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T ier 2/3 T owable Generators (T railer and Skid Mounted) (Diesel Liquid Cooled) TS25, 35, 45, 60, 80, 130, 175, 250 and 400 Installation & Operating Manual 10/06 MN2417.
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 MN2417 Section 1 Product Safety Information 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Notice 1-1 .
ii T able of Contents MN2417.
Section 1 Product Safety Information Product Safety Information 1-1 MN2417 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 MN2417 Precaution Statements Used In This Manual There are three classifications of precautionary statements used in this manual. The most critical is a W ARNING statement, then the Caution statement and the least critical is the Note statement.
Product Safety Information 1-3 MN2417 Operation Statements Continued W ARNING: Gasoline and diesel fuel are flammable and can cause fire, explosions, injury or death. For storage or refueling handle fuel with care and only in clean, approved, properly marked safety fuel containers.
1-4 Product Safety Information MN2417 Operation Statements Continued W ARNING: Never “jump start” a generator to start the engine. If the battery charge is insufficient to start the engine, charge or replace the battery and try to restart.
Product Safety Information 1-5 MN2417 Installation Statements Continued W ARNING: Circuit overload protection must be provided in accordance with the National Electrical Code and local regulations. W ARNING: Check Ground Fault Circuit Interrupt (GFCI) receptacles monthly by using the “T est” and “Reset” buttons.
1-6 Product Safety Information MN2417 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 MN2417 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 MN2417.
Section 3 Receiving & Installation Receiving & Installation 3-1 MN2417 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 MN2417 Several other factors should be carefully evaluated when selecting a location for installation: 1. For eff ective cooling and maintenance, the system should be mounted on a flat, smooth, noncombustible level surface.
Receiving & Installation 3-3 MN2417 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.
3-4 Receiving & Installation MN2417 Electrical Connections Class 1 wiring methods must be used for field wiring connections to terminals of a class 2 circuit.
Receiving & Installation 3-5 MN2417 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.
3-6 Receiving & Installation MN2417 Three Phase Connections Three phase connections are made at L1, L2, L3 and N connections shown in Figure 3-5. Figure 3-5 Three Phase Connections For power to be applied to these terminals, the Output V oltage Selector Switch must be in the 120/208V , 120/240V or 277/480V positions.
Receiving & Installation 3-7 MN2417 Frame Ground Connection W ARNING: Be sure the system is properly grounded before applying power . Do not apply AC power before you ensure that grounds are connected. Electrical shock can cause serious or fatal injury .
3-8 Receiving & Installation MN2417 W ARNING: A battery presents a risk of fire because they generate hydrogen gas. Hydrogen gas is extremely explosive. Never jump start a battery , smoke in the area around the battery or cause any spark to occur in the area around the battery .
Receiving & Installation 3-9 MN2417 Recommended Engine Oil and Battery T ype When replacing batteries, use only the recommended battery for your generator , see T able 3-5.
3-10 Receiving & Installation MN2417 Post Installation Checks Continued 16. Place the voltage output selector switch in the appropriate position. 17. V erify all loads are disconnected. 18. V erify the Master Control is in the “Stop” position.
Section 4 Operation Operation 4-1 MN2417 T owing the Generator W ARNING: 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 .
4-2 Operation MN2417 Selecting the Proper T owing Equipment Continued Electrical T railer Wiring All trailers must have taillights, brake lights and turn signals connected to the towing vehicle’s electrical system.
Operation 4-3 MN2417 Figure 4-1 T railer Component Identification Jack Single or Double Axle T railer Brake Safety Chains T railer Pintle Engine Compartment Lift Hook Battery Compartment Jack Coupler .
4-4 Operation MN2417 T owing Instructions 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).
Operation 4-5 MN2417 T railer Setup See Figure 4-1 for component identification. Carefully read all instructions before starting. 1. Locate a suitable, level location. Also be sure there are no overhead wires or obstructions. The trailer is balanced so the majority of the weight rests on the tow bar (Jack).
4-6 Operation MN2417 T able 4-2 Three/Single Phase Operation Alternator V oltage V oltage at T erminal Lugs V oltage at Plug Receptacles Switch Position Alternator Winding Connection V oltage Adjust P.
Operation 4-7 MN2417 Figure 4-5 Operator Control Panel Components P ANEL LIGHTS ON OFF Panel Lights switch (On−Off ) T urns on the panel lights. FUSE Fuse Fuses provides protection on some units. (Do not remove while generator is running). BREAKER Breaker Circuit Breakers provides protection on some units.
4-8 Operation MN2417 Pre − Start Procedure Before attempting to start the generator set, several things must first be verified or performed. These are: 1. Fill system fuel tank with clean, fresh diesel fuel. 2. Fill engine crankcase to full mark with clean, fresh lubricating oil per engine manufacturer operating guide.
Operation 4-9 MN2417 Digital Engine Controller Description EM0046A21 (MRS17) Figure 4-6 Operator Control Panel Stop Manual Run Display Menu Group LED Indicators Operating Modes and Horn & Fault Re.
4-10 Operation MN2417 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 4-7.
Operation 4-1 1 MN2417 Digital Engine Controller Description EM0046A21 (MRS17) Continued T able 4-4 Manual Mode Sequence Description Menu Status Condition of T ransition Action Next State Start re.
4-12 Operation MN2417 Alarms Following alarms are available: Sensor fail (FLS) see T able 4-5 Sensor fail is detected when measured value is 6% out of selected sensor characteristic.
Operation 4-13 MN2417 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.
4-14 Operation MN2417 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 = W ater temp, AI3 = Fuel level) is fix.
Operation 4-15 MN2417 T able 4-10 Engine Setpoints Start RPM “Firing” speed when iL controller stops cranking (starter goes OFF). Step: 1% of nominal RPM; Range: 5 − 50 % Starting POil When reached controller stops cranking (starter goes OFF).
4-16 Operation MN2417 T able 4-10 Engine Setpoints Continued Cooling time Runtime of the unloaded gen − set to cool the engine before stop. Step: 1s; Range: 0 − 3600 s AfterCoolT ime 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.
Operation 4-17 MN2417 T able 4-12 Generator Protect Setpoints Overload Threshold for generator overload (in % of Nominal power) Step: 1% of Nominal power; Range: 0 − 200% Overload Wrn Threshold for generator overload warning (in % of Nominal power) Step: 1% of Nominal power; Range: 0 − 200% Overload del Delay for generator overload alarm.
4-18 Operation MN2417 T able 4-13 Sensor Spec Setpoints Calibr AI1,AI2, AI3 Calibrating constant to adjust the measured value of IL analog inputs. Physical dimension of calibrating constant is corresponding to Analog input.
Operation 4-19 MN2417 Digital Engine Controller Description EM0046A21 (MRS17) Continued Figure 4-9 Controller Connection Diagram OIL PRESSURE WA TER TEMP FUELLEVEL RPM LOAD EMERGENCY STOP REMOT.
4-20 Operation MN2417 Digital Engine Controller Description EM0046A21 (MRS17) Continued Figure 4-10 Controller Connection Diagram LOAD EMERGENCY STOP REMOTE SSTART/STO P DI ESE L.
Section 5 T roubleshooting and Maintenance T roubleshooting and Maintenance 5-1 MN2417 W ARNING: Never “jump start” a generator to start the engine. If the battery charge is insufficient to start the engine, charge or replace the battery and try to restart.
5-2 T roubleshooting and Maintenance MN2417 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 MN2417 T able 5-1 T roubleshooting 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 .
5-4 T roubleshooting and Maintenance MN2417.
Appendix A Wiring Diagrams Wiring Diagrams A-1 MN2417 Replacement Parts Replacement parts information is provided in Replacement Parts Catalog CA2401. Engine parts are identified in the engine manual that was provided with your generator set.
A-2 Wiring Diagrams MN2417 Figure A-1 TS25 Connection Diagram.
Wiring Diagrams A-3 MN2417 Figure A-2 TS25 Connection Diagram.
A-4 Wiring Diagrams MN2417 Figure A-3 TS25 Connection Diagram.
Wiring Diagrams A-5 MN2417 Figure A-4 TS25 Connection Diagram.
A-6 Wiring Diagrams MN2417 Figure A-5 TS25 Connection Diagram.
Wiring Diagrams A-7 MN2417 Figure A-6 TS25 Connection Diagram.
A-8 Wiring Diagrams MN2417 Figure A-7 TS35 Connection Diagram.
Wiring Diagrams A-9 MN2417 Figure A-8 TS35 Connection Diagram.
A-10 Wiring Diagrams MN2417 Figure A-9 TS35 Connection Diagram.
Wiring Diagrams A-1 1 MN2417 Figure A-10 TS35 Connection Diagram.
A-12 Wiring Diagrams MN2417 Figure A-1 1 TS35 Connection Diagram.
Wiring Diagrams A-13 MN2417 Figure A-12 TS35 Connection Diagram.
A-14 Wiring Diagrams MN2417 Figure A-13 TS35 Power Connection Diagram.
Wiring Diagrams A-15 MN2417 Figure A-14 TS60 Connection Diagram.
A-16 Wiring Diagrams MN2417 Figure A-15 TS60 Connection Diagram.
Wiring Diagrams A-17 MN2417 Figure A-16 TS60 Connection Diagram.
A-18 Wiring Diagrams MN2417 Figure A-17 TS60 Connection Diagram.
Wiring Diagrams A-19 MN2417 Figure A-18 TS60 Connection Diagram.
A-20 Wiring Diagrams MN2417 Figure A-19 TS60 Connection Diagram.
Wiring Diagrams A-21 MN2417 Figure A-20 TS60 Connection Diagram.
A-22 Wiring Diagrams MN2417 Figure A-21 TS80 Connection Diagram.
Wiring Diagrams A-23 MN2417 Figure A-22 TS80 Connection Diagram.
A-24 Wiring Diagrams MN2417 Figure A-23 TS80 Connection Diagram.
Wiring Diagrams A-25 MN2417 Figure A-24 TS80 Connection Diagram.
A-26 Wiring Diagrams MN2417 Figure A-25 TS80 Connection Diagram.
Wiring Diagrams A-27 MN2417 Figure A-26 TS80 Connection Diagram.
A-28 Wiring Diagrams MN2417 Figure A-27 TS80 Connection Diagram.
Wiring Diagrams A-29 MN2417 Figure A-28 TS80 Connection Diagram.
A-30 Wiring Diagrams MN2417 Figure A-29 TS80 Connection Diagram.
Wiring Diagrams A-31 MN2417 Figure A-30 TS80 Connection Diagram.
A-32 Wiring Diagrams MN2417 Figure A-31 TS400 Connection Diagram.
Wiring Diagrams A-33 MN2417 Figure A-32 TS400 Connection Diagram.
A-34 Wiring Diagrams MN2417 Figure A-33 TS400 Connection Diagram.
Wiring Diagrams A-35 MN2417 Figure A-34 TS400 Connection Diagram.
A-36 Wiring Diagrams MN2417 Figure A-35 TS400 Connection Diagram.
Wiring Diagrams A-37 MN2417 Figure A-36 TS400 Connection Diagram.
A-38 Wiring Diagrams MN2417 Figure A-37 TS400 Connection Diagram.
Wiring Diagrams A-39 MN2417 Figure A-38 TS400 Connection Diagram.
A-40 Wiring Diagrams MN2417 Figure A-39 TS400 Connection Diagram.
Baldor District Offices.
© Baldor Electric Company MN2417 Printed in USA 10/06 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.
Een belangrijk punt na aankoop van elk apparaat Baldor TS60 (of zelfs voordat je het koopt) is om de handleiding te lezen. Dit moeten wij doen vanwege een paar simpele redenen:
Als u nog geen Baldor TS60 heb gekocht dan nu is een goed moment om kennis te maken met de basisgegevens van het product. Eerst kijk dan naar de eerste pagina\'s van de handleiding, die je hierboven vindt. Je moet daar de belangrijkste technische gegevens Baldor TS60 vinden. Op dit manier kan je controleren of het apparaat aan jouw behoeften voldoet. Op de volgende pagina's van de handleiding Baldor TS60 leer je over alle kenmerken van het product en krijg je informatie over de werking. De informatie die je over Baldor TS60 krijgt, zal je zeker helpen om een besluit over de aankoop te nemen.
In een situatie waarin je al een beziter van Baldor TS60 bent, maar toch heb je de instructies niet gelezen, moet je het doen voor de hierboven beschreven redenen. Je zult dan weten of je goed de alle beschikbare functies heb gebruikt, en of je fouten heb gemaakt die het leven van de Baldor TS60 kunnen verkorten.
Maar de belangrijkste taak van de handleiding is om de gebruiker bij het oplossen van problemen te helpen met Baldor TS60 . Bijna altijd, zal je daar het vinden Troubleshooting met de meest voorkomende storingen en defecten #MANUAl# samen met de instructies over hun opplosinge. Zelfs als je zelf niet kan om het probleem op te lossen, zal de instructie je de weg wijzen naar verdere andere procedure, bijv. door contact met de klantenservice of het dichtstbijzijnde servicecentrum.
