll to the desired generator supply voltage phases with the SPAN function selected.
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. The external pressure gauge should be connected as close as possible to the pressure sender.
Figure 4-4 Configuration Data Sheet j j j 4-18 Operation j j j j j j MN2408
Figure 4-5 Main Menu Loop Parameters Parameter System Voltage (Line To Line) System Frequency System y Phases Temperature Scale Pressure Scale Start Delay Crank Time Rest Time Starter Re–engage Delay Number Of Cranks Bypass Delay Cool down Delay Nominal RPM Flywheel Teeth (Engine Speed Sensing, Magnetic Pick Up Crank Disconnect Overspeed Overspeed Transient Run Output Loss Of Speed Signal Common Fail For Horn For Not In Auto Prog Output #1 Prog Output #2 Prog Output #3 Prog Output #4 Prog Output #5 Prog Ou
Figure 4-6 Analog Fault Menu Loop Parameters Fault Name Input Analog Type Fault E Enable E=Enable D=Disable Under Voltage AC Voltage E* Under Frequency AC Frequency E* Weak Battery DC Voltage E* Low Battery DC Voltage E* Voltage High Battery DC Voltage E* Voltage Low Engine Temp Temp Sender E* High ENG Temp #1 Temp Sender E* Alarm High ENG Temp #2 Temp Sender E* Shutdown Low Oil Press #1 Press Sender E* Alarm Low Oil Press #2 Press Sender E* Shutdown * Indicates parameter is non-programmable.
Figure 4-9 Engine Control Connections 12VDC (24VDC) STARTING BATTERY + 10A – 1A VA B+ B– GRD CR VC SPEED SENSING MAGNETIC PICKUP OIL PRESSURE SENDER ENGINE TEMPERATURE SENDER REMOTE EMERGENCY STOP (CLOSE TO STOP) REMOTE FAULT RESET (CLOSE TO RESET) RUN 19 MP1 MP2 GRD VN IA 18 RUN CIRCUIT 1A VB VC 23 24 RUN CIRCUIT (FUEL SOL., GOV.
Operator Control Panel (Analog Engine Controller Only) Figure 4-10 Analog Operator Control Panel Panel Light VOLTAGE Panel Light PANEL LIGHTS HERTZ AMPERAGE ON OFF HIGH TEMPERATURE LOW OIL PRESSURE OVERSPEED OVERCRANK PANEL LIGHT FUSE RUN TIME (HOURS) Battery Volts Engine Temp Oil Pressure AMMETER OFF 3 1 2 Panel Lights switch (On-Off ) Turns on two lamps to illuminate the operator panel. Panel Light Fuse Fuse for panel lights.
Manual Start/Stop To manually Start the Gen–Set, set the Master Control switch to the “Manual Run” position. The following happens: 1. 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.) 2. When the engine start delay time expires, an engine RUN and CRANK output signal will be initiated.
Figure 4-12 A121H Analog Engine Controller Connections Display LED’s Lamp Test LT OSL Overspeed High Water Temperature HTI HTL High Water Temperature Low Oil Pressure LPI LPL Low Oil Pressure Cycle Crank CCI OCL Overcrank Remote Start Contact + LC Run Off COM TDI Auto Contacts are shown below * Run Alarm AL RR Fuel Relay FS Ground CS B+ CS Start Relay Off AGC1 Auto Starting Battery External Components Figure 4-13 ASM160 Analog Engine Controller Connections Auto Starting
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.). With proper installation and maintenance, the KN will provide years of trouble–free service.
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. either set of mounts will adequately support the KN. The bottom set of holes has a 1 3/4” bolt spacing for use with all Garretson universal mounting brackets.
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.
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 the Baldor Generator Service Department by calling (920) 236–4200.
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 LCD Display cannot be viewed Microprocessor failure Check that there are no wiring errors/short circuits connected to the controller. The MEC 20 contains an electronic fuse that trips when an overload condition exists and does not reset until the supply voltage is removed and reapplied after the overload condition is corrected.
Note: See Engine Controller manual for additional information. Table 5-3 Troubleshooting Guide (Analog Controller Only) Problem Controller cannot be Reset" Engine alarms are ON for high engine temperature or low oil pressure when engine is operating properly Possible Cause Engine not stopped Controller not in OFF mode Sending unit is disconnected (open circuit) Defective sending unit Overspeed shutdown occurs at normal speed Controller has failed or input from Magnetic pickup is incorrect.
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. When replacing fuses, use the exact replacement fuse (manufacturer and part number).
Replacement Parts Continued Description WELDMENT, BASE ISOLATOR, GEN END ISOLATOR, CONTROL BOX SOLENOID, ENGINE 12V BRKT, BATTERY TIE DOWN TANK, COOLANT RECOVERY CAP, COOLANT RECOVERY TANK VALVE, FUMOTO F-107-N VALVE, FUMOTO FG-2N MAG PICK-UP ASSY GM ENGINES FUSE, 1A FUSE, 10A FUSE, AGC 2 FUSE, AGC 15 SWITCH, TOGGLE SWITCH, DPDT SWITCH, E, 3PH RELAY DIODE, 1N5408 LAMP FIXTURE, DASH LAMP, #67, 12 VOLT RHEOSTAT, 1K, 2W ENCLOSED KNOB, RHEOSTAT GASKET, EXHAUST RING DIODE, 1N5408 AIR CLEANER, ELEMENT SOLENOID, F
Replacement Parts Continued Description DECAL BONDED NEUTRAL" DECAL FUSE TYPE & WARNING" DECAL, CONTROL PANEL PLACARD, REMOTE START" DECAL, BALDOR LOGO,26" DECAL, BALDOR LOGO DECAL, DANGER-HIGH VOLTAGE DECAL, WARNING, AUTO START PLACARD, LINE" PLACARD, LOAD" PLACARD, NEUTRAL" PLACARD, L1" PLACARD, L2" PLACARD, L3" PLACARD, A.C.
GLC Circuit Breaker & Electrical Data Alternator GLC Model Model GLC125 GLC125 Engine Output Leads/ Winding Fuel Type Size KW Rated Phase Voltage Config VAC (L - L) VAC (L - N) FLA 115% FLA Circuit Breaker C.T. Ratio Wire Size (QTY) AWG UCI274E 4/06 Nat Gas UCI274E 12/311 Nat Gas GM/8.1L 115 GM/8.1L 125 1 Series 240 120 479 551 600 600:5 (2) #2/0 3 // WYE 208 120 434 499 500 500:5 (2) #1/0 GLC125 UCI274E 12/311 GLC125 UCI274E 12/311 Nat Gas GM/8.
GLC DATA Continued Alternator Engine Output GLC Model Model Leads/ Winding Fuel Type Size KW Rated Phase Voltage Config VAC (L - L) VAC (L - N) FLA 115% FLA Circuit Breaker C.T. Ratio Wire Size (QTY) AWG GLC100 UCI274E 4/06 Nat Gas GM/8.1L 84 1 Series 240 120 350 403 400 400:5 (2) #4/0 GLC100 UCI274E 12/311 Nat Gas GM/8.1L 86 3 // WYE 208 120 298 343 350 400:5 (1) #3/0 GLC100 UCI274E 12/311 Nat Gas GM/8.
GLC DATA Continued Alternator Engine Output GLC Model Model Leads/ Winding Fuel Type Size KW Rated Phase Voltage Config VAC (L - L) VAC (L - N) FLA 115% FLA Circuit Breaker C.T. Ratio Wire Size (QTY) AWG GLC60 UCI224F 4/06 Nat Gas GM/5.7L 54 1 Series 240 120 225 259 300 300:5 (1) #2/0 GLC60 UCI224E 12/311 Nat Gas GM/5.7L 53 3 // WYE 208 120 184 211 225 250:5 (1) #1 GLC60 UCI224E 12/311 Nat Gas GM/5.
GLC DATA Continued Alternator Engine Output GLC Model Model Leads/ Winding Fuel Type Size KW Rated Phase Voltage Config VAC (L - L) VAC (L - N) FLA 115% FLA Circuit Breaker C.T. Ratio Wire Size (QTY) AWG GLC45 UCI224D 4/06 Nat Gas GM/4.3L 37 1 Series 240 120 154 177 175 200:5 (1) #1 GLC45 UCI224D 12/311 Nat Gas GM/4.3L 39 3 // WYE 208 120 135 156 175 150:5 (1) #1 GLC45 UCI224D 12/311 Nat Gas GM/4.
GLC DATA Continued Alternator Engine Output GLC Model Model Leads/ Winding Fuel Type Size KW Rated Phase Voltage Config VAC (L - L) VAC (L - N) FLA 115% FLA Circuit Breaker C.T. Ratio Wire Size (QTY) AWG GLC30 BCI184G 4/06 Nat Gas GM/4.3L 30 1 Series 240 120 125 144 150 150:5 (1) #4 GLC30 UCI224C 12/311 Nat Gas GM/4.3L 30 3 // WYE 208 120 104 120 125 125:5 (1) #4 GLC30 UCI224C 12/311 Nat Gas GM/4.
GLC Wire Size Revision B Circuit Breaker Size 15 20 30 40 50 60 70 80 90 100 110 125 150 175 200 225 250 300 350 400 450 500 600 700 800 900 1000 1200 1400 1600 2000 2500 3000 4000 5–12–04 Quantity per Minimum Phase Wire Gauge EDI Plant Ampacity @125C 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 3 3 3 3 4 4 5 6 7 8 1 - #14 EPDM PER PHASE 1 - #14 EPDM PER PHASE 1 - #8 EPDM PER PHASE 1 - #8 EPDM PER PHASE 1 - #8 EPDM PER PHASE 1 - #8 EPDM PER PHASE 1 - #8 EPDM PER PHASE 1 - #8 EPDM PER PHASE 1 - #6 EP
MEC20 Figure A-2 Customer Interface Connection Diagram MEC2 A-10 Series GLC MN2408
Figure A-3 Customer Interface (w/o Breaker) Power Connection Diagram MN2408 Series GLC A-11
Figure A-4 Single Phase – (w/o Breaker) Connection Diagram A-12 Series GLC MN2408
Figure A-5 Single Phase – One Breaker Connection Diagram MN2408 Series GLC A-13
Figure A-6 Single Phase – Two Breaker Connection Diagram A-14 Series GLC MN2408
Figure A-7 Single Phase Connection Diagram (Wire 1/0 and Larger w/Breaker) MN2408 Series GLC A-15
Figure A-8 Single Phase Connection Diagram (Wire 1/0 and Smaller w/Breaker) A-16 Series GLC MN2408
Figure A-9 Single Phase Connection Diagram (Wire 1/0 and Smaller w/o Breaker) MN2408 Series GLC A-17
Figure A-10 Single Phase Connection Diagram (Wire Larger than 1/0 w/o Breaker) A-18 Series GLC MN2408
Figure A-11 Three Phase Connection Diagram MN2408 Series GLC A-19
Figure A-12 Three Phase Connection Diagram with PMG A-20 Series GLC MN2408
Figure A-13 Three Phase Connection Diagram (Wire 1/0 and larger) MN2408 Series GLC A-21
Figure A-14 Three Phase Connection Diagram (Wire Larger than 1/0 w/Breaker) A-22 Series GLC MN2408
Figure A-15 Three Phase Connection Diagram (Wire 1/0 and Smaller w/Breaker) MN2408 Series GLC A-23
Figure A-16 Three Phase Connection Diagram (Wire Larger than 1/0 w/o Breaker) A-24 Series GLC MN2408
Figure A-17 Three Phase Connection Diagram (Wire 1/0 and Smaller w/o Breaker) MN2408 Series GLC A-25
Figure A-18 Control Box Connections with MEC20 Controller Without Governor A-26 Series GLC MN2408
Figure A-19 Control Box Connections with MEC20 Controller & Governor With Governor MN2408 Series GLC A-27
Figure A-20 Control Box Connections with MEC2 Controller A-28 Series GLC MN2408
Figure A-21 Engine Wiring, Woodward 4.
Figure A-22 Engine Wiring, Woodward 5.
Figure A-23 Engine Wiring, Woodward 8.
A-32 Series GLC MN2408
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.
Pre Start-up Check List n n Start-up Procedure No freight damage (Components tight, straight, etc.). Check that all applicable warning decals are in their proper place and are legible. Proper belt alignment and tensions. The ATS engine start wires and other DC wires, if any, must be properly connected. Flex fuel lines installed between engine and tank. All wiring connections are tight. Fluid levels (Oil, Antifreeze, Battery, Governor, etc.) Check for leaks, tighten as necessary.
Baldor District Offices UNITED STATES ARIZONA PHOENIX 4211 S 43RD PLACE PHOENIX, AZ 85040 PHONE: 602-470-0407 FAX: 602-470-0464 CALIFORNIA LOS ANGELES 6480 FLOTILLA COMMERCE, CA 90040 PHONE: 323-724-6771 FAX: 323-721-5859 HAYWARD 21056 FORBES STREET HAYWARD, CA 94545 PHONE: 510-785-9900 FAX: 510-785-9910 COLORADO DENVER 2520 W BARBERRY PLACE DENVER, CO 80204 PHONE: 303-623-0127 FAX: 303-595-3772 CONNECTICUT WALLINGFORD 65 SOUTH TURNPIKE ROAD WALLINGFORD, CT 06492 PHONE: 203-269-1354 FAX: 203-269-5485 FLORID
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. BALDOR GENERATORS 3815 Oregon Street Oshkosh, WI 54902 (920) 236–4200 or (800) 872–7697 Fax (920) 236–4219 www.baldor.
