Towable Generators (Trailer and Skid Mounted) (Diesel Liquid Cooled) TS25, 45, 80, 130 and 175 Installation & Operating Manual 5/05 MN2416
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii Table of Contents MN2416
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: Hot exhaust gasses must never be directed toward anything that may catch fire or explode. WARNING: This generator must not be used on or near any forest covered, brush covered, or grass covered land unless the engine’s exhaust system is equipped with a spark arrestor. The spark arrestor must be maintained in effective working order by the operator. WARNING: Some parts of this generator rotate during operation.
Warning Statements Continued Burn WARNING: Parts of this generator are extremely hot during and after operation. To prevent severe burns, do not touch any part of the generator until you have first determined if the part is hot. Wear protective clothing and after use allow sufficient time for parts to cool before touching any part of the generator. WARNING: Do not touch the hot exhaust parts.
Warning Statements Continued WARNING: Incorrect installation of this generator set could result in property damage, injury or death. Connection of the generator to its fuel source must be done by a qualified professional technician or contractor. WARNING: Never stand under or close to an object that is being hoisted or lift into position.
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 MN2416
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.
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. Installation should prevent water levels from reaching the generator. 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.
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.
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.
Single Phase Connections Single phase connections are made at load receptacles located by the operator panel, see Figure 3-3. Simply open the rear panel access door and make the connections. When the panel door is closed, the connections are weather tight. Figure 3-3 Receptacle Panel (Single Phase) TS25 Use mating plug for a CS6369 250V 50A receptacle.
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 Frame Ground Connection Nut Washer Ground Wire Lug Washer Earth Ground Stud Frame 1. 2. Open the enclosure access panel door 2 ( Figure 3-2). Connect the ground wire to the “earth ground” terminal shown in Figure 3-5. This ground is the local reference ground to ground the generator frame only. Caution: This generator must have a battery installed for operation. The battery is used during starting and during operation.
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. Procedure: The correct type battery must be installed in the battery compartment provided, see Table 3-2.
Post Installation Checks 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 16. Place the voltage output selector switch in the appropriate position (120/240 so the receptacles are powered or as required for your load). 17. Verify all loads are disconnected. 18. Verify that the Master Control Switch is still in the “Stop” position. Connect the engine starting battery to the starter. Verify it is installed correctly. 19. Verify the fuel source is ON and the pressure and flow rate is correct. 20. Remove all tools, rags, etc.
Section 4 Operation Towing the Generator WARNING: Never allow a person to ride in or on a trailer that is being towed. All states prohibit passengers in towed vehicles. A person can fall off and be struck be another vehicle or run over by the towed trailer. Failure to observe this warning can result in death. WARNING: Before using a tow vehicle with a trailer mounted generator, verify that the vehicle is designed for the load. Using a vehicle that is too small is very dangerous.
Selecting the Proper Towing Equipment Continued Electrical Trailer Wiring All trailers must have taillights, brake lights and turn signals connected to the towing vehicle’s electrical system. It is also recommended that a heavy duty turn signal flasher and emergency flasher (if separate) be installed since the trailer lights place an extra load on car flasher units. Towing Heavy Trailer Loads 1. Trailer brakes.
Figure 4-1 Trailer Component Identification Lift Hook Jack Battery Compartment Coupler Handle Coupler Tow Vehicle Mounted Pintle Hook Trailer Brake Pintle Safety Chains Ball Coupler Caution: Safety Chains Jack Trailer Single or Double Axle Engine Compartment Large “Engine Compartment Doors” on each side of enclosure must remain closed during operation. If doors remain open, engine will overhead due to restricted air flow.
See Figure 4-1 for component identification. 1. Be sure the generator is off. 2. Shut all enclosure doors and latch the locks. 3. Back the tow vehicle to within a few inches of the trailer coupler (Pintle or Ball). 4. Be sure the Coupler Handle is in the “UP” (open) position or the Pintle Hook is Open. 5. Adjust the trailer jack for the height of the hitch on the tow vehicle. 6. Back the tow vehicle so the trailer coupler is directly over the tow vehicle ball hitch or the Pintle hook. 7.
Caution: c. Adequate clearance must be provided for access doors to fully open. Note: The exhaust also exits radiator end. When positioning a generator system ensure position does not cause a concentration of toxic emissions. 5. Switch the generator set to the applicable voltage setting. 6. Connect the load(s) at the Receptacle panel connections (Figure 4-3). 7. Verify that all electrical cables and wiring are in good condition, no cracked or frayed wires or cable insulation. 8.
Figure 4-3 Receptacle Panel (Single Phase) TS25 Use mating plug for a CS6369 250V 50A receptacle. 240V(50A) 240V(50A) 120V(20A) 120V(20A) TS45/80 For power to be applied to these receptacle, the Output Voltage Selector Switch must be in the 120/240V position. Use mating plug for a CS6369 250V 50A receptacle. 120V(20A) 120V(20A) 240V(50A) 240V(50A) 240V(50A) 120V(20A) TS130/175 Use mating plug for a CS6369 250V 50A receptacle.
Automatic Start/Stop First, ensure all “Pre−start Procedures” are complete. To setup the generator for automatic operation, set the Master Control switch to the “Auto Start” position. The following happens: 1. The engine will automatically start upon activation of the remote start contact input. The remote device initiates a start sequence upon contact closure. 2. When the remote start signal is activated, the engine will start as per the sequence of operation described for the manual start sequence. 3.
Engine Controller Description 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. The stop sequence will cause the controllers RUN output to be immediately terminated which will cause the engine to stop.
Factory adjustments are correct for most applications. If you choose to change the factory settings, here is the procedure. The potentiometer and switches are shown in Figure 4-4. Overspeed (30−8500Hz) R1 Sets the RPM at which the engine will be shutdown if the engine speed exceeds this preset value. To adjust Overspeed value, turn the Overspeed Pot (R1) fully clockwise. Run the engine up to the maximum operating speed.
Engine Controller Operation Auto Mode Operation When the controller receives an automatic start signal (across pins 10 and 11), the glow plug output turns on (if switch 3=On) and the delay begins. When the glow plug delay expires, the fuel and crank outputs turn on. When the engine starts, the glow plug output is turned off. At this time, the Shutdown Lockout and the Warm−up Time Delay (if selected) will begin, and the starter is disengaged.
Section 5 Troubleshooting and Maintenance Maintenance MN2416 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 5-1 Troubleshooting Guide Problem Engine will not start Possible Cause No fuel.
Table 5-1 Troubleshooting Guide Continued Problem Possible Cause Remedy Genset will not pull load Incorrect Engine Speed Load not connected properly Load too large for unit Remove electrical load, output should be 61−62 Hertz adjust engine speed if necessary. Verify voltage at the load and the connections to the proper receptacle. Verify load amperage is less than the generator set rated. Note: For inductive loads, use the starting amperage rating of the load (not the running amperage rating).
5-4 Troubleshooting and Maintenance MN2416
Appendix A 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. 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).
Description PANEL, RECEPTACLES PANEL, CONTROLS SWITCH, TOGGLE SWITCH, DPDT SWITCH, 3PH KNOB, RHEOSTAT CONTROL RHEOSTAT, 2K OHM, 2W GAUGE, PRESSURE GAUGE, TEMP METER, VOLT METER, ETM, 60HZ METER, VOLT, 600ACV METER, AMP, METER, FREQ RECEPTACLE, CS−6369, 250V, 50A, RECEPTACLE, GFI, 250V 20A CSA/NEMA BREAKER, 1 POLE 20 AMP BREAKER, 2 POLE 50A FUSE BUSS, MTH−5 FUSE, BUSS, AGC 2 FUSE, BUSS, ABC 15 DECAL, KEEP HANDS CLEAR DECAL, DANGER−HIGH VOLTAGE DECAL, CAUTION, LOAD STUD DOOR DECAL, WARNING, AUTO START DECAL,
Figure A-1 TS25 Connection Diagram MN2416 Parts & Wiring Diagrams A-3
Figure A-2 TS25 Receptacle Connection Diagram A-4 Parts & Wiring Diagrams MN2416
Figure A-3 TS25/45/80 Control Panel Connection Diagram MN2416 Parts & Wiring Diagrams A-5
Figure A-4 TS25/45 Generator Lead Connection Diagram A-6 Parts & Wiring Diagrams MN2416
Figure A-5 TS45 Connection Diagram MN2416 Parts & Wiring Diagrams A-7
Figure A-6 TS45/80 Receptacle Connection Diagram A-8 Parts & Wiring Diagrams MN2416
Figure A-7 TS80 Connection Diagram MN2416 Parts & Wiring Diagrams A-9
Figure A-8 TS80 Generator Lead Connection Diagram A-10 Parts & Wiring Diagrams MN2416
Figure A-9 TS80 Generator Wiring Diagram MN2416 Parts & Wiring Diagrams A-11
Figure A-10 TS130 Connection Diagram A-12 Parts & Wiring Diagrams MN2416
Figure A-11 TS130 Control Panel Connection Diagram MN2416 Parts & Wiring Diagrams A-13
Figure A-12 TS130 Generator Lead Connection Diagram A-14 Parts & Wiring Diagrams MN2416
Figure A-13 TS130 Receptacle Connection Diagram MN2416 Parts & Wiring Diagrams A-15
Figure A-14 TS130 Generator Wiring Diagram A-16 Parts & Wiring Diagrams MN2416
Figure A-15 TS175 Control Panel Connection Diagram MN2416 Parts & Wiring Diagrams A-17
Figure A-16 TS175 Generator Lead Connection Diagram A-18 Parts & Wiring Diagrams MN2416
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 FAX: 586−978−9969 MICHIGAN Continued GAND RAPIDS 668 3 MILE ROAD NW GRAND RAPIDS, MI 49504 PHONE: 616−785−1784 F
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 P.O. Box 2400 Ft. Smith, AR 72902--2400 (479) 646--4711 Fax (479) 648--5792 www.baldor.
