PRESENTS YOUR STANDBY PERMANENT MOUNT SERIES GENERATOR OPERATORS MANUAL BALDOR GENERATORS 3815 OREGON STREET OSHKOSH, WI 54902 PHONE: 920-236-4200 FAX: 920-236-4219 FORM#: S-PSG-002-91 C:\ISO9001\FORMS\S-PSG-00291.
FORWARD This manual contains the information you need to safely and efficiently operate your generator set. During the preparation of this manual every effort was made to ensure the accuracy of its contents. Never operate this generator set without first carefully reading this manual and observing all the safety warnings it presents.
Ƈ Place protective covers and guards over the rotating parts, if rotating parts such as the drive shaft, pulley, belt, etc. are left exposed, they are potentially hazardous. Ƈ When cleaning, repairing or inspecting, make sure all moving parts have stopped. Ƈ Prior to working on the generator set, disconnect the spark plug and battery to prevent accidental starting. Ƈ Use only original equipment or authorized replacement parts.
Ƈ Never permit anyone to operate the generator set without proper instructions. Ƈ Never allow children to operate the generator set. Ƈ Children and pets must be kept away from the area of operation due to the possibility of burns from hot engine components or injury from any equipment the generator set is powering. Ƈ Always wear eye protection and Hearing protection when working near the generator set.
Ƈ Always treat the electrical circuits as if they were energized. Ƈ Disconnect all leads plugged into the unit Prior to working on it. Ƈ Have the electrical circuits serviced only by qualified technicians. Ƈ Inspect wiring frequently and replace frayed, broken or poor leads. Ƈ Do not connect this unit to any building's electrical system unless you utilize an approved transfer switch or the main service entrance switch has been disconnected and locked open.
żżżż FOR GASOLINE OR DIESEL POWERED GENERATOR SETS żżżż Ƈ Check all fuel supply piping and their connections on a monthly basis for fuel leaks. Ƈ Use only approved piping and componentry in your fuel supply system. Ƈ A professional, experienced technician should only install the fuel supply system. Ƈ Do not run the fuel line up against any sharp objects. Ƈ Comply with NFPA regulations and your local codes in regard to shut-off valves, regulators, etc.
STANDBY PERMANENT- MOUNT SERIES GENERATOR Table of Contents ITEM VOLTAGE RATINGS: This informational page describes features and specifications for all Standby Permanent- Mount Series Units. ELECTRICAL CONNECTION INFORMATION: This information explains how to interface your generator with the AC loads and other standard and optional accessories. MOUNTING AND COOLING REQUIREMENTS: This section explains the necessary requirements for mounting and ventilating your Pow'R Gard Generator.
Farm Duty 1-Phase Model: DLC25 Baldor POWER SYSTEMS 4 Cycle Diesel Liquid Cooled Standby Power Ratings 60Hz kW 27.5 kVA 27.5 Continuous Power Ratings 60Hz kW 25 kVA 25 Assembled in USA Baldor Generator Features ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ Baldor generators are manufactured in a certified ISO9001 facility located in Oshkosh, Wisconsin.
Farm Duty 1-Phase Model: DLC25 Alternator Specifications Alternator Features Manufacturer Type Model Leads Voltage regulator Voltage regulation Insulation material: Rotor Insulation material: Stator Temperature rise Total harmonic distortion Bearing: quantity, type Coupling type One step load acceptance Stamford/Newage 4-Pole, Revolving field BCI184F 4 AVR 1/2% Class H Class H 125 C, Standby <5% 1, Sealed Flexible disc 100% of Rating Brushless design Class H insulation used throughout Solid-state volt
Farm Duty 1-Phase Model: D 50 Baldor POWER SYSTEMS 4 Cycle Diesel Liquid Cooled Standby Power Ratings 60Hz kW 50 kVA 50 50Hz 42 42 Continuous Power Ratings 60Hz kW 45 kVA 45 Assembled in USA Baldor Generator Features ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ Baldor generators are manufactured in a certified ISO 9001 facility located in Oshkosh, Wisconsin Every generator is design, prototype, and production tested Brushless synchronous four-pole alternator Industrial-grade exhaust silencer Engine
Farm Duty 1-Phase Model: DLC50 Alternator Specifications Alternator Features Manufacturer Type Model Leads Voltage regulator Voltage regulation Insulation material: Rotor Insulation material: Stator Temperature rise Total harmonic distortion Bearing: quantity, type Coupling type One step load acceptance Stamford/Newage 4-Pole, Revolving field UC224D 4 AVR 1/2% Class H Class H 125 C, Standby <5% 1, Sealed Flexible disc 100% of Rating Brushless design Class H insulation used throughout Solid-state volta
Farm Duty 1-Phase Model: D 60 Baldor POWER SYSTEMS 4 Cycle Diesel Liquid Cooled Standby Power Ratings 60Hz kW 60 kVA 60 50Hz 50 50 Continuous Power Ratings 60Hz kW 54 kVA 54 Assembled in USA Baldor Generator Features ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ Baldor generators are manufactured in a certified ISO 9001 facility located in Oshkosh, Wisconsin Every generator is design, prototype, and production tested Brushless synchronous four-pole alternator Industrial-grade exhaust silencer Engine
Farm Duty 1-Phase Model: DLC60 Alternator Specifications Alternator Features Manufacturer Type Model Leads Voltage regulator Voltage regulation Insulation material: Rotor Insulation material: Stator Temperature rise Total harmonic distortion Bearing: quantity, type Coupling type One step load acceptance Stamford/Newage 4-Pole, Revolving field UC224G 4 AVR 1/2% Class H Class H 125 C, Standby <5% 1, Sealed Flexible disc 100% of Rating Brushless design Class H insulation used throughout Solid-state volta
Farm Duty 1-Phase Model: D 75 Baldor POWER SYSTEMS 4 Cycle Diesel Liquid Cooled Standby Power Ratings 60Hz kW 75 kVA 75 50Hz 63 63 Continuous Power Ratings 60Hz kW 68 kVA 68 Assembled in USA Baldor Generator Features ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ Baldor generators are manufactured in a certified ISO9001 facility located in Oshkosh, Wisconsin.
Farm Duty 1-Phase Model: DLC75 Alternator Specifications Alternator Features Manufacturer Type Model Leads Voltage regulator Voltage regulation Insulation material: Rotor Insulation material: Stator Temperature rise Total harmonic distortion Bearing: quantity, type Coupling type One step load acceptance Stamford/Newage 4-Pole, Revolving field UCI224G 4 AVR 1/2% Class H Class H 125 C <5% 1, Sealed Flexible disc 100% of Rating Brushless design Class H insulation used throughout Solid state voltage regul
Farm Duty 1-Phase Model: D 100 Baldor POWER SYSTEMS 4 Cycle Diesel Liquid Cooled Standby Power Ratings 60Hz kW 100 kVA 100 50Hz 83 83 Continuous Power Ratings 60Hz kW 90 kVA 90 Assembled in USA Baldor Generator Features ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ Baldor generators are manufactured in a certified ISO9001 facility located in Oshkosh, Wisconsin.
Farm Duty 1-Phase Model: DLC100 Alternator Specifications Alternator Features Manufacturer Type Model Leads Voltage regulator Voltage regulation Insulation material: Rotor Insulation material: Stator Temperature rise Total harmonic distortion Bearing: quantity, type Coupling type One step load acceptance Stamford/Newage 4-Pole, Revolving field UCI274C 4 AVR 1/2% Class H Class H 125 C <5% 1, Sealed Flexible disc 100% of Rating Brushless design Class H insulation used throughout Solid state voltage regu
Farm Duty 1-Phase Model: D 130 Baldor POWER SYSTEMS 4 Cycle Diesel Liquid Cooled Standby Power Ratings 60Hz kW 130 kVA 130 50Hz 108 108 Continuous Power Ratings 60Hz kW 117 kVA 117 Assembled in USA Baldor Generator Features ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ ✓ ■ Baldor generators are manufactured in a certified ISO9001 facility located in Oshkosh, Wisconsin Every generator is design, prototype, and production tested Brushless synchronous four-pole alternator Industrial grade exhaust silencer E
Farm Duty 1-Phase Model: DLC130 Alternator Specifications Alternator Features Manufacturer Type Model Leads Voltage regulator Voltage regulation Insulation material: Rotor Insulation material: Stator Temperature rise Total harmonic distortion Bearing: quantity, type Coupling type One step load acceptance Stamford/Newage 4-Pole, Revolving field UCI274E 4 AVR 1/2% Class H Class H 125 C <5% 1, Sealed Flexible disc 100% of Rating Brushless design Class H insulation used throughout Solid state voltage regu
STANDBY PERMANENT - MOUNT SERIES GENERATOR ELECTRICAL CONNECTION INFORMATION High voltage may be present at receptacles and load studs while engine is operating - DANGER of electrical shock is present. Use extreme care. Voltage is present at the 120V/15 Amp convenience receptacle only when generator is operating. When configured for 277/480 main output, these receptacles Will be delivering 139 VAC. Disconnection to avoid possible equipment damage is suggested. HARD WIRE LOAD TERMINAL BLOCK 1. 2. 3.
CONNECTION INFORMATION Your new Pow'R Gard Generator has all interconnecting wiring terminated at a junction box. All wiring will be clearly labeled as being load, remote start contacts and AC input terminals and are to be connected as described below. LOAD - These connections are rated and sized according to the KW of the generator. Proper lead wire from these points to the automatic transfer switch (or load switching device) is mandatory.
STANDBY PERMANENT MOUNT SERIES GENERATOR GENERATOR MOUNTING REQUIREMENTS The generator set must be secured to a solid surface, which is non-combustible. A concrete floor is typical of this application. Wood floors should be prepared in accordance with local and state requirements for the load, heat and fluids that will be encountered with operation of this generator set. This generator base shall be anchored to the concrete floor with minimum 3/8" anchors.
ENGINE COOLING AIR The air, which will cool the engine, must be brought in from outside the building. A forced airflow of sufficient Cubic Feet per Minute (CFM) will prevent the incoming cooling air from mixing with the air inside the building and eventually overheating and damaging the engine. To do this requires that an exhaust fan of sufficient CFM be placed near the generator set to exhaust the heated cooling air and to also draw in cool external air.
When discharging the heated cooling air or the hot exhaust gases out through the side of the building or compartment please contact your local building inspector to find out what is necessary for your application to prevent a fire from occurring. You must clean and inspect both the exhaust fan and its louvers along with the building's cooling air intake on a regular basis to prevent reduction in the building's cooling air flow. This could lead to overheating and a potential fire or explosion.
If you are using a remote muffler it should be mounted as close to the engine as possible, since it will clog with carbon if it's operating temperature is too low. If you are using a remote muffler a flexible coupling of 12" or more must be installed between the exhaust line and the manifold to absorb the engine's vibration. However, a short, solid section of pipe between 6" and 8" long should be placed between the connection of the manifold and the flexible coupling.
When discharging the heated cooling air or the hot exhaust gases out through the side of the building please contact your local building inspector to find out what is necessary for your application to meet local building code requirements. Keep all fuel and its associated piping away from all components of the engine exhaust system. Once the exhaust system is installed it should be inspected on a regular basis to assure there are no toxic exhaust gas leaks.
BUILDING VENTILATION As hot air rises you must provide some type of power ventilation at the highest possible point of the building to permit the accumulating hot air to escape. This will help to prevent engine damage and it will help to eliminate hot restart problems. An electric powered exhaust fan of sufficient size will satisfy this requirement. This fan must connect to the generator set in a manner similar to the building's main heated cooling air exhaust fan.
EXHAUST REQUIREMENTS While it is important to supply the proper amount of clean air to the cylinder, it is equally important to discharge the gases of combustion. If these gases remain in the cylinder, the next cycle cannot burn the fuel completely. This condition results from excessive backpressure that is caused by any one or combination of these conditions: a. Exhaust pipe diameter too small. b. Exhaust pipe too long. c. Excessive number of sharp bends in exhaust system. d. Inadequate muffler. e.
FIGURE 6-2: DOUBLE THIMBLE - WALL OUTLET DETAILS EXHAUST PIPING THRU WALLS AND ROOFS Always check local and state laws pertaining to hot gas pipes before making plans for running exhaust piping thru walls or roofs. If the exhaust pipe must pass thru combustible walls or roofs, use an exhaust thimble to prevent exhaust pipe heat from being transmitted to the combustible material. Construction details of a typical thru wall double sleeve thimble is shown above — thimbles are not available.
FIGURE 6-3 — DOUBLE THIMBLE - ROOF OUTLET DETAILS a rain shield must be included above the thimble as shown in Figure 6-3. The rain cap as shown on the end of the exhaust pipe is recommended only in areas not subject to freezing temperatures. In an area where freezing is common, extend the exhaust piping well beyond the roof and use a gradual “U” bend at the end to direct the exhaust outlet downward which will keep rain, snow, etc., out of the pipe.
CONTROL PANEL OPERATION AND FUNCTION A. MASTER CONTROL SWITCH - This switch controls the starting and stopping of the engine via the engine control logic circuitry. With this switch in the “Manual” mode, the engine will start and run immediately after a 10 - 20 second time delay. CAUTION: Please note that once the engine has been told to start, the gen set should be treated as though it is operational, even though the start delay has not yet allowed the engine to crank.
The Hour Meter accumulates and displays the total running time of the generator set. E. VOLTAGE ADJUST - The rheostat allows the user to “fine tune” the generator set’s voltage output. It is normally used to adjust output voltage after switching the output of the generator set to a different voltage. F. METERS - These meters monitor and display the current operating parameters of the generator set. The Voltmeter monitors and displays the current operating AC output of the generator set.
OPERATION - PRE-START PROCEDURE 1. Fill system fuel tank with clean, fresh diesel fuel. Wipe up any and all fuel spillage 2. Fill Engine crankcase to full mark with clean, fresh lubricating oil per attached engine operating guide. 3. Radiator Coolant should be checked at the beginning of each day and filled in compliance with the engine manufacturer's guidelines. 4. Secure the generator for operation.
OPERATION The Prime mover utilized in this power generating system is controlled via an engine control module. Starting is accomplished by commanding the control to "start" the engine. This command can be given by a number of controls; The operator control mounted on the front panel. The remote controls via the transfer switch or remote start terminal. Initially, the system may be started and operated by placing the operation control in the "manual" position.
3. Overspeed Adjustment (OS) - Over Frequency Overspeed protection is provided by a frequency sensing network within the controller. The trip point of the frequency network is adjustable via a rheostat located on the top of the controller at the right hand side. Clockwise (CW) rotation increases the trip frequency and, thereby, raises the shutdown speed. CRANKING CONTROL 1. Overcrank Protection This feature provides a preset second crank cycle.
TROUBLESHOOTING - GENERATOR As with any machine, trouble may develop in electrical generators. It may be due to long service or neglect of regular maintenance. Servicing, and checking. Should trouble develop, the following instructions will be helpful in tracing the cause and making repairs. SPEED DEVITIONS: The generator speed should be maintained at rated nameplate speed. The frequency and voltage of the generator output depends on speed.
LOW VOLTAGE (Continued) CAUSE CHECK AND REMEDY High resistance connectionsConnections will be warm or hot Make better connection electrically and mechanically. Shorted field. Test field coils for possible short by checking resistance with an ohmmeter or resistance bridge. Return rotor assembly to factory for repair if alternator field coils are shorted. Low power factor Reduce inductive (motor) load. Some AC motors Draw approximately the same current regardless of load.
OVERHEATING (continued) CAUSE CHECK AND REMEDY High room temperature. Improve ventilation. Insufficient circulation. Provide cross-ventilation. Low power factory. Reduce inductive loads or install power factor improvement capacitors. Unbalanced load The load on each leg should be as evenly balanced as possible and should not exceed the rated current on any leg. Dry bearing. Replace bearing. MECHANICAL NOISE CAUSE CHECK AND REMEDY Defective bearing. Replace bearing. Rotor scrubbing on stator.
TROUBLESHOOTING - ENGINE CODE LIST OF POSSIBLE CAUSES 1. Battery capacity low. 2. Bad electrical connections. 3. Fault in starter motor. 4. Fault in starter motor. 5. Wrong grade of lubricating oil. 6. Low engine speed from starter motor. 7. Stop control fault. 8. Restriction in fuel lift pipe. 9. Fault in fuel lift pump. 10. Dirty fuel filter element. 11. Restriction in air filter or induction system. 12. Air in fuel system. 13. Fault in fuel injection pump. 14. Fault in atomizers or not correct type.
LIMITED WARRANTY Unless otherwise provided, Baldor generators are warranted against defects in Baldor workmanship and materials for a period of time as set forth in the Warranty Period chart on the following page. All warranty claims must be submitted to a Baldor Generator repair facility prior to the expiration of the warranty period. Baldor Generators shall have no responsibility or liability for any defect, latent or otherwise, discovered after the expiration of the warranty period provided herein.
WARRANTY PERIOD Generator Series Portable Products (Premier, PowerChief, DG Series, K Series) Towable Products (TS) 3600 RPM Standby Systems (Some AE Models) 1800 RPM Standby Systems (Some AE Models, DLC, GLC) Industrial Standby Systems Industrial Prime Power Systems International Labor* Parts 1 Year 3 Years 1 Year or 3,000 Hours Whichever comes first 1 Year or 1,000 Hours Whichever comes first 3 Years or 3,000 Hours Whichever comes first 3 Years or 1,000 Hours Whichever comes first 1 Year or 3,000 H
Limitations: Baldor Generators is not responsible for the repair of generators required because of normal wear, accident, misuse, abuse, improper installation, lack of maintenance, unauthorized modifications or improper storage. Normal Wear: This warranty will not cover repair where normal use has exhausted the life of a part or generator. It should be remembered that the service life of any generator is dependent on the care it receives and the conditions under which it has to operate.
It is required that both sides of this form be filled out completely, signed where indicated and returned to Baldor Generators within 30 days of initial Start-up and test. It is your responsibility to insure that copies are distributed to: For Standby, Automatic Emergency And Prime Power Generators Factory DISTRIBUTOR INFORMATION Name: Address: Address: Phone: Phone: Model Number: Job Number: HZ P.F.
Pre Start-Up Check List Start-Up Procedure No Freight Damage (Components Tight, Straight, Etc.). Check That All Applicable Warning Decals Are In Their Proper Place And Are Legible. The ATS Engine Start Wires and other DC Wires, if Any, Must be Properly Connected. Proper Belt Alignment And Tensions. Flex Fuel Lines Installed Between Engine And Tank. Fluid Levels (Oil, Antifreeze, Battery, Governor, Etc.) Check For Leaks, Tighten As Necessary. Correct Fuel And Exhaust Plumbing. Adequate Air Flow.
3518 Oregon Street Oshkosh WI 54902 Phone: 920-239-4200 Fax: 920-236-4219 Baldor Generators firmly believes proper installation along with proper maintenance are critical factors in assuring proper, dependable, safe and long term operation. The checklist was developed for making sure your installation is correct to help achieve these goals. If you have any questions about this checklist, please contact the Product Support Group at 920-236-4200.
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. CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm.
Service is just a phone call away: 800-872-7697 www.baldor.com/products/generators.
