GLC Generator (Gaseous Liquid Cooled) GLC10, 15, 20, 25 35, 45, 55, 75, 105 and 130 Installation & Operating Manual 1/10 MN2408
Any trademarks used in this manual are the property of their respective owners. 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 4 Operation Digital Engine Controller Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Inputs . . . . . . . . . .
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 Battery Safety 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. Battery electrolyte solution is caustic and can cause severe burns and blindness.
Warning Statements Continued Maintenance WARNING: Before cleaning, inspecting, repairing or performing any maintenance to the generator set, always be sure the engine has stopped and that all rotating parts have also stopped. After stopping, certain components are still extremely hot so be careful not to get burned. Before servicing the generator set, be sure to disconnect the spark plug wires and the battery terminals to prevent accidental engine rotation or starting.
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.
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.
Utility Power During periods when the generator is not running, utility power must be provided to power critical components. Battery chargers, block heaters, space heaters and other devices must have power to maintain the generator set components and allow fast easy starting. 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.
S Caution: Caution: 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. The base should be mounted to the foundation pad as shown in Figure 2-1 or as recommended by the isolator manufacturer.
Table 2-1 Approximate Load Bearing Capacities of Various Soil Types Soil Type Hard Rock − Granite etc. Medium Rock − Shale etc.
Multi−Engine Installations Caution: Do not connect multi−engine exhaust systems together. Each engine must have its own exhaust system for proper operation. Exhaust gases from an operating engine will migrate back through a non−operating engine and cause a hydraulic lock. This may interfere with starting of the second engine. The migrating gases will also tend to turn the turbos which are not being provided lubrication if the engine is not running.
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.
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.
Battery Starting System This section describes the battery starting system (nominal 12 or 24 volt rating of the battery supply) for the engine, battery charger, and precautions to take if the ambient temperature is expected to be below 70 °F (20°C). WARNING: If batteries are not mounted in the battery rack supplied with the Genset, protect batteries from vibration and do not locate them near a source of flame or spark. A battery presents a risk of fire and explosion because they generate hydrogen gas.
Battery Cables The wire size (wire gauge) of the cables connecting the starter to the batteries must be large enough to ensure the resistance of the cranking circuit is less than the “Maximum Allowable Resistance of the Cranking Circuit” as shown on the Engine−Generator Set Data Sheet. The total cranking circuit resistance includes the resistance of the cables from the starting motor to the battery and the resistance of all relays, solenoids, switches, and connections.
Formulas Single Phase − Electric Single Phase Power Factor is typically 1.0 1 kW = 1 kilo Watt = 1,000 Watts Watts + Volts x Amps x Power Factor Amps + Three Phase − Electric Watts Volts x Power Factor Three Phase Power Factor is typically 0.8 1 kW = 1 kilo Watt = 1,000 Watts Watts + (Volts x Amps x Power Factor) x 1.732 Amps + Watts Volts x Power Factor x 1.732 Length inches x 25.40 = mm feet x 0.305 = m yard x 0.914 = m mm x 0.03937 = inches m x 3.280 = feet m x 1.094 = yard Area inches2 x 6.
Section 3 Receiving & Installation Receiving & Inspection When you receive your Genset, 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.
Several other factors should be carefully evaluated when selecting a location for installation: 1. For effective cooling and maintenance, the system is mounted on a flat, smooth, noncombustible level surface. A concrete pad is ideal. 2. Installation should prevent water levels from reaching the Genset. Drainage must be adequate to keep concrete pad free from standing water. 3. Installation should prevent obstructions by buildup of leaves, grass, sand, snow, etc.
Figure 3-2 Genset Mounting 10−25kW MN2408 Receiving & Installation 3-3
Table 3-2 Mounting Dimensions 35−130kW 3-4 Receiving & Installation MN2408
Table 3-3 Mounting Dimensions 35−130kW Continued MN2408 Receiving & Installation 3-5
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.
WARNING: Never allow the exhaust outlet to be positioned so that the exhaust gases are directed towards any openings or air entry routes (doors, windows, vents, etc...) of an occupied building. When discharging the hot exhaust gases out of the building do not direct them towards anything that could catch fire or explode. WARNING: Exhaust fumes/gases are extremely dangerous and can cause severe illness or death. Never breath exhaust fumes produced by a running engine.
The following pamphlets are available from: National Fire Protection Association (NFPA) P.O. Box 9101 Quincy, MA 02269 No. 37 − Combustion Engines No. 54 − Gaseous Appliances and piping No. 58 − Storage and handling LPV Example: Determining Pipe Size for Natural Gas A Genset has a 16Hp engine 60 feet from the supply. An engine needs 10,000 BTU/hr per hp to run efficiently. For Natural Gas fuel there are 1015 BTU/ft3 Determine the supply pipe size for Natural Gas fuel.
Figure 3-3 Gas Line Connections Air Cleaner Carburetor (Typical piping as shown) External Supply Piping (by installer) U.L. requires a second shutoff valve and regulator to be installed in the supply piping to control the gas supply to the Genset.
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.
Transfer Switch Considerations The following are general considerations for the safe use of a transfer switch: 1. The transfer switch should be located inside the building near the main breaker box or the disconnect box. 2. The transfer switch must be kept away from any location that might allow water to get on it. 3. If the transfer switch is mounted outside, it must be protected from the environment and it’s elements. 4. Do not mount the transfer switch on the Genset. 5.
Figure 3-5 Single Phase Connections From Alternator (Factory Wired) Bond Jumper Note: Remove the Bonding jumper to meet local codes if required.
Frame Ground Connection It is important for safety reasons that the Genset, transfer switch and battery charger share a common Ground and neutral. The NEC requires that the frame and exposed metal surfaces be at local ground reference potential to avoid electrical shock hazard. A local ground reference may require a driven earth ground conductor at the Genset installation site. Make the ground connection as shown in Figure 3-7. Use the appropriate size wire as required by NEC and local codes.
Caution: This Genset must have a battery installed for operation. The battery is used during starting and during operation. If engine operation is attempted while the battery is removed, damage to the engine’s electrical components may result. Battery Connections 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.
Figure 3-8 Battery Installation (10−25kW only) 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. Battery Washers & Nut Battery Hold Down Bar (Install away from terminals) 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.
Post Installation Checks Continued 5. Verify that proper clearance exists on all sides and top of enclosure. 6. Verify that Genset power is properly connected to the transfer switch. 7. Verify that Genset and transfer switch are properly grounded. 8. Assure that Genset is a safe distance from any flammable or combustible material. 9. Verify that the Genset and transfer switch load are voltage compatible. 10. Verify that no load is connected to the circuit breaker and/or transfer switch. 11.
Section 4 Operation Digital Engine Controller Description EM0046A45 (MRS19) Figure 4-1 Operator Control Panel Operating Modes and Horn & Fault Reset Manual Run Display Stop Menu Group LED Indicators LED Indicators Note: The operator control panel is equipped with a heater element that allows the LCD display to operate to −40°C (not the entire generator set, see generator specifications). This heater operates from the main battery power. Alarm (red) − Alarm (shutdown) condition occurred.
Digital Engine Controller Description EM0046A45 (MRS19) Continued Operating Mode Press Mode 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 4-2. When the desired Control Mode is highlighted, press Start to begin operation. Press Stop to terminate operation. OFF − Generator set operation is not allowed. MAN − Press Start to manually start the generator set immediately.
Digital Engine Controller Description EM0046A45 (MRS19) Continued Table 4-2 Manual Mode Sequence Description Menu Status Condition of Transition Start request Ready Prestart RPM > 2 or Oil pressure detected or Gen voltage > 10V OFF mode selected or Shut down alarm active RPM < 2, Oil pressure not detected, Vgen < 10V, no shutdown alarm active, other than OFF mode selected Prestart time elapsed Cranking RPM> Start RPM D+ input activated or oil pressure detected or Gen voltage > 25% Vgnom MaxCrank time
Alarms Following alarms are available: Sensor fail (FLS) see Table 4-3 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 4-3 When warning comes up, only alarm outputs and common warning output are closed. Shut down (SD) see Table 4-3 When the shut−down alarm comes up, InteliLite opens outputs GCB CLOSE/OPEN, FUEL SOLENOID, STARTER and PRESTART to stop the engine immediately.
Inputs and Outputs Any Binary input or output can be configured to any controller terminal Inputs are BI1 − BI7, Outputs are BO1 − BO7) or changed to different function by LiteEdit software. There is fixed 1 sec delay when any binary input is configured as protection. Table 4-4 Binary Inputs Alarm Alarm type Warning or Shut down Alarm active All the time, or Engine running only External request for engine run. AUT mode only. If the input is opened, shut down is immediately activated.
Analog Inputs Three analog inputs for resistive sensor 0 to 2400 ohms measuring are available on the controller. Use LiteEdit software to modify configuration. The Analog inputs values assignment (AI1 = Oil press, AI2 = Water temp, AI3 = Fuel level) is fixed. It is possible to configure on each Analog input: Reading from Analog inputs or from Engine Control Unit via CAN bus (J1939) Sensor characteristics − from the list, Value dimension (e.g.
Table 4-8 Engine Setpoints Start RPM Starting POil Prestart time MaxCrank time CrnkFail pause Crank attemps Idle time GCB CloseDelay Stabil time MinStpValvTime “Firing” speed when iL controller stops cranking (starter goes OFF). Step: 1% of nominal RPM; Range: 5 − 50 % 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).
Table 4-8 Engine Setpoints Continued Cooling time AfterCoolTime CoolingSpeed D+ function Runtime of the unloaded gen−set to cool the engine before stop. Step: 1s; Range: 0 − 3600 s Runtime of engine after cooling pump. Binary output Cooling pump is closed when the engine starts and opens AfterCool time delayed after gen−set stops. Step: 1s Range: 0 − 3600s Selects the function of the Binary output IDLE/NOMINAL during engine Cooling state.
Table 4-10 Generator Protect Setpoints Overload Overload Wrn Overload del Ishort 2Inom del Curr unbal Curr unbal del Gen >V Gen >V Wrn Gen f Gen >f Wrn Gen
Table 4-11 Sensor Spec Setpoints Calibr AI1,AI2, AI3 AnOut−kW/20mA Calibrating constant to adjust the measured value of IL analog inputs. Physical dimension of calibrating constant is corresponding to Analog input. Step: 1; Range: −1000 to +1000 Conversion coefficient from gen−set power to iG−IOM or PTM analog output.
Digital Engine Controller Description EM0046A45 (MRS19) Continued Figure 4-4 Controller Connection Diagram LOAD GENERATOR ENGINE L1 G L3 N FUEL SOLENOID PE REMOTE SSTART/STOP − Remote Start + BATTERY START ER EMERGENCY STOP EC U L2 MN2408 ALARM PRESTART FUEL SO LENOID STARTER GENSET Control Operation 4-11
4-12 Operation MN2408
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 a qualified generator service center. Table 5-1 General Troubleshooting Guide Problem Engine cranks but will not start Possible Cause No fuel.
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 Check that there are no wiring errors/short circuits connected to the controller. Check breaker on the Control Panel. Check Fuses on Control Panel. Overload Condition LCD Display cannot be viewed Improper Supply Voltage Improper contrast adjustment Check DC supply voltage at terminals B+ & B- (10-30VDC).
Note: See Engine Controller manual for additional information. Table 5-3 Troubleshooting Guide (Analog Controller Only) Problem Controller cannot be “Reset" Possible Cause Engine not stopped Controller not in OFF mode Remedy Verify the engine is at a complete stop before trying to reset. Set the controller to the OFF mode before trying to reset.
Appendix A Options & Accessories Battery Charger BTCGR10A Battery Charger − 12 Volt /10 Amp Float. Includes terminal strip for AC input power and DC output. UL Listed. Figure A-1 Recommended Mounting Locations GLC35 Battery Charger GLC45−105 Battery Charger Mounting Location Mounting Location Frame Frame Battery Tray BTCGR10A BTCGR10A Battery Tray Installation Considerations: Shore power must be available (120VAC or 240VAC) to power the battery charger and other components that may be installed).
Battery Heaters Battery Heater (BTHTR81) − 120 Volt / 80 Watt. Includes 6 ft power cord. Installation Considerations: Shore power must be available (120VAC or 240VAC) to power the battery heater and other components that may be installed). Shore power outlets or wiring must be located close to battery heater. Figure A-2 Battery Heating Pad Installation BTHTR81 Heater 1. Carefully disconnect the Negative battery terminal from the battery. 2.
Silencers Refer to enclosure procedure to install silencer when enclosure is present. Industrial Silencer for Open Skid Mount Units − Provides silenced exhaust for up to 11 dBA sound attenuation. Kit includes engine adapters, flex pipe, clamps, silencer, and rain cap. Critical Silencer for Open Skid Mount Units − Provides silenced exhaust for up to 18 dBA sound attenuation. Kit includes engine adapters, flex pipe, clamps, silencer, and rain cap.
Flexible Fuel Lines A flexible fuel line can be installed at the fuel pressure regulator to make connection to the fuel main shutoff valve easier. Either 1−1/4” or 2” fittings may be specified. Figure A-5 Fuel Strainer and Flex Fuel Line Connections Fuel Solenoid Valve GLCFFL1 3/4" NPT Male fittings, 12" long GLCFFL2 1 - 1/4" NPT Male fittings, 18" long GLCFFL3 2" NPT Male fittings, 12" long GLCFS1 3/4" NPT Fuel Strainer female Inlet, male outlet. GLCFS3 2" NPT Fuel Strainer female Inlet, male outlet.
Remote Annunciators Remote Annunciator provides remote annunciation of faults and generator status. Individual fault conditions are remotely monitored using both visual LED lights & audible alarm annunciation. Lamp test and alarm horn silence pushbuttons are provided. Each fault is individually programmable for audible horn operation and alarm labels are field configurable. Requires 12VDC 100mA power supply to operate (engine starting battery can be power supply).
Radiator Duct Flange Radiator Duct Flange for Open Skid Mount − Provides easy connection to air ducting to carry away hot air from engine radiator. Duct flange mounts to front of engine radiator. Add 3” to length. Figure A-8 Frame B Optional Radiator Duct Flange Radiator/Fan As sembly Optional Radiator Duct Flange A C Frame Frame Table A-1 Mounting Dimensions Generator IGLC25 IGLC35 IGLC45-75 IGLC105 IGLC130 A-6 Series GLC A 3.00 3.00 3.00 3.00 3.00 B 22.00 26.00 26.38 26.38 26.63 C 20.00 26.
Appendix B Series GLC Information & Wiring Diagrams GLC Circuit Breaker Wire Size (Line Side) Circuit Breaker Size Wire Size AWG or kcmil Qty /Phase Type of Conductor Ampacity @ 600VAC 20 30 40 50 60 70 80 90 100 110 125 150 175 200 225 250 300 350 400 450 500 600 700 800 10 10 8 8 6 6 4 4 2 2 1 1 2/0 4/0 4/0 4/0 300 400 500 4/0 4/0 300 400 500 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 THHN, THWN, XHHW THHN, THWN, XHHW THHN, THWN, XHHW THHN, THWN, XHHW THHN, THWN, XHHW THHN, THWN, XHHW THHN, T
Figure B-9 Enclosure Grounding B-2 Series GLC MN2408
Figure B-10 Customer Interface Connection Diagram MN2408 Series GLC B-3
Figure B-11 Single Phase Diagram B-4 Series GLC MN2408
Figure B-12 Three Phase Diagram MN2408 Series GLC B-5
Figure B-13 DC Schematic for 10−25kW MUST USE UL APPROVED WIRE B-6 Series GLC MN2408
Figure B-14 DC Schematic for 10−25kW Continued MN2408 Series GLC B-7
Figure B-15 DC Schematic for 35−130kW MUST USE UL APPROVED WIRE B-8 Series GLC MN2408
Figure B-16 DC Schematic for 35−130kW Continued MN2408 Series GLC B-9
Figure B-17 B-10 Series GLC MN2408
Figure B-18 MN2408 Series GLC B-11
Figure B-19 B-12 Series GLC MN2408
Figure B-20 MN2408 Series GLC B-13
Figure B-21 B-14 Series GLC MN2408
Figure B-22 MN2408 Series GLC B-15
Figure B-23 B-16 Series GLC MN2408
Baldor District Offices
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. World Headquarters P.O. Box 2400 Fort Smith, AR 72902−2400 USA Ph: (1) 479.646.4711, Fax: (1) 479.648.5792 www.baldor.
