GLC Generator (Gaseous Liquid Cooled) GLC10, 15, 20, 25 30, 40, 45, 60, 65, 100 and 105 Installation & Operating Manual 2/08 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Digital Engine Controller Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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.
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 charges the batteries during engine operation. Standby gensets should include 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 utility power emergency circuit. The batteries on prime power gensets are charged by the engine mounted alternator, if equipped.
2‐14 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 LPV 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 Vapor Connections (vapor withdrawal only) The LPV connections should only be made if your generator is setup to run on LPV.
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 generator set. 5.
Figure 3‐5 Single Phase Connections From Alternator (Factory Wired) Bond Jumper Note: Remove the Bonding jumper to meet local codes if required.
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 may be shipped with no battery installed. Procedure: The correct type battery must be installed in the battery compartment provided, see Table 3‐7. 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. 1. Open access doors and locate battery tray. 2. Place the correct battery (see Table 3‐7) on the tray. 3.
Post Installation Checks Caution: When the initial installation is complete, these checks must be performed before starting the engine. These checks are not required before each start, only after the initial installation. 1. Generators that have been in transit or storage for long periods may be subjected to extreme temperature and moisture changes. This can cause excessive condensation, and the generator windings should be thoroughly dried before bringing the generator up to full nameplate voltage.
Post Installation Checks Continued 22. With the engine running, several checks must be made: a. Verify there are no fuel leaks. If a fuel leak is detected, stop the engine immediately (move the Master Control Switch to the “Stop” position) and repair the leak before proceeding. b. Verify there are no coolant or oil leaks. If a leak is detected, stop the engine immediately and repair the leak before proceeding. c. Verify that operation is smooth.
3‐16 Receiving & Installation MN2408
Section 4 Operation Digital Engine Controller Description EM0046A21 (MRS17) Figure 4‐8 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 equyipped 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 EM0046A21 (MRS17) 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 4‐9. 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 EM0046A21 (MRS17) Continued Table 4‐9 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 4‐10 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 4‐10 When warning comes up, only alarm outputs and common warning output are closed. Shut down (SD) see Table 4‐10 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 - 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 4‐11 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 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 - from the list, Value dimension (e.g.
Table 4‐15 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 4‐15 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 4‐17 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 4‐18 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 EM0046A21 (MRS17) Continued Figure 4‐11 Controller Connection Diagram LOAD DI ESE L /GAS ENGIN E GENERATOR L1 L2 G L3 FUEL SOLENOID N BI6 BI5 BI4 BI3 EMERGENCY STOP REMOTE SSTART/STOP BI1 BINARY INP UTS LB 1 GENER ATOR V O LTA G E 3 x 230 / 400 V GENERATOR CURRENT 0- 5A BI2 L3 L2 N L1 L3l L2l CO M START ER PE RPM L1l BATTERY OIL PRESSURE FUELLEVEL + WATER TEMP - Remote Start RS 232 CAN D+ BO6 ALARM BO5 + -
Digital Engine Controller Description EM0046A21 (MRS17) Continued Figure 4‐12 Controller Connection Diagram LOAD DI ESE L /GAS ENGIN E GENERATOR L1 L2 G L3 BI6 BI5 BI1 L3 L2 N L1 BINARY INP UTS LB 1 L2l L1l CO M L3l GENER ATOR V O LTA G E 3 x 230 / 400 V GENERATOR CURRENT 0- 5A BI4 TO BATTERY START ER BI3 + BATTERY EMERGENCY STOP PE REMOTE SSTART/STOP - JDIC +- BI2 FUEL SOLENOID N Remote Start RS 232 CAN D+ BO6 + - BO5 PO W ER 8- 36VDC BO4
Operator Control Panel (MICROPROCESSOR Engine Controller Only) The Operator Control Panel is shown in Figure 4‐13. 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 4‐14. 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 4‐15 Engine Controller Inputs & Outputs 4‐18 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 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). Engine Temperature/Oil Pressure ENG TEMP OIL PRESS BATTERY SPEED ENG TEMP OIL PRESS 57 Deg C 200 KPA Displays engine temperature in either degrees Celsius or Fahrenheit (as selected).
Navigation Hints Programming parameters are displayed in the same order as the Programming Sheets (see Figures 4‐17 to 4‐20). 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 Caution: The controller's digital fault settings are described as follows: 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 4‐16 Configuration Data Sheet j j j 4‐30 Operation j j j j j j MN2408
Figure 4‐17 Main Menu Loop Parameters Parameter System Voltage (Line To Line) System Frequency System 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 Out
Figure 4‐18 Analog Fault Menu Loop Parameters Fault Name Input Analog Type Fault 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 4‐21 Engine Control Connections 12VDC (24VDC) STARTING BATTERY + 10A - 1A B+ VA VA 1A B - VB VB 1A GRD VC VC VN N 23 CRANK CRANK PILOT RELAY CR 24 IA 18 RUN CIRCUIT RUN CIRCUIT (FUEL SOL., GOV.
4‐34 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 5‐2 Troubleshooting Guide (Digital Controller Only) Problem Controller does not power up even with correct DC power applied Possible Cause Wiring Mistake Overload Condition LCD Display cannot be viewed Microprocessor failure Improper Supply Voltage Improper contrast adjustment Remedy Check that there are no wiring errors/short circuits connected to the controller.
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 BTCGR6 Battery Charger - 12 Volt / 6 Amp Float. Includes 6 ft power cord with grounding plug for AC input power and 4 ft power cord with ring terminals for DC output. UL Listed. BTCGR10A Battery Charger - 12 Volt /10 Amp Float. Includes terminal strip for AC input power and DC output.UL Listed.
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.
Engine Block Heater Installation Considerations: Shore power must be available (120VAC or 240VAC) to power the block heater and other components that may be installed). Shore power outlets or wiring must be located close to block heater. Figure A‐3 Catalog # G10A Block Heater (refer to block heater manual for specific details) 1. Mount the block heater, refer to Figure A‐3 to determine suggested location. 2. Connect the inlet hose to the inlet hose bib on the block heater. 3.
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.
Fuel Strainers & Fuel Lines A fuel strainer and flexible fule 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 GLCFFL1 3/4” NPT Female fittings, 12” long GLCFFL2 1 - 1/4” NPT Female fittings, 18” long GLCFFL3 2” NPT Female fittings, 12” long GLCFFS1GLCFFLS3 3/4” NPT Fuel Strainer female Inlet, male outlet.
E-Stop E-Stop Switch Kit - Mounts to Baldor supplied Enclosure to provide easy access to shut down engine with the press of a button. Connects to Remote Run Terminals on genset. Must be adapted for remote mounting when used with open skid mount units. Figure A‐6 1 3 Installation: 1. 2. 3. 4. A‐6 Series GLC Locate and drill 4 holes shown in Figure A‐6. Mount the E-Stop Switch box to the enclosure, Install the E-Stop assembly into the E-Stop Switch box enclosure.
Remote Annuciators Remote Annunciator - For use with MEC2 Controller. Provides remote anunciation of faults and generator status. Up to 20 individual fault conditions are remotely monitored utilizing 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‐9 Table A‐1 Mounting Dimensions Generator GLC10-25 GLC30-60 GLC80-100 A‐8 Series GLC A 3.00 3.00 3.00 B 22.00 26.00 26.38 C 20.00 26.70 29.
Enclosures Weather Resistant Enclosure - Heavy-duty 12 gauge hot rolled steel with welded corners and baked powder coat finish. Fasteners are zinc chromate plated and the locking latches are chrome plated on the lift off access doors. Silencer is mounted on top of reinforced pitched roof. Sound Attenuated Enclosure - Heavy-duty 12 gauge hot rolled steel with welded corners and baked powder coat finish includes sound deadening insulation for 15 dB of attenuation.
A‐10 Series GLC MN2408
Appendix B Series GLC Information & Wiring Diagrams GLC Circuit Breaker & Electrical Data 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 Qty per Phase 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 Min Wire Gauge #16 #16 #14 #12 #10 #8 #8 #6 #6 #6 #6 #4 #2 #2 #1 1/0 2/0 4/0 4/0 #1 1/0 1/0 3/0 4/0 2/0 3/0 3/0 250 4/0 250 250 250 250 300 OSH Plant 1 - #8 EPDM PER PHASE 1 - #8 EP
Figure B‐11 Customer Interface Connection Diagram MEC20 MEC2 B‐2 Series GLC MN2408
Figure B‐12 Customer Interface (w/o Breaker) Power Connection Diagram MN2408 Series GLC B‐3
Figure B‐13 Single Phase - (w/o Breaker) Connection Diagram B‐4 Series GLC MN2408
Figure B‐14 Single Phase - One Breaker Connection Diagram MN2408 Series GLC B‐5
Figure B‐15 Single Phase - Two Breaker Connection Diagram B‐6 Series GLC MN2408
Figure B‐16 Single Phase Connection Diagram (Wire 1/0 and Larger w/Breaker) MN2408 Series GLC B‐7
Figure B‐17 Single Phase Connection Diagram (Wire 1/0 and Smaller w/Breaker) B‐8 Series GLC MN2408
Figure B‐18 Single Phase Connection Diagram (Wire 1/0 and Smaller w/o Breaker) MN2408 Series GLC B‐9
Figure B‐19 Single Phase Connection Diagram (Wire Larger than 1/0 w/o Breaker) B‐10 Series GLC MN2408
Figure B‐20 Three Phase Connection Diagram MN2408 Series GLC B‐11
Figure B‐21 Three Phase Connection Diagram with PMG B‐12 Series GLC MN2408
Figure B‐22 Three Phase Connection Diagram (Wire 1/0 and larger) MN2408 Series GLC B‐13
Figure B‐23 Three Phase Connection Diagram (Wire Larger than 1/0 w/Breaker) B‐14 Series GLC MN2408
Figure B‐24 Three Phase Connection Diagram (Wire 1/0 and Smaller w/Breaker) MN2408 Series GLC B‐15
Figure B‐25 Three Phase Connection Diagram (Wire Larger than 1/0 w/o Breaker) B‐16 Series GLC MN2408
Figure B‐26 Three Phase Connection Diagram (Wire 1/0 and Smaller w/o Breaker) MN2408 Series GLC B‐17
Figure B‐27 Control Box Connections with MEC20 Controller B‐18 Series GLC MN2408
Figure B‐28 Control Box Connections with MEC20 Controller & Governor MN2408 Series GLC B‐19
Figure B‐29 Control Box Connections with MEC2 Controller B‐20 Series GLC MN2408
Figure B‐30 Engine Wiring, Woodward 4.
Figure B‐31 Engine Wiring, Woodward 5.
Figure B‐32 Engine Wiring, Woodward 8.
B‐24 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. BALDOR ELECTRIC COMPANY World Headquarters P.O. Box 2400 Fort Smith, AR 72901-2400 (479) 646-4711 Fax (479) 648-5792 www.baldor.
