Baldor GLC30, GLC35, GLC50, GLC45, GLC60 Installation & Operating Manual

GLC Generator

(Gaseous Liquid Cooled)

GLC30, 35, 45, 50, 60, 80, 100 and 125

Installation & Operating Manual

5/04 MN2408

WARNING:

CALIFORNIA PROPOSITION 65 WARNING:

Engine exhaust from this product contains chemicals known
to the state of California to cause cancer, birth defects and
other reproductive harm.

WARNING:

CALIFORNIA PROPOSITION 65 WARNING:

Battery posts, terminals and related accessories are known to
the state of California to cause cancer, birth defects and other
reproductive harm.

Table of Contents

Section 1

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

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

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

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

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air System 2-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator Cooling 2-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Other Engine Cooling Systems 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Crankcase Ventilation 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transfer Switch 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Starting System 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Location 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Size 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Charger 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Cables 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents iMN2408

Section 4

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

Operator Control Panel (Digital Engine Controller Only) 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Procedures 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Start/Stop 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Start/Stop 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Fault Shutdown 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Mains Failure (AMF) 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standard Faults 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Output Contacts 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Modes 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Status 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fault Display 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Timer Countdown 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator AC Metering 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Parameter Display 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Program Menus 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Menu Loop 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Analog Fault Menu Loop 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Fault Menu Loop 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Calibration Menu Loop 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Sensing Calibration 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Calibration Procedure 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Sensing Calibration 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Voltage Calibration 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Temperature & Oil Pressure Calibration 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Control Panel (Analog Engine Controller Only) 4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Procedures 4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Start/Stop 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Start/Stop 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Fault Shutdown 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Garretson Model KN Fuel Valve Considerations 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5

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

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

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

Appendix A

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

Replacement Parts A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GLC Circuit Breaker & Electrical Data A-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GLC Wire Size A-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Diagrams A-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start–up Inspection Form A-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Read This Manual Thoroughly

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.

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.

Baldor Generators
3815 Oregon Street
Oshkosh, WI 54902
(920) 236–4200 (voice); or (920) 236–4219 (fax); or www.baldor.com

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.

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
Maintenance
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: 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: 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.
WARNING: Do not mutilate the battery or dispose of a battery 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: A battery presents a risk of electrical shock hazard and high short circuit current. Electrical

shock can cause serious or fatal injury. Never wear jewelry, watch or any metal objects when

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

electrically conductive and corrosive. If electrolyte contacts the skin, flush the area

immediately with water and wash it off using soap and water. If electrolyte contacts the eyes,

immediately flush the eye thoroughly with water and seek medical attention quickly.
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

Continued on next page.

Product Safety Information 1-5MN2408

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 to the factory for repair, and consequent expense and loss of time.

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 ! 2004. 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 Generators 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, at the risk of the
party requiring warranty service, to a Baldor Generator repair facility, or to Baldor Generators
Department in Oshkosh, Wisconsin. Written notification of the alleged defect in addition to a description of the
manner in which the Baldor generator is used, and the name, address and telephone number of the party 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 party requiring warranty service.
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 party requesting warranty service will be responsible for the cost of any necessary repairs.
EXCEPT FOR THE EXPRESSED WARRANTY SET FORTH ABOVE, BALDOR GENERATORS DISCLAIMS ALL
OTHER EXPRESSED AND IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF FITNESS
FOR A PARTICULAR PURPOSE AND MERCHANTABILITY. NO OTHER WARRANTY, EXPRESSED OR
IMPLIED, WHETHER OR NOT SIMILAR IN NATURE TO ANY OTHER WARRANTY PROVIDED HEREIN, SHALL
EXIST WITH RESPECT TO THE GOODS SOLD UNDER THE PROVISIONS OF THESE TERMS AND
CONDITIONS. ALL OTHER SUCH WARRANTIES ARE HEREBY EXPRESSLY WAIVED BY THE BUYER.
UNDER NO CIRCUMSTANCES SHALL BALDOR GENERATORS BE LIABLE OR RESPONSIBLE IN ANY
MANNER WHATSOEVER FOR ANY INCIDENTAL, CONSEQUENTIAL OR PUNITIVE DAMAGES, OR
ANTICIPATED PROFITS RESULTING FROM THE DEFECT, REMOVAL, REINSTALLATION, SHIPMENT OR
OTHERWISE. This is the sole warranty of Baldor Generators and no other affirmations or promises made by
Baldor Generators shall be deemed to create an expressed or implied warranty. Baldor Generators has not
authorized anyone to make any representations or warranties other than the warranty contained herein.

Warranty Period

Generator Series Labor* Parts

(Premier, Powerchief, DG Series, K Series)

Portable Products

Towable Products (TS) 1 Year 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

Industrial Prime Power Systems 1 Year or 1,000 Hours

International 1 Year or 1,000 Hours

Whichever comes first
1 Year or 1,000 Hours

Whichever comes first
1 Year or 3,000 Hours

Whichever comes first

Whichever comes first

Whichever comes first

Whichever comes first

*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).
No warranty registration card is necessary to obtain warranty on Baldor Generators.
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.
For all other products, 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.

1 Year 3 Years

3 Years or 3,000 Hours

Whichever comes first

3 Years or 1,000 Hours

Whichever comes first

3 Years or 3,000 Hours

Whichever comes first

2 Years or 1,000 Hours

Whichever comes first
1 Year or 1,000 Hours

Whichever comes first
1 Year or 1,000 Hours

Whichever comes first

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 T

ype

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

2

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

Cooling System

Cooling System Checklist

A. Have noise considerations been taken into account?
B. Has system piping been properly sized?
C. Has system been properly protected from freeze up and corrosion?
D. Have standby equipment heaters been specified?
E. Have all electrically driven devices been connected to load side of EPS connection points?
F. Have system drain valves and air eliminators been installed?

The system consists of the cooling medium which is generally a solution of water and ethylene
glycol, a method of rejecting engine produced heat, and a means to transport cooling medium
between the engine and heat rejection system. The first determination is the type of cooling
system to use – radiator cooling or heat exchanger cooling.

Radiator Cooling

The first and simplest is the engine mounted radiator shown in Figure 2-8. The radiator, water
circulating pump, fan and fan drive are mounted to the generator set base rails by the factory.
This method of engine cooling is the most economical, but may require large ventilation vents
and ducts. An added advantage of this arrangement is that the cooling air removes radiated heat
from the engine, generator, and other equipment located in the emergency power system room.

The only remaining design work with the engine mounted radiator is arranging a method of
providing air to the room, and exhausting it from the radiator. See “Air Systems”.

Figure 2-8 Engine Mounted Radiator Cooled System With Wind/Noise Barrier

The radiator can be mounted remotely (not mounted directly at the engine). The remote/close
system uses the same radiator type except it is mounted in another room or outside the building,
but within close proximity to the genset. See Figure 2-9.

Figure 2-9 Remote Radiator Cooled System

General Information 2-11MN2408

The remote radiator may be mounted either vertically or horizontally. In general, the radiator will
have an electric fan to provide cooling air and may be able to utilize the engine mounted coolant
pump to provide coolant flow.

The piping system friction and head loss between engine and radiator must be calculated and
not exceed the capacity of the engine pump. If the maximum coolant friction head loss external to
the engine is exceeded, a hot well system must be used. Before designing the piping system
using an auxiliary pump and hot well, the consultant should look very closely at increasing the
system’s pipe size.

The electric fan and auxiliary pump, if used, must be connected to the emergency power system.
Radiator and cooling fan must be sized to provide the cooling capacity required at an acceptable
sound level.

Caution: In cold climates, the high volume of outside air drawn into the genset room can quickly

reduce temperatures in the room to freezing. Any water piping or other equipment susceptible

to freeze damage should be properly insulated or located elsewhere.

Heat Exchanger

In the heat exchanger system, engine coolant is circulated through the shell side of a heat
exchanger, while city water, well water, or some other cooling medium, is circulated through the
tube side. The primary consideration in this type cooling system is to remember that during
certain types of disasters, these cooling mediums may not be available, especially city water. The
system is relatively inexpensive to install and maintenance is low. See Figure 2-10.

Figure 2-10 Heat Exchanger Cooled System

The heat exchanger cooling system can be used with a cooling tower. These systems are
complex, and consists of circulating pumps, heat exchanger for engine coolant, and cooling
tower for heat rejection. The system design requires that several pieces of equipment be sized
and installed. Overall, this system is more expensive than other methods of engine cooling.

Cooling System Determination

After cooling system selection, gather the required basic information before proceeding through
this section. Information required includes engine heat rejection load, pumping capacity of the
engine mounted pump, engine coolant flow requirements and pressure drop through the engine,
and allowable operating temperature. This information is found on the engine data sheet.

Cooling System Design

Engine Mounted Radiator Cooling

If the engine mounted radiator is selected, the only remaining design work is arranging a method
of providing air to the room, and exhausting that air from the radiator. See “Air Systems”.

2-12 General Information MN2408

Remote Radiator Cooling

g

Remote Radiator Airflow generally assumed there will be no external restrictions to airflow. If this
is not true, restriction must be considered in sizing and selection of a cooling fan and drive motor.
Typical examples of restrictions include landscaping, nearby buildings, air turbulence created by
buildings or other structures, and sight or noise “screens”. See Figure 2-9.

Remote Radiator Fan Motor. Remote radiator cooling systems require the use of an electrically
driven fan. This fan must be connected to the emergency power source. Size of the motor is
determined by the fan size and fan speed.

1. To specify a radiator to cool the coolant you will need to determine the amount of heat
rejected to the coolant. This is listed on the Engine Data Sheet as Heat Rejected to
Coolant in BTU/min. for engines using dry or water cooled type exhaust manifolds, as
applicable.

2. Determine the minimum water flow required at the engine, and the maximum top tank
temperature. Using this information, determine the heat rejection capacity required of
the radiator. Radiator systems should be sized with approximately 15% greater
capacity than the engine’s maximum full load heat rejection to allow for overload and
cooling system deterioration. Whether water flow is produced by an engine mounted or
auxiliary pump, total piping system friction loss must be calculated. To do this, genset
location, remote radiator location and friction loss within the radiator, and piping system
must be estimated.

3. Pressure drop through the radiator must be obtained from radiator manufacturer.

4. If total piping system pressure exceeds the allowable Maximum Coolant Friction Head
External to the engine as listed on the Engine Data Sheet, the coolant piping size
should be increased and/or a radiator with less restriction must be used.

5. Pressure drop in pipelines may be determined by the use of information in Table 2-2
Figure 2-11, and friction of water tables which may be found in most mechanical
handbooks such as “Cameron Hydraulic Data” handbook.

Table 2-2

Fitting Size Flow Restriction of Fittings Expressed as Equivalent of Straight Pipe (in inches)

1.5 2 2.5 3 4 5 6 8 10 12 14 16

90 Elbow 4.4 5.5 6.5 8 11 14 16 21 26 32 37 42
45 Elbow 2.5 3 3.8 5 6.3 7.5 10 13 15 17 19
Long Sweep Elbow 2.8 3.5 4.2 5.2 7 9 11 14 17 20 24 27
Close Return Bend 13 15 18 24 31 37 51 61 74 85 100
Tee–Straight Run 3.5 4.2 5.2 7 9 11 14 17 20 24 27
Tee–Side Inlet or Outlet 9.3 12 14 17 22 27 33 43 53 68 78 88
Globe Valve Open 55 67 82 11 0 140
Angle Valve Open 27 33 41 53 70
Gate Valve Fully Open 1.2 1.4 1.7 2.3 2.9 3.5 4.5 5.8 6.8 8 9
Gate Valve Half Open 27 33 41 53 70 100 130 160 200 230 260
Check Valve 19 23 32 43 53

Hot Well Installations

One final consideration on the water side is the Maximum Static Head. This is the maximum
height allowable from the engine crank center line to the highest point in the coolant system. The
maximum static head is specified on generator specification sheets. If this number must be
exceeded, a hot well tank system must be used. A typical example is shown in Figure 2-12.

The design of hot well tanks and piping systems is somewhat complex. Your authorized Baldor
Distributor has experience in the design and installation of hot well systems. Consult your Baldor
Distributor if the static head of the coolant system in your genset application exceeds this criteria
and requires a hot well system.

General Information 2-13MN2408

Figure 2-11 Valves & Fittings and Fluid Flow in Pipe

Figure 2-12 Hot Well Installation

2-14 General Information MN2408

Other Considerations

General:

1. Deaeration of the coolant. This can be accomplished through the use of the system
deaerators in very large systems, or simply ensuring the radiator top tank or surge tank
is at the highest point in the piping system. Unvented piping systems can create air
pockets which reduce coolant flow and can lead to engine overheating. Baldor
furnished radiators are equipped with deaerating top tanks.

2. Flexible hoses must be installed at all engine connections and to the radiator to isolate
vibration and allow for thermal expansion.

3. Drain valves must be installed at the lowest point of the cooling system to facilitate
system cleaning and flushing.

4. Water treatment and antifreeze must be added to system coolant. Baldor recommends
50/50 ethylene glycol and coolant treatment for all engines.

5. Thermostatically controlled engine coolant heaters are required to be installed on all
standby gensets. These will increase starting reliability under cold conditions, and
improve the start–up load handling ability.

6. According the NFPA 110, priority level 1 equipment jacket water heaters shall maintain
coolant at a minimum of 90 "F (32 "C). In outdoor installations where temperatures will
be expected to drop below 32 "F (0 "C), a battery heater should be employed to keep
the batteries at a minimum of 50 "F (10 "C), and will shut off at 90 "F (32 "C).
All heaters will shut off when the engine is operating. Adequate antifreeze protection
will be provided and ether starting aids will not be permitted.

7. The consultant should also consider oil sump heaters if conditions warrant.

Heat Exchanger Cooling:

1. If the engine is to be heat exchanger cooled, the system will require a reliable raw
cooling water source and controls to regulate water flow during genset operation.

2. The system will also need a reliable method of starting and stopping water flow
automatically. The heat exchanger cooled system may be used with a cooling tower.

3. Baldor Gensets are available with heat exchangers sized and mounted on the engine
by the factory. If a heat exchanger cooled system is required, specify with order.

4. Shell and tube type heat exchangers are connected such that raw cooling water flows
through the tube side of the heat exchanger, and engine coolant through the shell side.
Tubes are more easily cleaned and the potential for fouling is much greater on the raw
water side.

5. For economic reasons, the raw water flow can be regulated by varying the flow of raw
cooling water through the heat exchanger. This control can be accomplished with a
temperature actuated control valve. The thermostatic bulb for this control must be in
the engine jacket water discharge line. The control valve should be a fully modulated
type with a minimum flow setting. NEVER attempt to regulate engine water flow.

6. Water flow regulators are used only if raw water is from a city or well water source. Do
not attempt to regulate flow if a cooling tower is used. Maintain at least 2 ft/second of
water flow through the tube side of the heat exchanger.

7. Heat exchanger cooled systems using city or well water, and cooling, tower heat
rejection, however, will not be protected on the tube side of the heat exchanger, nor
interconnecting piping and cooling tower as engine coolant is not circulated through
these components. These systems must be heat traced, and have sump heaters
installed to protect the various components when the genset is on standby.

It must also be noted that if an antifreeze solution is used in the shell side of the engine
cooling system heat exchanger, local codes may restrict the discharge of the tube side
cooling water after flowing through the heat exchanger.

General Information 2-15MN2408

Coolant Treatment: See Figure 2-13.

1. Engine coolant should be treated with a Diesel Coolant Additive (DCA) to minimize
corrosion of the engine and cooling system components. A 50/50 ethylene glycol
antifreeze solution is recommended for all genset engines. This will provide freeze
protection and increase the boiling point of the engine coolant. A solution can be
increased to 65%. Do not exceed 65% as freeze protection begins to diminish at 65%.

2. It is recommended that the consultant specify Baldor supplied DCA and water filters,
and Baldor antifreeze.

3. When the proper solution concentration of antifreeze is used with radiators (engine
mounted as well as remote mounted), and hot well systems, the system will be
adequately protected from freeze–up.

Figure 2-13 Coolant Mixture

2-16 General Information MN2408

Air System

Radiator Cooling

Air System Checklist

A. Air inlet faces the direction of prevailing winds.
B. Air outlet does not face noise sensitive areas without noise attenuating devices.
C. All heat loads have been taken into consideration in sizing air flow.
D. Gravity louvers face inward for air intake and outward for discharge.
E. Where electrically operated ventilation devices are used, power must be present under all
operating situations. Be certain these devices are on the emergency circuit.

The room in which the generator set is to be installed must have adequate air flow through it to
provide combustion air, and remove heat radiated from the engine, exhaust system and
generator. See Figure 2-14 for air flow calculations.

Figure 2-14 Air Flow Calculations

The engine mounted radiator shown in Figure 2-8. With an engine mounted radiator cooling
system, air movement is provided by the engine driven radiator fan. The consultant must design
the inlet and outlet duct work and louvers to accommodate the air flow required. The radiator fan
is limited in the amount of external static pressure it will tolerate. The maximum air restriction on
the discharge side of the radiator is shown under the heading of Cooling System on the Engine
Data Sheets. Cooling fan air flow is listed under Engine Data by dry type and water cooled
exhaust manifold for 100 "F and 125 "F cooling systems.

The ideal setup for cooling air would be to arrange the inlet or inlets such that relatively clean,
cool, dry air is drawn across the electrical switchgear, generator, and engine. The air is then
drawn into the radiator fan, and is blown through the radiator and exhausted by duct work outside
the building. Air inlets must be sized to minimize air restriction and provide the quantity of air
required by the radiator fan, engine combustion air, and any other air exhausts which might be
used in the room. On engine mounted radiator cooled systems, the engine mounted fan will
handle 0.25” of water column. This is combined intake and exhaust restriction.

The room air intakes must be located so as to minimize drawing exhaust fumes and other
outside contaminants into the room. Be very cautious about the location of the engine exhausts
in relation to room air intakes. Also, when locating the inlet and outlet, the consultant should
consider prevailing winds and noise. Motor operated louvers or properly designed and sized
gravity louvers should be used on the air intake and exhaust to minimize static pressure drop.

Electric motorized louvers used with engine mounted radiators should be connected to the
standby genset and controlled to open whenever the genset is running. Operable outlet louvers
should be temperature actuated on remote radiator or heat exchanger cooled units. Louvers
have resistance to air flow. Openings with louvers should be twice the area of an unobstructed
opening to provide proper air flow. At times duct work is necessary to provide cooling air for the
room, see Figure 2-15. Duct work must be sized and installed according to SMACNA Standards.

Wind Barrier

Wind blowing against air exhaust or intake openings of the genset room must be considered,
especially where the radiator and fan are located on the engine. Wind blowing against an
exhaust opening creates restriction to the fan. Wind blowing against intake openings can blow
open gravity louvers causing low temperature and moisture problems in bad weather.

General Information 2-17MN2408

Figure 2-15 Radiator Cooling with Ducted Air Handling

Other Engine Cooling Systems

Remote radiator and heat exchanger cooled engine cooling systems will not have an engine
driven fan. As a result, the consultant must provide a means of supplying air to the room, and
exhausting it. The air movement must be provided by an electrically driven fan. This fan may be
located in the air inlet or exhaust opening. If the fan is located on the exhaust side, care must be
taken to not create a high negative pressure in the room and starve the engine of combustion air.

If the fan is located in the air inlet, it must be noted that odors may be forced into other parts of
the building if the room is not properly sealed. This electrically driven fan must be connected so
as to run whenever the generator is operating. Any fans for the engine room should be on the
emergency circuit. An example may be seen in Figure 2-16.

Figure 2-16

Engine Crankcase Ventilation

For gensets operating more than 1000 hours per year, the engine crankcase breather should be
vented upward and outside of the engine room. This prevents the buildup of oil vapors inside the
building.

2-18 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 2-17.

Figure 2-17 Typical Emergency power System Installations

Multiple Gensets can be arranged either in parallel or separately connected to dedicated
emergency loads. Figure 2-17 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, contract 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 2-19MN2408

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 2-18. High starting circuit resistance substantially reduces starting cranking ability. The
genset data sheet lists the maximum allowable cranking system resistance. Mount batteries on a
level rack away from dirt and liquids. Allow space for servicing (checking water level and level of
charge). Baldor gensets can be ordered with battery racks already installed. Cold ambient
temperature at the battery location substantially reduces the battery output.

Figure 2-18 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 at various ambient temperatures. The recommended battery capacities are listed in the
Electric Systems section of the Engine Data Sheet, cold cranking amps (CCA) at 0 "F (–18 "C).

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. Baldor requires thermostatically controlled coolant heaters on all
after cooled standby gensets. After cooling is called out on the Engine Data Sheet under General
Engine Data section as “aspiration“.
Oil pan immersion heaters are recommended for standby gensets housed outside where ambient
temperatures may drop below 0 "F (–18 "C). Coolant heaters and oil pan immersion heaters are
available from Baldor as factory installed options.

2-20 General Information MN2408