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GLC Generator (Gaseous Liquid Cooled) GLC30, 35, 45, 50, 60, 80, 100 and 125 Installation & Operating Manual 5/04 MN2408.
W ARNING: CALIFORNIA PROPOSITION 65 W ARNING: Engine exhaust from this product contains chemicals known to the state of California to cause cancer , birth defects and other reproductive harm.
T able of Contents T able of Contents i MN2408 Section 1 Product Safety Information 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Notice 1-1 .
ii T able of Contents MN2408 Section 4 Operation 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Control Panel (Digital Engine Controller Only) 4-1 .
Section 1 Product Safety Information Product Safety Information 1-1 MN2408 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.
1-2 Product Safety Information MN2408 This symbol is shown throughout the manual to indicate a connection to ground reference point. Symbols 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.
Product Safety Information 1-3 MN2408 Operation W arning Statements Continued W ARNING: 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.
1-4 Product Safety Information MN2408 W arning Statements Continued Installation W ARNING: 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.
Product Safety Information 1-5 MN2408 W arning Statements Continued Maintenance W ARNING: 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.
1-6 Product Safety Information MN2408 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.
Section 2 General Information General Information 2-1 MN2408 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.
2-2 General Information MN2408.
General Information 2-3 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.
2-4 General Information MN2408 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).
General Information 2-5 MN2408 Foundation Design W ARNING: 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.
2-6 General Information MN2408 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.
General Information 2-7 MN2408 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.
2-8 General Information MN2408 T able 2-1 Approximate Load Bearing Capacities of V arious Soil T ypes Soil T ype Safe Bearing Capacity S o il T ype lb per ft 2 kilo Pascals Hard Rock – Granite etc. 50,000 – 200,000 2,395 – 9,576 Medium Rock – Shale etc.
General Information 2-9 MN2408 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.
2-10 General Information MN2408 Figure 2-6 Exhaust System Calculations Exhaust Piping Caution: The weight of the exhaust system must never be imposed on the turbo–charger outlet.
General Information 2-1 1 MN2408 Cooling System Cooling System Checklist A. Have noise considerations been taken into account? B. Has system piping been properly sized? C. Has system been properly protected from freeze up and corrosion? D. Have standby equipment heaters been specified? E.
2-12 General Information MN2408 The remote radiator may be mounted either vertically or horizontally . In general, the radiator will have an electric fan to provide cooling air and may be able to utilize the engine mounted coolant pump to provide coolant flow .
General Information 2-13 MN2408 Remote Radiator Cooling Remote Radiator Airflow generally assumed there will be no external restrictions to airflow . If this is not true, restriction must be considered in sizing and selection of a cooling fan and drive motor .
2-14 General Information MN2408 Figure 2-1 1 V alves & Fittings and Fluid Flow in Pipe Figure 2-12 Hot Well Installation.
General Information 2-15 MN2408 Other Considerations General: 1. Deaeration of the coolant. This can be accomplished through the use of the system deaerators in very large systems, or simply ensuring the radiator top tank or surge tank is at the highest point in the piping system.
2-16 General Information MN2408 Coolant T reatment: See Figure 2-13. 1. Engine coolant should be treated with a Diesel Coolant Additive (DCA) to minimize corrosion of the engine and cooling system components. A 50/50 ethylene glycol antifreeze solution is recommended for all genset engines.
General Information 2-17 MN2408 Air System Air System Checklist A. Air inlet faces the direction of prevailing winds. B. Air outlet does not face noise sensitive areas without noise attenuating devices. C. All heat loads have been taken into consideration in sizing air flow .
2-18 General Information MN2408 Figure 2-15 Radiator Cooling with Ducted Air Handling Other Engine Cooling Systems Remote radiator and heat exchanger cooled engine cooling systems will not have an engine driven fan. As a result, the consultant must provide a means of supplying air to the room, and exhausting it.
General Information 2-19 MN2408 T ransfer Switch T ransfer 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.
2-20 General Information MN2408 6. Conduit, wire, circuit protective device sizes, insulation etc. must conform to applicable local and national codes and regulations.
General Information 2-21 MN2408 Battery Charger An engine mounted alternator to charge the batteries during operation is an available option. Standby gensets require a solid state battery charger that is connected to utility power so the battery is charged continuously while the genset is not running.
2-22 General Information MN2408.
Section 3 Receiving & Installation Receiving & Installation 3-1 MN2408 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.
3-2 Receiving & Installation MN2408 W ARNING: 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.
Receiving & Installation 3-3 MN2408 Secure the Generator Six (eight for the GLC125) mounting bolts in the base frame secure the generator to the shipping pallet.
3-4 Receiving & Installation MN2408 Hot Exhaust Gasses W ARNING: 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.
Receiving & Installation 3-5 MN2408 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.
3-6 Receiving & Installation MN2408 Installation The generator is completely assembled, tested and adjusted at the factory before it is shipped to you.
Receiving & Installation 3-7 MN2408 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.
3-8 Receiving & Installation MN2408 Example: Determining Pipe Size for LPG A generator has a 16Hp engine 60 feet from the supply . Determine the supply pipe size for Natural Gas fuel. 16 x 10,000 = 160,000 BTU’s / per hour for proper operation. 160, 000 2, 516 + 63.
Receiving & Installation 3-9 MN2408 Electrical Connections Class 1 wiring methods must be used for field wiring connections to terminals of a class 2 circuit.
3-10 Receiving & Installation MN2408 Figure 3-4 Three Phase WYE and DEL T A Connections.
Receiving & Installation 3-1 1 MN2408 Battery Charger Considerations 1. Mount the battery charger on the generator or as close to the generator as possible. 2. If you mount the battery charger inside the building, mount it near the main breaker box or disconnect box.
3-12 Receiving & Installation MN2408 Battery Connections The generator is shipped with no battery installed. W ARNING: Installation and servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions.
Receiving & Installation 3-13 MN2408 Figure 3-6 Battery Installation W ashers & Nut Battery Battery Hold Down Rod W ashers & Nut Battery T ray 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 .
3-14 Receiving & Installation MN2408 2. V erify that the transfer switch is in Utility Power mode. No power must be present at the generator or transfer switch connections. V erify with a voltmeter . 3. V erify that the engine starting battery is disconnected so accidental starting is not possible.
Section 4 Operation Operation 4-1 MN2408 Operator Control Panel (Digital Engine Controller Only) The Operator Control Panel is shown in Figure 4-1. W ARNING: Never connect this generator to any buildings electrical system unless a licensed electrician has installed an approved transfer switch.
4-2 Operation MN2408 Operator Control Panel Continued Auto Switch - When pushed, initiates automatic operation of the engine (generator set). Starting and stopping of the engine is controlled by a remote contact (transfer switch).
Operation 4-3 MN2408 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.
4-4 Operation MN2408 When the controller is applied in an Auto Mains Failure (AMF) application with a transfer switch, it must be wired as shown in Figure 4-2. Programmable output #3 must be selected for Utility Ready T o Load and programmable output #4 must be selected for Gen Ready T o Load.
Operation 4-5 MN2408 No Load T est T o allow a timed No Load T est 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 T est The sequence of operation for a No Load T est condition is as follows: 1.
4-6 Operation MN2408 Figure 4-3 Engine Controller Inputs & Outputs.
Operation 4-7 MN2408 Analog Faults Eight analog fault inputs are user programmable for 12 fault conditions. Each analog fault input requires a specific analog signal type.
4-8 Operation MN2408 Output Contacts All output contacts are non–powered (i.e. dry contacts) and are rated 10A/240V AC, 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.
Operation 4-9 MN2408 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 , T imer Countdown, Generator AC Metering or Programming Menus.
4-10 Operation MN2408 Timer Countdown T imer 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.
Operation 4-1 1 MN2408 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 , T imer Countdown, Generator AC Metering or Programming Menus.
4-12 Operation MN2408 Engine Parameter Display T wo engine operating parameter screens are provided. Battery V oltage/Engine Speed (T achometer) BA TTER Y SPEED 27.0 Vdc 1800 rpm Battery Displays battery voltage in DC volts. The voltage is displayed with a resolution of 1/10 of a volt.
Operation 4-13 MN2408 Navigation Hints Programming parameters are displayed in the same order as the Programming Sheets (see Figures 4-5 to 4-8). T o skip over parameters that do not require changes, push and hold the ENTER push–button until the desired parameter is displayed.
4-14 Operation MN2408 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.
Operation 4-15 MN2408 Digital Fault Menu Loop The controller ’ s digital fault settings are described as follows: Caution: The Digital Fault Label selection must agree with the external control wiring prior to energizing the controller . Failure to do so may cause severe equipment damage.
4-16 Operation MN2408 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.
Operation 4-17 MN2408 Engine T emperature & Oil Pressure Calibration T o 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 .
4-18 Operation MN2408 Figure 4-4 Configuration Data Sheet j j j j j j j j j.
Operation 4-19 MN2408 Figure 4-5 Main Menu Loop Parameters Parameter Setting Range System V oltage (Line T o Line) XXXXX V AC 120–15000V AC System Frequency 50Hz/60Hz T oggle Between 50/60 Hz System.
4-20 Operation MN2408 Figure 4-6 Analog Fault Menu Loop Parameters Fault Name Input Analog T ype Fault E Enable Setpoint Level (Pick up) Setpoint Level Action S Shutdown Alarm Latch YY e s Bypass On S.
Operation 4-21 MN2408 Figure 4-9 Engine Control Connections 1 2 3 4 5 6 7 8 9 10 11 12 17 16 15 14 13 38 37 GRD CR MP2 MP1 19 18 24 23 B – B + + – CRANK RUN 25 26 27 28 29 30 31 32 33 34 24 35 36 .
4-22 Operation MN2408 Operator Control Panel (Analog Engine Controller Only) Figure 4-10 Analog Operator Control Panel –+ OFF 1 2 3 Panel Lights switch (On-Off ) Turns on two lamps to illuminate the operator panel. Panel Light Fuse Fuse for panel lights.
Operation 4-23 MN2408 Manual Start/Stop T o manually Start the Gen–Set, set the Master Control switch to the “Manual Run” position. The following happens: 1. When the “Manual Run” push–button is pressed, an Engine Start Delay timer is initiated.
4-24 Operation MN2408 Figure 4-12 A121H Analog Engine Controller Connections External Components High W ater T emperature Low Oil Pressure Overspeed High Water T emperature Low Oil Pressure Overcrank .
Operation 4-25 MN2408 Garretson Model KN Fuel V alve Considerations General The KN is designed for sensitivity and simple operation. It is used with low–pressure vaporized gaseous fuels, where dependable starting is a requirement.
4-26 Operation MN2408 Installation The KN should be mounted as close to the carburetor as possible with the arrow on the cover pointing up and the diaphragm in a vertical position. This helps to minimize the effects of gravity on diaphragm travel. This unit should also be placed for easy access to the primer if provided.
Section 5 T roubleshooting and Maintenance T roubleshooting and Maintenance 5-1 MN2408 Maintenance 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.
5-2 T roubleshooting and Maintenance MN2408 Problems and Solutions Some of the more common problems are listed in T able 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.
T roubleshooting and Maintenance 5-3 MN2408 T able 5-2 T roubleshooting Guide (Digital Controller Only) Problem Possible Cause Remedy Controller does not power up even with correct DC power applied Wiring Mistake Overload Condition Check that there are no wiring errors/short circuits connected to the controller .
5-4 T roubleshooting and Maintenance MN2408 Note: See Engine Controller manual for additional information. T able 5-3 T roubleshooting Guide (Analog Controller Only) Problem Possible Cause Remedy Controller cannot be Reset" Engine not stopped Controller not in OFF mode Verify the engine is at a complete stop before trying to reset.
Appendix A Series GLC Parts & Wiring Diagrams Series GLC A-1 MN2408 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.
A-2 Series GLC MN2408 Replacement Parts Continued Description Part No. D escr i p ti on GLC 80 GLC 100 GLC125 WELDMENT , BASE BA0236A06L2B BA0236A06L2B BA0236A06L2B ISOLA TOR, GEN END RM1088A18 RM1088.
Series GLC A-3 MN2408 Replacement Parts Continued Description Part No. D escr i p ti on GLC 80 GLC 100 GLC125 DECAL BONDED NEUTRAL" LB0300A00 LB0300A00 LB0300A00 DECAL FUSE TYPE & WARNI.
A-4 Series GLC MN2408 GLC Circuit Breaker & Electrical Data GLC Alternator Engine Output GLC Model Model Leads/ Winding Fuel T ype Size KW Rated Phase V oltage Config VA C (L - L) VA C (L - N) FLA 1 15% FLA Circuit Breaker C.T . Ratio Wire Size (QTY) AWG GLC125 UCI274E 4/06 Nat Gas GM/8.
Series GLC A-5 MN2408 GLC DA T A Continued GLC Alternator Engine Output GLC Model Model Leads/ Winding Fuel T ype Size KW Rated Phase V oltage Config VA C (L - L) VA C (L - N) FLA 1 15% FLA Circuit Breaker C.T . Ratio Wire Size (QTY) AWG GLC100 UCI274E 4/06 Nat Gas GM/8.
A-6 Series GLC MN2408 GLC DA T A Continued GLC Alternator Engine Output GLC Model Model Leads/ Winding Fuel T ype Size KW Rated Phase V oltage Config VA C (L - L) VA C (L - N) FLA 1 15% FLA Circuit Breaker C.T . Ratio Wire Size (QTY) AWG GLC60 UCI224F 4/06 Nat Gas GM/5.
Series GLC A-7 MN2408 GLC DA T A Continued GLC Alternator Engine Output GLC Model Model Leads/ Winding Fuel T ype Size KW Rated Phase V oltage Config VA C (L - L) VA C (L - N) FLA 1 15% FLA Circuit Breaker C.T . Ratio Wire Size (QTY) AWG GLC45 UCI224D 4/06 Nat Gas GM/4.
A-8 Series GLC MN2408 GLC DA T A Continued GLC Alternator Engine Output GLC Model Model Leads/ Winding Fuel T ype Size KW Rated Phase V oltage Config VA C (L - L) VA C (L - N) FLA 1 15% FLA Circuit Breaker C.T . Ratio Wire Size (QTY) AWG GLC30 BCI184G 4/06 Nat Gas GM/4.
Series GLC A-9 MN2408 GLC Wire Size Revision B 5–12–04 Circuit Breaker Size Quantity per Phase Minimum Wire Gauge EDI Plant Ampacity @125C 15 1 #16 1 - #14 EPDM PER PHASE 40 20 1 #16 1 - #14 EPDM .
A-10 Series GLC MN2408 Figure A-2 Customer Interface Connection Diagram MEC20 MEC2.
Series GLC A-1 1 MN2408 Figure A-3 Customer Interface (w/o Breaker) Power Connection Diagram.
A-12 Series GLC MN2408 Figure A-4 Single Phase – (w/o Breaker) Connection Diagram.
Series GLC A-13 MN2408 Figure A-5 Single Phase – One Breaker Connection Diagram.
A-14 Series GLC MN2408 Figure A-6 Single Phase – T wo Breaker Connection Diagram.
Series GLC A-15 MN2408 Figure A-7 Single Phase Connection Diagram (Wire 1/0 and Larger w/Breaker).
A-16 Series GLC MN2408 Figure A-8 Single Phase Connection Diagram (Wire 1/0 and Smaller w/Breaker).
Series GLC A-17 MN2408 Figure A-9 Single Phase Connection Diagram (Wire 1/0 and Smaller w/o Breaker).
A-18 Series GLC MN2408 Figure A-10 Single Phase Connection Diagram (Wire Larger than 1/0 w/o Breaker).
Series GLC A-19 MN2408 Figure A-1 1 Three Phase Connection Diagram.
A-20 Series GLC MN2408 Figure A-12 Three Phase Connection Diagram with PMG.
Series GLC A-21 MN2408 Figure A-13 Three Phase Connection Diagram (Wire 1/0 and larger).
A-22 Series GLC MN2408 Figure A-14 Three Phase Connection Diagram (Wire Larger than 1/0 w/Breaker).
Series GLC A-23 MN2408 Figure A-15 Three Phase Connection Diagram (Wire 1/0 and Smaller w/Breaker).
A-24 Series GLC MN2408 Figure A-16 Three Phase Connection Diagram (Wire Larger than 1/0 w/o Breaker).
Series GLC A-25 MN2408 Figure A-17 Three Phase Connection Diagram (Wire 1/0 and Smaller w/o Breaker).
A-26 Series GLC MN2408 Figure A-18 Control Box Connections with MEC20 Controller Without Governor.
Series GLC A-27 MN2408 Figure A-19 Control Box Connections with MEC20 Controller & Governor With Governor.
A-28 Series GLC MN2408 Figure A-20 Control Box Connections with MEC2 Controller.
Series GLC A-29 MN2408 Figure A-21 Engine Wiring, Woodward 4.3L GM.
A-30 Series GLC MN2408 Figure A-22 Engine Wiring, Woodward 5.7L GM.
Series GLC A-31 MN2408 Figure A-23 Engine Wiring, Woodward 8.1L GM.
A-32 Series GLC MN2408.
Series GLC A-33 MN2408 Start–up Inspection Form It is required that both sides of this form be completed, signed where indicated and returned to Baldor Generators within 30 days of initial Start–up and test.
A-34 Series GLC MN2408 n Pre Start-up Check List n Start-up Procedure No freight damage (Components tight, straight, etc.). Check that all applicable warning decals are in their proper place and are legible. Proper belt alignment and tensions. The A TS engine start wires and other DC wires, if any , must be properly connected.
Baldor District Offices UNITED ST A TES ARIZONA PHOENIX 421 1 S 43RD PLACE PHOENIX, AZ 85040 PHONE: 602-470-0407 FAX: 602-470-0464 CALIFORNIA LOS ANGELES 6480 FLOTILLA COMMERCE, CA 90040 PHONE: 323-72.
BALDOR GENERA TORS 3815 Oregon Street Oshkosh, WI 54902 (920) 236–4200 or (800) 872–7697 Fax (920) 236–4219 www .baldor .com ) Baldor Electric Company MN2408 Printed in USA 5/04 F AR200 W ARNING.
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