Baldor GLC GENERATOR GLC45 User Manual

GLC Generator(Gaseous Liquid Cooled)GLC30, 35, 45, 50, 60, 80, 100 and 125Installation & Operating Manual5/04 MN2408

1-6 Product Safety Information MN2408Caution StatementsCaution: Avoid installing the generator set beside heat generating equipment, or directly below

A-24 Series GLC MN2408Figure A-16 Three Phase Connection Diagram (Wire Larger than 1/0 w/o Breaker)

Series GLC A-25MN2408Figure A-17 Three Phase Connection Diagram (Wire 1/0 and Smaller w/o Breaker)

A-26 Series GLC MN2408Figure A-18 Control Box Connections with MEC20 Controller Without Governor

Series GLC A-27MN2408Figure A-19 Control Box Connections with MEC20 Controller & GovernorWith Governor

A-28 Series GLC MN2408Figure A-20 Control Box Connections with MEC2 Controller

Series GLC A-29MN2408Figure A-21 Engine Wiring, Woodward 4.3L GM

A-30 Series GLC MN2408Figure A-22 Engine Wiring, Woodward 5.7L GM

Series GLC A-31MN2408Figure A-23 Engine Wiring, Woodward 8.1L GM

A-32 Series GLC MN2408

Series GLC A-33MN2408Start–up Inspection FormIt is required that both sides of this form be completed, signed where indicated andreturned to Baldor Ge

Section 2General InformationGeneral Information 2-1MN2408Thank you for purchasing your Baldor Generator Set. This manual contains information you ne

A-34 Series GLC MN2408 nPre Start-up Check List nStart-up ProcedureNo freight damage (Components tight, straight, etc.). Check that all applicable war

Baldor District OfficesUNITED STATESARIZONAPHOENIX4211 S 43RD PLACEPHOENIX, AZ 85040PHONE: 602-470-0407FAX: 602-470-0464CALIFORNIALOS ANGELES6480 FL

BALDOR GENERATORS3815 Oregon StreetOshkosh, WI 54902(920) 236–4200 or (800) 872–7697Fax (920) 236–4219www.baldor.com) Baldor Electric CompanyMN2408

2-2 General Information MN2408

General Information 2-3MN2408Important Be sure you are completely familiar with all Safety Instructions detailed in Section 1 of thismanual. Do not

2-4 General Information MN2408Room Location Often a separate building located on the site away from the main building is the most simple andcost effec

General Information 2-5MN2408Foundation DesignWARNING: An open bottom stationary engine generator set must be installed over noncombustiblematerials

2-6 General Information MN2408S Steel spring isolators are a very effective and commonly used. Steel spring isolatorsare typically 95–98% efficient

General Information 2-7MN2408Designing An Isolated FoundationIf the genset cannot be mounted directly on a floor slab, or if it is desirable to isola

2-8 General Information MN2408Table 2-1 Approximate Load Bearing Capacities of Various Soil TypesSoil TypeSafe Bearing CapacitySoil Typelb per ft2kil

General Information 2-9MN2408Exhaust SystemExhaust ChecklistA. Exhaust outlets are not located upwind or near any building air intakes.B. Flexible pi

WARNING:CALIFORNIA PROPOSITION 65 WARNING:Engine exhaust from this product contains chemicals knownto the state of California to cause cancer, birth

2-10 General Information MN2408Figure 2-6 Exhaust System Calculations Exhaust PipingCaution: The weight of the exhaust system must never be imposed o

General Information 2-11MN2408Cooling SystemCooling System ChecklistA. Have noise considerations been taken into account?B. Has system piping been

2-12 General Information MN2408The remote radiator may be mounted either vertically or horizontally. In general, the radiator willhave an electric fan

General Information 2-13MN2408Remote Radiator CoolingRemote Radiator Airflow generally assumed there will be no external restrictions to airflow. If

2-14 General Information MN2408Figure 2-11 Valves & Fittings and Fluid Flow in Pipe Figure 2-12 Hot Well Installation

General Information 2-15MN2408Other ConsiderationsGeneral:1. Deaeration of the coolant. This can be accomplished through the use of the systemdeaerat

2-16 General Information MN2408Coolant Treatment: See Figure 2-13.1. Engine coolant should be treated with a Diesel Coolant Additive (DCA) to minimiz

General Information 2-17MN2408Air SystemAir System ChecklistA. Air inlet faces the direction of prevailing winds.B. Air outlet does not face noise se

2-18 General Information MN2408Figure 2-15 Radiator Cooling with Ducted Air Handling Other Engine Cooling SystemsRemote radiator and heat exchanger co

General Information 2-19MN2408Transfer SwitchTransfer Switch ChecklistA. Locate transfer switch in a clean, dry place, near the emergency load.B. P

Table of ContentsTable of Contents iMN2408Section 1Product Safety Information 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-20 General Information MN24086. Conduit, wire, circuit protective device sizes, insulation etc. must conform to applicablelocal and national codes a

General Information 2-21MN2408Battery ChargerAn engine mounted alternator to charge the batteries during operation is an available option.Standby gen

2-22 General Information MN2408

Section 3Receiving & InstallationReceiving & Installation 3-1MN2408Receiving & Inspection When you receive your generator, there are sev

3-2 Receiving & Installation MN2408WARNING: An open bottom stationary engine generator set must be installed over noncombustiblematerials and sha

Receiving & Installation 3-3MN2408Secure the GeneratorSix (eight for the GLC125) mounting bolts in the base frame secure the generator to the shi

3-4 Receiving & Installation MN2408Hot Exhaust GassesWARNING: Exhaust fumes/gases are extremely dangerous and can cause severe illness or death.

Receiving & Installation 3-5MN24088. As much of the exhaust piping as possible should be located near the power ventilationexhaust. This will red

3-6 Receiving & Installation MN2408InstallationThe generator is completely assembled, tested and adjusted at the factory before it is shipped toy

Receiving & Installation 3-7MN2408Example: Determining Pipe Size for Natural GasA generator has a 16Hp engine 60 feet from the supply. Determine

ii Table of Contents MN2408Section 4Operation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-8 Receiving & Installation MN2408Example: Determining Pipe Size for LPGA generator has a 16Hp engine 60 feet from the supply. Determine the sup

Receiving & Installation 3-9MN2408Electrical Connections Class 1 wiring methods must be used for field wiring connections to terminals of a clas

3-10 Receiving & Installation MN2408Figure 3-4 Three Phase WYE and DELTA Connections

Receiving & Installation 3-11MN2408Battery Charger Considerations1. Mount the battery charger on the generator or as close to the generator as po

3-12 Receiving & Installation MN2408Battery Connections The generator is shipped with no battery installed.WARNING: Installation and servicing o

Receiving & Installation 3-13MN2408Figure 3-6 Battery Installation Washers & NutBatteryBattery Hold Down RodWashers & NutBattery TrayTh

3-14 Receiving & Installation MN24082. Verify that the transfer switch is in Utility Power mode. No power must be present atthe generator or tra

Section 4OperationOperation 4-1MN2408Operator Control Panel (Digital Engine Controller Only)The Operator Control Panel is shown in Figure 4-1.WARNING

4-2 Operation MN2408Operator Control Panel ContinuedAuto Switch - When pushed, initiates automatic operation of the engine (generator set). Start

Operation 4-3MN24085. When the cool down time delay period expires (typically 5 minutes), the controllersRUN output will be immediately terminated wh

Section 1Product Safety InformationProduct Safety Information 1-1MN2408Safety NoticeBe sure that you are completely familiar with the safe operation o

4-4 Operation MN2408When the controller is applied in an Auto Mains Failure (AMF) application with a transfer switch,it must be wired as shown in Fig

Operation 4-5MN2408No Load TestTo allow a timed No Load Test of the engine/generator set while using the AMF controlapplication, a digital input cont

4-6 Operation MN2408Figure 4-3 Engine Controller Inputs & Outputs

Operation 4-7MN2408Analog Faults Eight analog fault inputs are user programmable for 12 fault conditions. Each analog fault input requires a specific

4-8 Operation MN2408Output ContactsAll output contacts are non–powered (i.e. dry contacts) and are rated 10A/240VAC, 8A/28VDCresistive (3A inductive,

Operation 4-9MN2408Display Modes The controller is in the display mode at all times except when in the programming mode. Thedisplay screens and menu

4-10 Operation MN2408Timer Countdown Timer countdown menus are automatically displayed when a specific time delay functionoccurs during a control se

Operation 4-11MN2408Generator AC Metering The controller is in the display mode at all times except when in the programmingmode. The display screen

4-12 Operation MN2408Engine Parameter Display Two engine operating parameter screens are provided. Battery Voltage/Engine Speed(Tachometer)BATTERYSP

Operation 4-13MN2408Navigation HintsProgramming parameters are displayed in the same order as the Programming Sheets (seeFigures 4-5 to 4-8). To skip

1-2 Product Safety Information MN2408This symbol is shown throughout the manual to indicate a connection to ground reference point. SymbolsIndicates a

4-14 Operation MN2408Main Menu Loop ContinuedLoss Of Speed Signal Select the desired action (i.e. alarm or shutdown) when a loss of speed signal is

Operation 4-15MN2408Digital Fault Menu Loop The controller’s digital fault settings are described as follows:Caution: The Digital Fault Label sele

4-16 Operation MN2408Span Calibration Energize the generator supply voltage to the controller at nominal level. Note: It may be necessary to program

Operation 4-17MN2408Engine Temperature & Oil Pressure CalibrationTo accurately calibrate the controller’s temperature sensor, an external tempora

4-18 Operation MN2408Figure 4-4 Configuration Data Sheet jjjjjjjjj

Operation 4-19MN2408Figure 4-5 Main Menu Loop ParametersParameter Setting RangeSystem Voltage (Line To Line) XXXXX VAC 120–15000VACSystem Frequency

4-20 Operation MN2408Figure 4-6 Analog Fault Menu Loop ParametersFault Name Input AnalogTypeFaultE EnableSetpoint Level(Pick up)Setpoint Level Actio

Operation 4-21MN2408Figure 4-9 Engine Control Connections 12345678910111217161514133837GRDCRMP2MP119182423B –B ++–CRANKRUN2526272829303132333424353

4-22 Operation MN2408Operator Control Panel (Analog Engine Controller Only)Figure 4-10 Analog Operator Control Panel–+OFF123Panel Lights switch (On-

Operation 4-23MN2408Manual Start/Stop To manually Start the Gen–Set, set the Master Control switch to the “Manual Run” position. Thefollowing happe

Product Safety Information 1-3MN2408Operation Warning Statements ContinuedWARNING: Never connect or disconnect loads during operation. Always connec

4-24 Operation MN2408Figure 4-12 A121H Analog Engine Controller Connections External ComponentsHigh Water TemperatureLow OilPressureOverspeedHigh W

Operation 4-25MN2408Garretson Model KN Fuel Valve ConsiderationsGeneralThe KN is designed for sensitivity and simple operation. It is used with low–p

4-26 Operation MN2408InstallationThe KN should be mounted as close to the carburetor as possible with the arrow on the coverpointing up and the diaph

Section 5Troubleshooting and MaintenanceTroubleshooting and Maintenance 5-1MN2408MaintenanceThis manual contains only very minimal engine maintenance

5-2 Troubleshooting and Maintenance MN2408Problems and SolutionsSome of the more common problems are listed in Table 5-1. This information is intende

Troubleshooting and Maintenance 5-3MN2408Table 5-2 Troubleshooting Guide (Digital Controller Only)Problem Possible Cause RemedyController does not po

5-4 Troubleshooting and Maintenance MN2408Note: See Engine Controller manual for additional information.Table 5-3 Troubleshooting Guide (Analog Contr

Appendix ASeries GLC Parts & Wiring DiagramsSeries GLC A-1MN2408Replacement Parts Replacement parts information is provided in this section of th

A-2 Series GLC MN2408Replacement Parts ContinuedDescriptionPart No.DescriptionGLC 80 GLC 100 GLC125WELDMENT, BASE BA0236A06L2B BA0236A06L2B BA0236A0

Series GLC A-3MN2408Replacement Parts ContinuedDescriptionPart No.DescriptionGLC 80 GLC 100 GLC125DECAL BONDED NEUTRAL" LB0300A00 LB0300A00 LB

1-4 Product Safety Information MN2408Warning Statements ContinuedInstallationWARNING: Installation and servicing of batteries is to be performed or s

A-4 Series GLC MN2408GLC Circuit Breaker & Electrical DataGLCAlternator Engine OutputGLCModelModelLeads/WindingFuelTypeSizeKWRatedPhaseVoltageConf

Series GLC A-5MN2408GLC DATA ContinuedGLCAlternator Engine OutputGLCModelModelLeads/WindingFuelTypeSizeKWRatedPhaseVoltageConfigVAC(L - L)VAC(L - N)F

A-6 Series GLC MN2408GLC DATA ContinuedGLCAlternator Engine OutputGLCModelModelLeads/WindingFuelTypeSizeKWRatedPhaseVoltageConfigVAC(L - L)VAC(L - N)

Series GLC A-7MN2408GLC DATA ContinuedGLCAlternator Engine OutputGLCModelModelLeads/WindingFuelTypeSizeKWRatedPhaseVoltageConfigVAC(L - L)VAC(L - N)F

A-8 Series GLC MN2408GLC DATA ContinuedGLCAlternator Engine OutputGLCModelModelLeads/WindingFuelTypeSizeKWRatedPhaseVoltageConfigVAC(L - L)VAC(L - N)

Series GLC A-9MN2408GLC Wire SizeRevision B 5–12–04CircuitBreakerSizeQuantity perPhaseMinimumWire Gauge EDI Plant Ampacity @125C15 1 #16

A-10 Series GLC MN2408Figure A-2 Customer Interface Connection DiagramMEC20MEC2

Series GLC A-11MN2408Figure A-3 Customer Interface (w/o Breaker) Power Connection Diagram

A-12 Series GLC MN2408Figure A-4 Single Phase – (w/o Breaker) Connection Diagram

Series GLC A-13MN2408Figure A-5 Single Phase – One Breaker Connection Diagram

Product Safety Information 1-5MN2408Warning Statements ContinuedMaintenanceWARNING: Disconnect the battery’s ground terminal before working in the vi

A-14 Series GLC MN2408Figure A-6 Single Phase – Two Breaker Connection Diagram

Series GLC A-15MN2408Figure A-7 Single Phase Connection Diagram (Wire 1/0 and Larger w/Breaker)

A-16 Series GLC MN2408Figure A-8 Single Phase Connection Diagram (Wire 1/0 and Smaller w/Breaker)

Series GLC A-17MN2408Figure A-9 Single Phase Connection Diagram (Wire 1/0 and Smaller w/o Breaker)

A-18 Series GLC MN2408Figure A-10 Single Phase Connection Diagram (Wire Larger than 1/0 w/o Breaker)

Series GLC A-19MN2408Figure A-11 Three Phase Connection Diagram

A-20 Series GLC MN2408Figure A-12 Three Phase Connection Diagram with PMG

Series GLC A-21MN2408Figure A-13 Three Phase Connection Diagram (Wire 1/0 and larger)

A-22 Series GLC MN2408Figure A-14 Three Phase Connection Diagram (Wire Larger than 1/0 w/Breaker)

Series GLC A-23MN2408Figure A-15 Three Phase Connection Diagram (Wire 1/0 and Smaller w/Breaker)