Baldor GLC30, GLC40, GLC105, GLC20, GLC25 User Manual

...

GLC Generator

(Gaseous Liquid Cooled)

GLC10, 15, 20, 25 30, 40, 45, 60, 65, 100 and 105

Installation & Operating Manual

2/08 MN2408

Any trademarks used in this manual are the property of their respective owners.

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.

Section 1

Product Safety Information 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Notice 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Responsibility 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMPORTANT SAFETY INSTRUCTIONS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Caution Statements 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2

General Information 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Limited Warranty 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Guidelines 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Site Planning 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Room Size 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Room Location 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Foundation Design 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust System 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Level Of Attenuation 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

System Placement 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Multi-Engine Installations 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Manifold 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Gas Restriction 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Piping 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rain Protection 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transfer Switch 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Starting System 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Location 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Size 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Charger

Battery Cables 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3

Receiving & Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Receiving & Inspection 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lifting the Generator 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Physical Location 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Secure the Generator 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cooling 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hot Exhaust Gasses 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Connections 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Connections 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Connections 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Engine Oil and Battery Type 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Post Installation Checks 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents iMN2408

Section 4

Operation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Engine Controller Description 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alarms 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inputs and Outputs 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Inputs 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Set points 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Control Panel (MICROPROCESSOR Engine Controller Only) 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Procedures 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Start/Stop 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Start/Stop 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Fault Shutdown 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Mains Failure (AMF) 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Faults 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Output Contacts 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Modes 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Status 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Display 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timer Countdown 4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator AC Metering 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Parameter Display 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Program Menus 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Menu Loop 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Fault Menu Loop 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Fault Menu Loop 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calibration Menu Loop 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Sensing Calibration

Voltage Calibration Procedure 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Sensing Calibration 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Voltage Calibration 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Temperature & Oil Pressure Calibration 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5

Troubleshooting and Maintenance 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintenance 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Problems and Solutions 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A

Options & Accessories A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Charger A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Heaters A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Block Heater A-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Silencers A-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Strainers & Fuel Lines A-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

E-Stop A-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Annuciators A-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator Duct Flange A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Enclosures A-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B

Series GLC Parts & Wiring Diagrams B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GLC Circuit Breaker & Electrical Data B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GLC Wire Size B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Diagrams B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start-up Inspection Form B-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii Table of Contents MN2408

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. Any person that installs or repairs this generator must have these specialized skills to ensure that this generating unit is safe to operate. Contact Baldor service department for repairs or any questions you may have about the safe installation and operation of this system.

The precaution statements are general guidelines for the safe use and operation of this generator. It is not practical to list all unsafe conditions. Therefore, if you use a procedure that is not recommended in this manual you must determine if it is safe for the operator and all personnel in the proximity to the generator and connected loads. If there is any question of the safety of a procedure please contact Baldor before starting the generator.

This equipment contains high voltages. Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment.

This equipment may be connected to other machines that have rotating parts or parts that are driven by this equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment.

- System documentation must be available to anyone that operates this equipment at all times.

- Keep non‐qualified personnel at a safe distance from this equipment.

- Only qualified personnel familiar with the safe installation, operation and maintenance of this device should attempt start‐up or operating procedures.

- Always stop engine before making or removing any connections.

- Always stop engine and allow it to cool before refueling.

Responsibility When your generator is delivered, it becomes the responsibility of the owner/operator of the

generator set to prevent unsafe conditions and operation of the equipment. Some responsibilities include (but are not limited to) the following:

1. It is the responsibility of the owner/operator of this generator to ensure that this equipment is correctly and safely installed.

2. It is the responsibility of the owner/operator of this generator to ensure that this equipment, when installed fully complies with all federal, state and local codes.

3. It is the responsibility of the owner/operator of this generator to ensure that any person operating this equipment has been properly trained.

4. It is the responsibility of the owner/operator of this generator to ensure that any person operating this equipment has access to all manuals and information required for the safe use and operation of this equipment.

5. It is the responsibility of the owner/operator of this generator to ensure that it is properly maintained and safety inspected at regular scheduled intervals.

6. It is the responsibility of the owner/operator of this generator to ensure that any person who has not been trained on the safe use of this equipment does not have access to this equipment.

Read This Manual Thoroughly

If you do not understand any concept, any procedure, any safety warning statement, any safety caution statement or any portion of this manual, contact Baldor or your nearest authorized Baldor representative. We are happy to make sure you understand the information in this manual so that you can safely enjoy the full use of this generator.

Product Safety Information 1‐1MN2408

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.

Precaution Statements Used In This Manual

WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in injury or

Caution: Indicates a potentially hazardous situation which, if not avoided, could result in damage to

Note: Additional information that is not critical to the installation or operation.

There are three classifications of precautionary statements used in this manual. The most critical is a WARNING statement, then the Caution statement and the least critical is the Note statement. The usage of each statement is as follows:

death.

property.

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS - This manual contains important instructions for the generator that

should be followed during installation, operation and maintenance of the generator and battery (batteries). For ease of reading, the Warning statements are divided into four categories: Operation, Burn, Installation, and Maintenance.

Operation WARNING: Never operate this generator in a manner other than as described in this manual. Operation

in any manner not described in this manual should be considered unsafe and should not be attempted. Never start the engine unless you have first verified that the installation and operation of the generator are as described in this manual.

WARNING: 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.

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. If you or anyone else experiences these symptoms, get out into fresh air immediately. Stop the engine and do not restart the engine until it has been inspected and if

necessary repaired or reinstalled in a well ventilated area. 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. Rotating parts can present extreme

danger if clothing or body extremities are caught by the rotating part and can cause serious

or fatal injury. Never touch a part of the generator until the engine has been stopped and all

rotating parts are completely stopped. Also, disconnect the spark plug wires and battery

connection to prevent accidental engine rotation during servicing. WARNING: Never move a generator set that is running. Loads should be connected and position secure

before starting the engine. Hazards are caused by moving a generator set that is running.

Continued on next page.

1‐2 Product Safety Information MN2408

Operation Warning Statements WARNING: 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.

WARNING: Be sure that you understand how to stop the engine quickly in case of an emergency situation.

Become familiar with the controls and safety systems provided with this generator set.

WARNING: Always wear safety glasses with side shields and hearing protection when working near the

generator.

WARNING: Improper operation may cause violent motion of connected equipment. Be certain that

unexpected movement will not cause injury to personnel or damage to equipment.

WARNING: Never operate the generator set indoors or in a poorly ventilated area such as a tunnel or cave.

Exhaust fumes are extremely dangerous to all personnel that are in or in contact with that area.

WARNING: Never permit anyone to operate the generator without proper instructions. Be sure to keep a

copy of this manual with the generator so that all users can be properly informed of its safe operation.

WARNING: Never allow children or pets to be in the area where the generator is running. The generator

and the equipment being powered by the generator may cause injury or death.

WARNING: Never operate the generator unless all guards, covers, shields and other safety items are

properly installed.

WARNING: Do not put hands, feet, tools clothing or other objects near rotating parts such as drive shaft,

pulley, belt etc. Rotating parts cause extremely dangerous situations because they can catch loose clothing or extremities and cause serious or fatal injury.

WARNING: When operating this generator remain alert at all times. Never operate machinery when

physically or mentally fatigued, or while under the influence of alcohol, drugs or medication.

WARNING: Never operate the engine when the air cleaner is removed. An engine backfire can cause

serious burns.

WARNING: 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. Jump starting a battery can cause the battery to explode and cause severe injury or death to anyone in the area.

WARNING: High voltage is present whenever engine is running. Electrical shock can cause serious or

fatal injury. Never operate electrical equipment while standing in water, on wet ground or with wet hands, feet or shoes or while barefoot.

WARNING: High voltage is present whenever the engine is running. Electrical shock can cause serious

or fatal injury. Always stop engine before connecting or disconnecting power cords or external devices.

WARNING: Do not smoke near generator during operation or when close to fuel source. LPG and natural

gas fuels are flammable and can cause fire, explosions, injury or death. WARNING: Keep generator at least three feet away from buildings and other structures. WARNING: Keep generator away from flammable or hazardous materials (trash, rags, lubricants,

explosives, paints etc.) and grass or leaf build up. WARNING: Keep a fire extinguisher near the generator while generator is in use. An extinguisher rated

“ABC” by the National Fire Protection Association is appropriate. 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 or the high voltage spark plug or coil terminals of the

engine. Although spark plug voltages are not normally lethal, a sudden involuntary jerk of the

hand or body part caused by contact with high voltage or a hot surface can result in injury to

yourself or others. WARNING: Engine coolant is under pressure and is near the boiling point of water when engine is hot.

Do not open the coolant system until the engine has completely cooled. Hot coolant can

cause severe burns and other injuries. When engine is cool, coolant level can be checked.

Continued on next page.

Continued

Product Safety Information 1‐3MN2408

Warning Statements Installation WARNING: 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.

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.

WARNING: 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.

WARNING: Installation and repair procedures requires specialized skills with electrical generating

equipment and small engine systems. Any person that installs or performs repairs must have these specialized skills to ensure that the generator set is safe to operate. Contact Baldor for installation or repairs.

WARNING: Be sure all wiring complies with the National Electrical Code (NEC) and all regional and local

codes or CE Compliance. Improper wiring may cause a hazardous condition and exposure to electrical hazards can cause serious injury or death.

WARNING: 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. NEC requires that the frame and exposed conductive surfaces (metal parts) be connected to an approved earth ground. Local codes may also require proper grounding of generator systems.

WARNING: Place protective covers over all rotating parts such as drive shaft, pulley, belt etc. Rotating

parts cause extremely dangerous situations because they can catch loose clothing or extremities and cause serious or fatal injury.

WARNING: Unauthorized modification of a generator set may make the unit unsafe for operation or may

impair the operation of the unit. Never start a generator set that has been modified or tampered with. Be sure that all covers and guards are properly installed and that the unit is safe before starting the engine. If you are unsure, contact Baldor before starting the engine.

WARNING: When moving the generator, use reasonable caution. Be careful where you place fingers and

toes to prevent injury “Pinch Points”. Never try to lift a generator without a hoist or lift means because they are heavy and bodily injury may result.

Warning: Never connect this generator to the electrical system of any building unless a licensed

electrician has installed an approved transfer switch. The national electrical code (NEC) requires that connection of a generator to any electrical circuit normally powered by means of an electric utility must be connected by means of approved transfer switch equipment to isolate the electrical circuit from the utility distribution system when the generator is operating. Failure to isolate the electrical circuits by such means may result in injury or death to utility power workers due to backfeed of electrical energy onto the utility lines.

WARNING: Circuit overload protection must be provided in accordance with the National Electrical Code

and local regulations.

WARNING: Check Ground Fault Circuit Interrupt (GFCI) receptacles monthly by using the “Test” and

“Reset” buttons.

WARNING: Only a professional experienced technician should install a fuel supply system. LPG and

natural gas fuels are flammable and can cause fire, explosions, injury or death. Fuel supply lines should be kept away from sharp objects to prevent rupture. Comply with all NFPA regulations and local codes for shut-off valves, regulators, fuel line type, connectors etc.

WARNING: Have electrical circuits and wiring installed and checked by licensed electrician or qualified

technician. Electrical shock can cause serious or fatal injury.

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: 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.

Continued

Continued on next page.

1‐4 Product Safety Information MN2408

Warning Statements Battery Safety WARNING: 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. WARNING: Do not dispose of battery or batteries in a fire. The battery is capable of exploding. If the

battery explodes, electrolyte solution will be released in all directions. Battery electrolyte

solution is caustic and can cause severe burns and blindness. If electrolyte contacts skin or

eyes, immediately flush the area with water and seek medical attention quickly. WARNING: Do not mutilate the battery . The battery contains electrolyte solution which is caustic and

can cause severe burns and blindness. If electrolyte contacts skin or eyes, immediately flush

the area with water and seek medical attention quickly. WARNING: A battery presents a risk of electrical shock hazard and high short circuit current. The

following precautions are to be followed when working on batteries:

WARNING: The battery electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes. It is

electrically conductive and corrosive. The following precautions are to be followed when

working on batteries:

WARNING: 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. The following precautions are to be

followed when working on batteries:

Continued

1. Remove watches, rings, necklaces and all other metal objects.

2. Use tools with insulated handles.

1. Wear full eye protection (safety glasses or goggles) and protective clothing.

2. Where electrolyte contacts the skin, flush the area immediately with water and wash it off using soap and water.

3. Where electrolyte contacts the eyes, immediately flush the eye thoroughly with water and seek medical attention quickly.

4. Spilled electrolyte is to be washed down with an acid neutralizing agent. A common practice is to use a solution of one pound (500 grams) bicarbonate of soda to one gallon (four liters) of water. The bicarbonate solution is to be added until evidence of reaction (foaming) has ceased. The resulting liquid is to be flushed with water and the area dried.

1. Do not smoke when near batteries.

2. Do not cause flame or spark in battery area.

3. Discharge static electricity from body before touching batteries by first touching a grounded metal surface.

Continued on next page.

Product Safety Information 1‐5MN2408

Warning Statements Maintenance WARNING: Before cleaning, inspecting, repairing or performing any maintenance to the generator set,

always be sure the engine has stopped and that all rotating parts have also stopped. After stopping, certain components are still extremely hot so be careful not to get burned. Before servicing the generator set, be sure to disconnect the spark plug wires and the battery terminals to prevent accidental engine rotation or starting.

WARNING: Engine coolant is under pressure and is near the boiling point of water when engine is hot.

Do not open the coolant system until the engine has completely cooled. Hot coolant can cause severe burns and other injuries. When engine is cool, coolant level can be checked.

WARNING: Before servicing the generator set, be sure to disconnect the spark plug wires and the battery

terminals to prevent accidental engine rotation or starting.

WARNING: Inspect all wiring frequently and replace any damaged, broken or frayed wiring or wires with

damaged insulation immediately. Electrical shock can cause serious or fatal injury.

WARNING: Disconnect all electrical wires and load devices from generator power outlets before servicing

the generator. Electrical shock can cause serious or fatal injury. Always treat electrical circuits as if they are energized.

WARNING: Check all fuel supply piping, and their connections monthly for fuel leaks. LPG and natural

gas fuels are flammable and can cause fire, explosions, injury or death. If a leak is found, replace only with approved pipe or components.

Continued

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. Moisture can cause insulation breakdown, making it necessary to return the generator for repair.

Caution: Use only original equipment or authorized replacement parts. Using the correct parts will

assure continued safe operation as designed. Caution: Do not support the generator from the top of the frame or enclosure. Caution: Do not tamper with or change the engine speed. Engine speed is factory set to produce the

correct voltage and output frequency. Caution: Never operate the engine without a muffler. The engine is designed to have the correct

exhaust components installed and operating without these components can present a fire

hazard, cause excessive exhaust gases and cause damage to engine. Inspect muffler

periodically and replace if necessary. Caution: The Programmable Output Contacts selection must agree with the external control wiring

prior to energizing the controller. Failure to do so may cause severe equipment damage.

1‐6 Product Safety Information MN2408

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. Please refer to the engine manual for information relative to engine operation, maintenance, recommendations and additional safety warnings.

Copyright Baldor  2008. All rights reserved. This manual is copyrighted and all rights are reserved. This document may not, in whole or in part, be copied or reproduced in any form without the prior written consent of Baldor Electric Company, Inc.

Baldor Generators have earned the reputation of being high quality and dependable. We take pride in this fact and continue to keep our quality standards high on our list of priorities. We are also constantly researching new technological ideas to determine if they could be used to make our generator sets even better.

Baldor makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied warranties of fitness for any particular purpose. The information in this document is subject to change without notice. Baldor assumes no responsibility for any errors that may appear in this document.

Limited Warranty

Baldor will replace or repair free of charge any part or parts of the generator of their manufacture that are defective in workmanship and materials for a period of time as set forth in the Warranty Period chart below. All Baldor products requiring warranty service shall be transported or shipped freight pre-paid to a Baldor Generator repair facility. Notification of the defect or problem, a description of the manner in which the Baldor generator is used, and the name, address and telephone number of the customer requiring warranty service must be included. Baldor is not responsible for removal and shipment of the Baldor product to the service center or for the reinstallation of the Baldor product upon its return to the customer, or any incidental or consequential damages resulting from the defect, removal, reinstallation, shipment or otherwise. Problems with Baldor products can be due to improper maintenance, faulty installation, non-Baldor additions or modifications, or other problems not due to defects in Baldor workmanship or materials. If a Baldor Generator repair facility determines that the problem with a Baldor product is not due to defects in Baldor workmanship or materials, then the customer will be responsible for the cost of any necessary repairs. Genset engines are covered under the engine manufacturers warranty. Proper engine maintenance is required. Any request for engine warranty or repair should be made directly with the engine manufacturers warranty center. See engine manufacturers data for applicable engine warranty periods and location of repair centers. This Limited Warranty and Service Policy represents Baldor's sole and exclusive warranty obligation with respect to Baldor products. Baldor's liability to a customer or any other person shall not exceed Baldor's sales price of the applicable Baldor product. BALDOR DISCLAIMS ALL OTHER EXPRESSED AND IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY.

Warranty Period

Portable Products (Premier, Powerchief,

*For products covered under labor coverage, travel expenses will be allowed up to 7 hours straight labor or 300 miles, whichever occurs first, and only applies to permanently wired and mounted products (AE, DLC, GLC, IDLC). You must save the purchase receipt. Proof of purchase, date, serial number and model number will be required for all portable and Towable products to qualify for any warranty consideration. A start-up inspection form/warranty registration must be completed in its entirety and submitted to Baldor Generators within 30 days of start-up to qualify for any warranty consideration, excluding: Portables, Towables and Light Towers.

Generator Series Labor* Parts

DG Series)

Towable Products (TS) 1 Year or 3,000 Hours 3 Years or 3,000 Hours

POW'R LITE Light Towers 1 Year or 3,000 Hours 3 Years or 3,000 Hours

3600 RPM Standby Systems

(Some AE Models)

1800 RPM Standby Systems

(Some AE Models, DLC, GLC)

Industrial Standby Systems 1 Year or 1,000 Hours 2 Years or 1,000 Hours

Industrial Prime Power Systems 1 Year or 1,000 Hours 1 Year or 1,000 Hours

International 1 Year or 1,000 Hours 1 Year or 1,000 Hours

1 Year or 1,000 Hours 3 Years or 1,000 Hours

1 Year or 3,000 Hours 3 Years or 3,000 Hours

1 Year 3 Years

Light Fixture, Lamps and Ballasts are excluded from

any warranty coverage

General Information 2‐1MN2408

2‐2 General Information 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.

Installation Guidelines

The procedures presented in this manual are suggestions and it is the responsibility of the Owner/Operator to arrange for these procedures to be performed by licensed contractors according to all applicable codes including local codes for your Municipality/City/County and State. In addition to these suggestions, before installing your generator you should obtain the most up to date copies of the following documents from the National Electrical Code and other authorities:

S National Electric Code, Articles 230, 250, 445, 517, 700. S National Fire Protection Association

No. 30 - Storage, Handling and Use of Flammable Liquids. No. 37 - Stationary Combustion Engines and Gas Turbines. No. 99 - Essential Electrical Systems for Health Care Facilities. No. 101 - Life Safety Code No. Systems. No. 110 - 1985 Emergency and Standby Power Systems.

S NEMA MG1 S Local Codes applicable to Genset Installation. See your local building inspector.

NFPA (National Fire Protection Association (617) 770-3000 (includes NEC)

1 Batterymarch Park, Quincy, MA 02169-7471 USA

NEMA (National Electrical Manufacturers Association) (703) 841-3200

1300 N. 17th Street, Suite 1847, Rosslyn, VA, 22209 USA

Site Planning

Room Size Open frame generators must be protected from the environment while having good ventilation

and cooling. Here are some considerations for planning a generator room or enclosure:

S Never use the Genset room for storage as well. S The room must be large enough to contain the genset and all the accessories, such as

batteries and their charging system, transfer switch and other controls, and elements of the cooling and fuel systems.

S A minimum of 2 feet (preferably 4 feet), must be allowed on the two sides of the engine

for service access.

S On the generator end of the engine, allow a space equal to the length of the generator

(generator length only, not the entire genset).

S At the front of the engine, 4 feet of clearance is preferable. Allow clearance between

hot parts of the system (exhaust) and structural members of the building.

S Certain safety and building codes may require the genset room not to be used to house

any other mechanical or electrical equipment.

General Information 2‐3MN2408

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).

S Assure the genset is not located so far from the emergency loads that reliability is

compromised.

S The floor's load carrying capacity must be checked and must exceed the weight of the

genset and its associated equipment.

S Engine Cooling System

A genset with an engine mounted radiator is the least costly to install; however, the room must be located in a place where sufficient radiator cooling air can be brought into and exhausted from the room.

S Exhaust System

The exhaust system must minimize exhaust restriction. Exhaust restriction must be limited to 3 in. Hg (76 mm Hg) maximum, to ensure proper engine operation. The exhaust system should be as short and have as few bends as possible.

S Room Air

If the genset is cooled with an engine mounted radiator, and sufficient air is brought into and exhausted from the room to satisfy the radiator cooling requirements and the combustion air requirements, the room will not overheat when the genset is running. If a remote mounted radiator or a heat exchanger is used, and adequate air is circulated through the room to keep it at a reasonable temperature, there will be adequate air for combustion.

S Fuel Tanks (Diesel Only)

Locate the fuel storage tank as near the genset as possible. This will minimize the cost of fuel system installation and will maximize fuel system reliability.

S Controls and Transfer Switch

Locate the control switch gear as close to the emergency loads and the genset as practical. This will minimize the chances that a failure of the power line to the emergency load will go undetected. In locating the switchgear, accessibility for service and maintenance must be considered.

S Genset Noise

Internal combustion engines produce noise, so the room should be located away from occupied buildings. In addition the genset room can be treated to reduce noise transmission. In locating the genset room, both engine, fan and exhaust noise must be considered.

If noise within the genset room, or noise transmitted to the surrounding parts of the building are a concern, then the room must be made large enough to allow for installation of noise attenuating walls and noise absorbing walls. Light weight concrete blocks filled with sand or special “sound block” concrete blocks are commonly used. Noise attenuating, tight fitting windows and doors also help reduce noise transmission to the rest of the building. A double-walled room should be considered. Vibration isolators under the genset rails will also reduce the transmission of noise through the floor.

S Code Requirements

Building and safety codes deal with engine location. These requirements are concerned with fire rated walls, a location that minimizes the possibility of damage to the genset and interruption of the emergency system due to storms, foods, fire, vandalism, etc.

Codes often deal with the need to maintain certain temperatures in the genset room and with fuel system location. The most important codes in the USA are the National Fire Protection Association Code Numbers 99 and 110, but local codes must also be observed.

2‐4 General Information MN2408

Foundation Design WARNING: 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.

Foundation Checklist

A. Evaluate if a separate, isolated foundation is required for the application. B. Observe local codes on soil bearing capacity freezing and thawing. C. Design the separate foundation for the genset and specify the appropriate concrete mix. D. Determine if the application requires vibration isolators and if so, order as a factory option.

The foundation must be strong enough to support the weight of the genset and its associated equipment, must prevent any deflection of the genset base and absorb vibration produced by the rotating and reciprocating masses.

Setting The Genset On An Existing Concrete Floor Slab

S If an existing floor is used, the floor slab must be strong enough to carry 1.50 times the

genset wet weight (including coolant and oil) to accommodate dynamic loads.

S The actual mounting arrangement (ie., surface area in contact with the floor) will

determine the compressive strength required.

S The genset should be securely fastened to the floor slab with expansion anchors that fit

the mounting holes shown on the genset installation diagram.

S For installations not expected to be permanent, elastomer pad with non-slip surface

placed between the base and the floor will also prevent movement.

S Any floor/slab surface should be as flat as possible to prevent sub-base deflection.

Vibration Isolators

S Mounting to the pad, will result in overall reduced motion on other parts of the genset.

The trade-off is that slightly more vibration is transmitted to the structure.

S A more common practice when mounting to a concrete pad is to use vibration isolators.

The two most common types of vibration isolators are steel spring and elastomer pad. The primary purpose of vibration isolators is to reduce the noise and vibration which would be transmitted from the genset to the foundation or supporting structure.

S A simple and effective method of mounting and applying pad type isolators is to place

non-skidding type isolation pads directly between the sub-base and floor. The number of pads required will be determined by the load bearing capability of the pads and the genset's weight.

Figure 2‐1 Typical Installation of Spring Type Isolator

General Information 2‐5MN2408

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.

Spring steel isolators offer the highest level of vibration isolation, however higher levels of vibration (although not detrimental) may be seen on some areas of the genset when mounted on steel springs, due to the (almost) total isolation from the foundation. The base of most steel spring isolators contains a non-skid pad. The base should be mounted to the foundation pad as shown in Figure 2‐1 or as recommended by the isolator manufacturer.

A common practice is to pour a concrete pad directly on top of the floor slab and to mount the genset on this pad. The purpose of the pad is to facilitate cleaning around the genset and to provide a more level base. When using this method, floor strength must support the pad and the genset. The pad should be at least 6in (150mm) thick and extend beyond the genset in all directions 12in (300mm).

Weight Of The Genset

The dry weight of the entire genset is shown on the Generator Set Specification Sheet. The wet weight includes the fluids (coolant and oil). Figure 2‐2 can be used to design the foundation except in critical situations.

Figure 2‐2 Approximate Weight vs. kW Output

2‐6 General Information 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. Outside dimensions of the foundation should exceed the outside genset dimensions by 12in (300mm). For single genset installation, the foundation weight should be a minimum of 1.50 times the genset wet weight. For multiple genset installation, the foundation weight should be a minimum of 2.0 times the genset wet weight. Figure 2‐3 shows a method to calculate foundation thickness and the soil bearing load of the foundation and generator set. The soil load bearing capacity under the foundation must equal or exceed the load from the foundation and genset. If it does not, then a footing, as shown in Figure 2‐4 must be added to spread the load over a larger area.

Figure 2‐3 Calculate Soil Bearing Load (SBL) Capacity

Figure 2‐4 Typical Footing on Foundation in Soil With Low Soil Load Bearing Capacity

General Information 2‐7MN2408

Table 2‐1 Approximate Load Bearing Capacities of Various Soil Types

Soil Type

Hard Rock - Granite etc. 50,000 - 200,000 2,395 - 9,576 Medium Rock - Shale etc. 20,000 - 30,000 958 - 1,436 Hardpan 16,000 - 20,000 766 - 958 Soft Rock 10,000 - 20,000 479 - 958 Compacted Sand and Gravel 10,000 - 12,000 479 - 575 Hard Clay 8,000 - 10,000 383 - 479 Gravel and Coarse Sand 8,000 - 10,000 383 - 479 Loose, Medium and Coarse Sand 8,000 - 10,000 383 - 479 Compacted Fine Sand 6,000 - 8,000 287 - 383 Medium Clay 4,000 - 8,000 192 - 383 Loose Fine Sand 2,000 - 4,000 96 - 192 Soft Clay 2,000 96

Safe Bearing Capacity

lb per ft

kilo Pascals

Table 2‐1 shows approximate load bearing capacities for various types of soil if the actual load bearing capacity of the soil under the foundation is not known.

Caution: Check the local building codes for load bearing capacity requirements. Caution: If the soil is subject to freezing and thawing, the foundation must be extended below the frost

line. Check the local building codes.

S Reinforce the foundation with No. 8 gauge steel wire mesh placed horizontally on

6in (150mm) centers. As an alternative, use No. 6 re-bars on 12in (300mm) centers horizontally. Minimum cover over the bars should be 3in (76mm).

S Suggested concrete mixture by volume is 1 part cement, 2 parts sand, and 3 parts

aggregate. Maximum slump of 4in (100mm) and a 28-day compressive strength of 3000 psi (20,600 kPa).

S The size of the bolts holding the sub-base to the foundation should be sized to fit the

mounting holes shown on the Installation Diagram.

S Three-inch (76mm) iron pipe sleeves should be placed around the bolts in the

foundation to allow for any mislocation of the bolts after the foundation hardens. “J” or “L” type bolts are recommended for the foundation bolts.

S After the foundation is cured and the genset is located, the sleeves are filled with grout.

Figure 2‐5 shows a typical foundation installation.

Figure 2‐5 Typical Foundation Installation

2‐8 General Information 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. D. Exhaust piping sizing is adequate to prevent back pressure. E. Exhaust piping components are insulated as necessary to prevent operator burns and reduce pipe radiant heat losses. F. Pipe sleeves or fire proof materials are used where exhaust pipe passes through building materials as per local and state codes. G. Exhaust pipe includes rain cap or is horizontal.

The purpose of the exhaust system is to safely discharge the engine combustion products into the atmosphere outside the building. A silencer should be installed in the exhaust system to reduce noise levels. Compliance with local noise codes is always required.

Level Of Attenuation

In general, manufacturers offer three grades of silencers: industrial, residential, and critical. In most cases, these grades are comparable from make to make. However, attenuation curves for the silencer should be checked to assure the desired level of silencing is met.

System Placement

By this time, the general genset placement within the room or building has been decided. The routing of the exhaust system should be as direct as possible to the building exterior.

WARNING: Never allow the exhaust outlet to be positioned so that the exhaust gases are directed

towards any openings or air entry routes (doors, windows, vents, etc...) of an occupied building. When discharging the hot exhaust gases out of the building do not direct them towards anything that could catch fire or explode.

For aesthetic reasons, consider exhaust placement in relation to the building. Over a period of time, exhaust gas carbon deposits will tend to accumulate on any nearby wall or structure. Attention must also be given to exhaust noise in selecting placement of the exhaust system.

Multi-Engine Installations Caution: Do not connect multi-engine exhaust systems together. Each engine must have its own

exhaust system for proper operation.

Exhaust gases from an operating engine will migrate back through a non-operating engine and cause a hydraulic lock. This may interfere with starting of the second engine. The migrating gases will also tend to turn the turbos which are not being provided lubrication if the engine is not running. The use of check valves in the exhaust system are discouraged due to their tendency to “stick”.

Exhaust Manifold

There are two exhaust manifold types. Dry type which is standard and the optional water cooled. The dry type is simply exposed to the surrounding air and becomes very hot. Shields, insulating wraps, or other types of guards can be used to limit operator contact with the hot surfaces. This practice is common where engine room size is small, creating cramped conditions.

Water cooled exhaust manifolds are not available on all engine models. This type manifold has passages through which engine coolant is circulated to remove heat from the manifold surface. It also will help protect the operator from contact with the hot manifold surface. This will reduce the amount of heat that is radiated by the engine to the surrounding air by approximately 20%. In addition, this type manifold significantly increases the amount of heat the cooling system must dissipate. Marine and Mining Safety Administration (MSA) codes may require water cooled manifolds in all genset installations. If you are in doubt on your particular application, consult your Baldor Distributor.

Exhaust Gas Restriction

The maximum allowable back pressure, or system restriction, is 3 inches of mercury. If this back pressure is exceeded, the air-fuel ratio is reduced due to incomplete scavenging of the cylinders, fuel economy and power output is reduced, engine life is reduced and exhaust temperatures and smoke levels increase. Any restriction of the exhaust gas reduces horsepower. Take every precaution to reduce restriction. Proper design and installation will provide safe genset operation.

It is essential that all engine exhaust systems by designed with the least possible restriction to exhaust gas flow. This can be calculated through the use of Figure 2‐6, or in the case of simple exhaust systems, the nomograph in Figure 2‐6 may be used.

General Information 2‐9MN2408

Figure 2‐6 Exhaust System Calculations

Exhaust Piping Caution: The weight of the exhaust system must never be imposed on the turbo-charger outlet.

Damage to the turbo-charger and other components may result.

An exhaust system must withstand the vibration and thermal expansion that they are subjected to, yet supported well enough to remain independent of the engine.

The most common method of providing flexibility is with the use of bellows type flexible piping. This piping component allows lateral and linear movement of the piping system without subjecting fixed components to excessive stress. A minimum of 12 inches of flexible connection must be provided at the engine exhaust manifold to allow for thermal expansion and vibration. If the engine is to be mounted on spring type vibration isolators, increase the length to 24 inches. This component can be specified to be provided by your Baldor distributor. Flexible pipe should never be used for pipe bends or to cure misalignment problems.

Exhaust piping systems may be supported by a wide variety of methods to long as the system remains flexible, and capable of withstanding thermal expansion.

The material most commonly used for straight runs and elbows in exhaust systems is Schedule 40 black iron. If hanging weight is a problem, other materials may be used. Galvanized piping should never be used in exhaust system. Where exhaust piping passes through combustible material, exhaust thimbles must be used. See Figure 2‐7.

Figure 2‐7 Exhaust Pipe Thimble Installation

Rain Protection

Moisture entering the engine through an exhaust system can cause extensive damage. Exhaust outlets must have a rain cap or be horizontal to prevent such damage. See Figure 2‐7.

2‐10 General Information MN2408

Transfer Switch

Transfer 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. D. Observe applicable codes in wiring-in the transfer switch and genset.

The transfer switch connects the genset to the emergency power system. The emergency power system may include several gensets and several transfer switches. Typically, the genset is wired to the emergency power system through a transfer switch as shown in Figure 2‐8.

Figure 2‐8 Typical Emergency power System Installations

Multiple Gensets can be arranged either in parallel or separately connected to dedicated emergency loads. Figure 2‐8 also shows a typical arrangement of two gensets in parallel with transfer switches for loads that have different levels of priority. A typical multiple genset installation is shown for NFPA 110 Level 1 and Level 2 emergency power circuits and a priority control to select the appropriate transfer switch.

Wattmeters should be installed on each genset so load sharing can be checked. The control system should include an automatic paralleling control. Paralleling identical gensets is not difficult, but paralleling dissimilar sets can cause load sharing problems. When designing an installation that includes the paralleling of dissimilar generators, contact your nearby Baldor Distributor.

Transfer Switch Location

The transfer switch location is important and key considerations are:

1. Locate the transfer switch as close to the emergency load as practical to avoid

2. Locate the transfer switch in a clean, dry, well ventilated location, away from excessive

3. A circuit breaker (or fuses) should be installed in the line between the generator and

4. Install power and control wires in separate solid conduit with flexible sections at the

5. Never install control wires in the same conduit as power conductors.

interruptions of the emergency power system due to natural or man-made disasters, or to equipment failures. Consider several small transfer switches instead of one large one to increase reliability.

heat. When the ambient air is above 104 F (40 C), fuses and circuit breakers must be derated. Allow adequate working space around the transfer switch.

the transfer switch. Baldor Gensets are available with properly sized circuit breaker built into the generator control through 1200 amp breakers. The circuit breaker can be separately mounted. In the case of very large circuit breakers, a separate floor mounted circuit breaker is easier to wire up than a wall mounted breaker.

genset. The flexible sections prevent vibration from damaging the conduit. All power conduits from the genset must contain all three phases.

General Information 2‐11MN2408

6. Conduit, wire, circuit protective device sizes, insulation etc. must conform to applicable local and national codes and regulations.

7. Be certain to seal around conduits that penetrate the walls of the genset room to reduce the amount of noise that is transmitted to the surrounding areas of the building and maintain site fire code rating.

Battery Starting System

This section describes the battery starting system (nominal 12 volt rating of the battery supply) for the engine, battery charger, and precautions to take if the ambient temperature is expected to be below 70 F (20C).

WARNING: If batteries are not mounted in the battery rack supplied with the genset, protect batteries

from vibration and do not locate them near a source of flame or spark. A battery presents a risk of fire and explosion 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.

Battery Location

Locate batteries as close as possible to the genset to minimize starting circuit resistance, see Figure 2‐9. High starting circuit resistance substantially reduces starting cranking ability. Mount batteries on a level rack away from dirt and liquids. Allow space for servicing (checking water level and level of charge). Cold ambient temperature at the battery location substantially reduces the battery output.

Figure 2‐9 Battery Starting System

Battery Size

The ability to start the engine depends upon battery capacity, ambient temperature and coolant and oil temperatures. The Engine/Generator Set Data Sheet lists minimum recommended battery capacity.

Battery capacities decrease as ambient temperatures decrease so it is important to specify batteries with the appropriate CCA rating at a temperature no higher than the minimum ambient temperature for the application.

2‐12 General Information MN2408

Battery Charger

Battery Cables

An engine mounted alternator charges the batteries during engine operation. Standby gensets should include a solid state battery charger that is connected to utility power so the battery is charged continuously while the genset is not running. The battery charger should be connected to the utility power emergency circuit. The batteries on prime power gensets are charged by the engine mounted alternator, if equipped.

The output of the battery charger or the belt driven alternator must be connected directly to the battery or to the battery terminals on the starter to prevent the electronic governor from acting erratically. Make control connections to the genset control using a conduit with a flexible section at the genset to avoid damage due to genset vibrations.

The wire size (wire gauge) of the cables connecting the starter to the batteries must be large enough to ensure proper voltage at the engine starter motor during cranking. The total cranking circuit resistance includes the resistance of the cables from the starting motor to the battery and the resistance of all relays, solenoids, switches, and connections. The resistance of various sizes of cables is shown in Figure 2‐10. For purposes of calculating cranking circuit resistance to select cable size, the resistance of each connection can be taken as .00001 ohms and the resistance of each relay, solenoid, and switch can be taken as .0002 ohms. Figure 2‐10 illustrates an example of a typical cranking circuit resistance calculation.

Figure 2‐10 Typical Battery Cable Calculations

General Information 2‐13MN2408

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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. If the system is to be stored for several weeks before use, be sure that it is stored in a location that conforms to published storage temperature and humidity specifications.

Lifting the Generator When lift or hoist equipment is used to lift the generator and move it to position, be careful not

to contact overhead wires or other obstacles. Be sure lift or hoist equipment has appropriate tires for the terrain to avoid becoming stuck or tipping over. If the shipping pallet is intact, use a fork lift to move the generator. If the shipping pallet has been removed, use two steel pipes through the “Lift Point” holes to lift the generator. See Figure 3‐1.

Figure 3‐1 Generator Lifting

Height

To lift the generator, always use spreader bars, chains, eyehooks and other hardware that is of sufficient strength to lift at least three times the weight of the generator.

Lift Point

Length

Width

Lift Point

Physical Location The mounting location of the system is important. It should be installed in an area that is

protected from direct harmful gases or liquids, dust, metallic particles, shock and vibration. It should be installed in an outdoor location so the exhaust fumes are vented to the atmosphere.

When the Generator is installed outdoors

The factory installed enclosure is designed to keep out undesirable weather elements while providing cooling and ventilation.

When the Generator is installed in a building it is essential to provide:

1. Adequate control and exhausting of the heated air.

2. An adequate and constant supply of incoming cooling air.

3. Adequate control and discharge of the engine's hot exhaust gases.

4. Adequate ventilation of the building when the engine shuts down.

Receiving & Installation 3‐1MN2408

WARNING: 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.

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. If these items pose a problem, consider building a small fence or other break to protect the unit from accumulation of debris.

4. Installation should place the generator as close as possible to the fuel supply and transfer switch.

5. At least twenty-four (24) inches clearance must be provided on all sides for air flow.

6. Access must be provided to allow the enclosure covers to be opened or removed for service and maintenance.

7. Maximum Ambient temperature is 122F (50C).

Figure 3‐2 Generator Mounting

Fuel Stub Up GLC125 ONLY

Large Exhaust Area

For all models with enclosure

Electrical Stub Up

A2A1

Fuel Stub Up

Table 3‐2 Mounting Dimensions

Generator A

(Open)A(Weather.)A(Sound)

GLC10-25 60.25 72.0 72.0 GLC30-45 78.0 78.0 108.0 6.0 33.0 30.0 44.0 42.5 21 58 GLC60-65 88.0 88.0 118.0 6.0 38.0 30.0 44.0 42.5 23 63

GLC80-105 88.0 88.0 118.0 6.0 38.0 30.0 44.0 42.5 27 68

 Add 11.75 in for Weather & Sound Attenuated enclosures.

A1 A2 A3 B B1 F1 F2

4.0

26.1 11.75 31.5 30.5

17.6 34.2

Table 3‐3 Stub Up Detail

Generator

GLC10-25 6.25” x 5” 5” x 18” GLC30-45 15” x 6” 18”x 6” GLC60-65 21” x 6” 20” x 6” 1-1/4” NPT, C/L is 12” above base bottom.

GLC80-105 16” x 6” 21” x 6” 1-1/4” NPT, C/L is 12” above base bottom.

Stub Up Area

Electrical Fuel

Fuel Connection (NG or LP Vapor)

/4” NPT, C/L is 3” above base bottom.

/4” NPT, C/L is 12” above base bottom.

3‐2 Receiving & Installation MN2408

Secure the Generator

Six (eight for the GLC125) mounting bolts in the base frame secure the generator to the shipping pallet. Remove these bolts, lift the generator and remove the shipping pallet. Secure the generator to the concrete pad using

/8 anchor hardware (not provided) in the base frame mounting holes. See Figure 3‐2. Anchor bolts must be long enough to extend through the generator mounting frame.

Engine Cooling A sufficient flow of clean, cool air is required for combustion and to dissipate the heat produced

by the engine. Approximately 60% of the heat value of the fuel used is given off as heat (cooling air and exhaust).

The air that will cool the engine must be brought in from outside the building. A sufficient air-flow of rate “Cubic Feet per Minute” (CFM) will allow the incoming fresh air to cool the engine. This requires a power ventilation system of sufficient CFM to be located at the highest possible point of the building to exhaust hot air and draw in cool fresh air.

Note: The exhaust fan must not be located where it could easily become blocked by leaves,

snow, water, debris, etc.

It is recommended that the cool air intake have at least three (3) times the cross-sectional area of the power ventilation system. It is also recommended that the cool air intake be located as close as possible to the top of the generator set.

The exhaust fan must be connected to the AC power terminals of the generator set so that when the generator set starts it will provide immediate cooling air flow. The fan will operate until the generator set stops. To test the ventilation system, do the following:

Ventilation Test

1. Place a thermometer as close to the cool air intake of the engine's blower housing as you can without allowing the thermometer to touch any material surface.

2. Place another thermometer outside of the building or compartment in the open air (Keep the thermometer out of direct sunlight or any other heat sources).

3. Run the engine under maximum load for an extended period of time (at least one hour).

4. The temperature difference between the two should not exceed 15 degrees F.

Note that opening any door, window or other opening can upset the air-flow pattern and result in a significant reduction in the cooling air-flow across the generator set. This may result in overheating, fire, or explosion.

Receiving & Installation 3‐3MN2408

Hot Exhaust Gasses WARNING: Exhaust fumes/gases are extremely dangerous and can cause severe illness or death. Never

WARNING: Hot exhaust gasses must never be directed toward anything that may catch fire or explode.

It is extremely important to discharge engine exhaust gasses away from the engine and out of the building. If these gasses remain in the cylinder, poor performance or eventual engine damage may result. This condition results from excessive back-pressure, which could be caused by any one or a combination of the following conditions:

1. Exhaust pipe too long or the diameter is too small.

2. Excessive number of sharp bends in the exhaust system.

3. Obstruction in the exhaust system.

Backpressure must not exceed 20” of water column.

The direction of the discharged hot air and hot exhaust gases is important as they have the potential to create brown spots on the lawn or adjacent structures. In extreme cases this extremely hot air could cause dried grass or other debris to ignite.

Exhaust lines should be as short and straight as possible. Long pipe lengths and elbows tend to resist the flow of gases and accumulate carbon deposits. Each pipe fitting and elbow will further restrict the exhaust flow.

Guidelines for Exhaust System

1. 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.

2. 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. This nipple will reduce the possibility of the hot gases burning up the flexible coupling.

3. It is extremely important that you do not allow the hot exhaust gases to re-circulate into the engine's cooling air intake.

4. Water is one by-product of combustion and is present in the exhaust pipes or muffler. This water must be kept from draining back into the engine. This can be done by slanting the horizontal section of the exhaust system piping downward slightly, away from the engine. A water trap consisting of a tee extension with a drain cock should also be provided. This water trap should be located between the flex coupling and the muffler, but as close to the engine as possible on a horizontal section of the exhaust piping.

5. It is also recommended that an exhaust rain cap be used whenever it is possible that rain could get into the system. This will help to prevent corrosion and damage to the exhaust system and engine.

6. The exhaust system is subject to the engine's vibration and it must therefore be solidly secured to reduce mechanical stress and the potential for breakage.

7. The engine's exhaust system is the hottest component of the installation and extreme care and considerations must be given to it.

3‐4 Receiving & Installation 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.

10. After the exhaust system is installed it should be inspected on a regular basis to assure there are no toxic exhaust gas leaks. In some areas this inspection may be provided by your local public service.

11. A carbon monoxide tester may be installed to detect the presence of the deadly gas during times when you are in the building with the engine running (during testing or maintenance).

WARNING: Never allow the exhaust outlet to be positioned so that the exhaust gases are directed

WARNING: Exhaust fumes/gases are extremely dangerous and can cause severe illness or death. Never

Receiving & Installation 3‐5MN2408

Installation The generator is completely assembled, tested and adjusted at the factory before it is shipped to

you. The procedures presented in this manual are suggestions and it is the responsibility of the Owner/Operator to arrange for these procedures to be performed by licensed contractors according to all applicable codes including local codes for your Municipality/City/County and State. External connections required at the time of installation are:

1. Fuel System.

2. Electrical Connections - power wiring (optional transfer switch) and control wiring.

3. Battery (not included).

4. Ground Connection. After installation, the post installation checks must be performed prior to starting the engine. After these checks have been performed and the system operation is verified to be good, refer to

Section 5 Maintenance for periodic checks that must be performed at scheduled intervals to ensure continued operation with minimal problems.

Fuel Connections

Fuel selection is Natural Gas or LPV (Liquid Propane Vapor). If natural gas supply is used, follow the “Natural Gas Connections” procedure. If LPV supply is used, follow the “LP Vapor Connections” procedure. Table 3‐4 defines the flow rate required for each fuel type.

Table 3‐4 Fuel Consumption Natural and LPV

Model Fuel Consumption at 100% load

cubic ft/Hr (cubic m/Hr)

Natural Gas LP Vapor Natural Gas LP Vapor

GLC10 348(9.9) 145.2(4.1) GLC45 584(16.5) 242(6.9) GLC15 438(12.4) 189.3(5.4) GLC50 731(20.7) 269(8.2) GLC20 528(15.0) 233.4(6.6 GLC60 780(22.1) 321(9.1) GLC25 618(17.5) 277.5(7.9) GLC80 1012(28.7) 425(12) GLC30 526(14.9) 197(5.6) GLC100 1133(32.1) 487(13.8) GLC35 575(16.3) 240(6.0) GLC125 1651(46.8) 852(16.5)

Model Fuel Consumption at 100% load

cubic ft/Hr (cubic m/Hr)

General Considerations

1. A generator set needs the engine to deliver 2 hp of energy to the alternator for every

1000 watts of electric output power (example: an 8000 watt generator needs the engine to deliver 16 hp of energy to the generator end).

2. An engine needs 10,000 BTU's of fuel energy per horsepower of engine power to

provide a sufficient supply of fuel (example: a 16 Hp engine needs 160,000 BTU's of fuel energy for it to work properly). This fuel must be supplied to the regulator on the generator set at a pressure of 6 oz (11 inches of water column). To achieve this 6 oz. pressure in a L.P. System, you will normally have to reduce the tank pressure by means of a primary regulator or a regulator system of 2 or more regulators.

3. There are 2,516 BTU's in one cubic foot of Propane (LP Fuel).

There are 1,096 BTU's in one cubic foot of Natural Gas.

4. There are 36.39 cubic feet in one gallon of Propane.

There are 57.75 cubic feet in one gallon of Natural Gas.

5. There are 8.58 cubic feet per pound of Propane.

There are 23.56 cubic feet per pound of Natural Gas.

6. When installing the piping for the gaseous fuel supply please refer to the pipe chart in

Tables 3‐5 and 3‐6 to be sure you are using piping of significantly large size to deliver the necessary amount of fuel.

7. If copper tubing is used, it should be “K” or “L” having a minimum wall thickness of

0.032 inches. Black Iron Pipe is recommended but follow building codes for your area.

The following pamphlets are available from:

National Fire Protection Association (NFPA) P.O. Box 9101 Quincy, MA 02269

No. 37 - Combustion Engines No. 54 - Gaseous Appliances and piping No. 58 - Storage and handling LPV

3‐6 Receiving & Installation MN2408

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