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Baldor GLC10, Installation & Operating Manual

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Table of Contents

Table of Contents  i

MN2408

Section 1
Product Safety Information

1-1

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

Safety Notice

1-1

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Responsibility

1-1

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IMPORTANT SAFETY INSTRUCTIONS

1-2

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Caution Statements

1-6

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Section 2
General Information

2-1

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Limited Warranty

2-1

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Installation Guidelines

2-3

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Site Planning

2-3

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Room Size

2-3

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Room Location

2-4

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Foundation Design

2-5

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Exhaust System

2-9

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Level Of Attenuation

2-9

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System Placement

2-9

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Multi-Engine  Installations

2-9

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Exhaust Manifold

2-9

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Exhaust Gas Restriction

2-9

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Exhaust Piping

2-10

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Rain Protection

2-10

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Transfer Switch

2-1 1

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Battery Starting System

2-12

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Battery Location

2-12

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Battery Size

2-12

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

Battery Charger

2-13

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

Battery Cables

2-13

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

Section 3
Receiving & Installation

3-1

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Receiving & Inspection

3-1

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Lifting the Generator

3-1

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Physical Location

3-1

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Secure the Generator

3-3

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Engine Cooling

3-3

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

Hot Exhaust Gasses

3-4

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Installation

3-6

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Fuel Connections

3-6

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Electrical Connections

3-9

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Battery Connections

3-12

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Recommended Engine Oil and Battery Type

3-13

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Post  Installation Checks

3-13

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Summary of Contents for GLC10

Page 1: ...GLC Generator Gaseous Liquid Cooled GLC10 15 20 25 30 40 45 60 65 100 and 105 Installation Operating Manual 2 08 MN2408...

Page 2: ...ine 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 term...

Page 3: ...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 Batt...

Page 4: ...s 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 4 27 Voltage Calibration Procedure 4 27 Current Sensing Calib...

Page 5: ...ipment 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 att...

Page 6: ...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 WAR...

Page 7: ...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 batter...

Page 8: ...tart 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 Ba...

Page 9: ...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 1 Wear fu...

Page 10: ...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...

Page 11: ...stallation 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 Bald...

Page 12: ...2 2 General Information MN2408...

Page 13: ...tandby 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 Par...

Page 14: ...f 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...

Page 15: ...ct 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 ins...

Page 16: ...lators 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 direct...

Page 17: ...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 founda...

Page 18: ...he 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 horizon...

Page 19: ...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...

Page 20: ...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...

Page 21: ...g 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...

Page 22: ...rogen 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 batteri...

Page 23: ...the genset control using a conduit with a flexible section at the genset to avoid damage due to genset vibrations Battery Cables The wire size wire gauge of the cables connecting the starter to the ba...

Page 24: ...2 14 General Information MN2408...

Page 25: ...r 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 Lift Point Lift Point Height Width Length T...

Page 26: ...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 f...

Page 27: ...d 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 recom...

Page 28: ...gths 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 re...

Page 29: ...oned 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 d...

Page 30: ...5 618 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 General Considerations 1 A generator set needs the engine...

Page 31: ...1 1712 3559 9937 20298 240 183 289 596 933 1616 3357 9235 18990 270 171 274 558 875 1520 3127 8658 17903 300 164 260 524 827 1433 2886 8177 16998 Note Almost all operation problems are related to the...

Page 32: ...6 25004 75 49 98 218 345 709 1108 1899 3798 10957 22345 90 44 89 196 310 633 987 1709 3482 10001 20414 105 41 83 180 285 582 905 1551 3228 9254 18895 120 76 171 266 544 848 1456 3038 8659 17673 150 69...

Page 33: ...ious 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...

Page 34: ...fer System Utility Power Generator Power L1 L2 N Main Panel Fuses or Circuit Breakers Transfer Switch Mechanical Interlock L1 L2 N Fuses or Circuit Breakers Power To Load L1 L2 N Remote Start Contact...

Page 35: ...tor Factory Wired AC Power Connections Neutral Connections Ground Connections LOAD NEUTRAL GROUND Customer Connections Bond Jumper L1 L2 Note Remove the Bonding jumper to meet local codes if required...

Page 36: ...mount the battery charger where flammable liquids or vapors are present General Wiring Considerations 1 When routing the interface wiring do not route it up against anything that could cut or chafe t...

Page 37: ...the positive terminal of your battery Battery Hold Down Bar Install away from terminals 4 Connect the positive lead to the positive battery terminal 5 Connect the negative lead to the negative batter...

Page 38: ...proper clearance exists on all sides and top of enclosure 6 Verify that generator power is properly connected to the transfer switch 7 Verify that generator and transfer switch are properly grounded...

Page 39: ...voltage exists line to line and line to neutral at the generator and at the transfer switch e Minor adjustment of the output voltage is made using the Voltage Adjust potentiometer on the control panel...

Page 40: ...3 16 Receiving Installation MN2408...

Page 41: ...ut voltage to load Table 4 8 Alarm Warning Conditions Alarm Warning X X High Coolant temperature X X Low Oil pressure X X Low Fuel level X X Generator Under Over Voltage X X Generator Under Over Frequ...

Page 42: ...r keys to change and accept setpoint values or press the Page button to cancel changes Measurement Menu The measurement menu shown in Figure 4 9 displays the operating mode and operating parameters su...

Page 43: ...ime counter started Running Running Stop request READY TO LOAD off Cooling time timer started Cooling RPM 0 or any other shutdown condition READY TO LOAD off FUEL SOLENOID off Shutdown Loaded RPM 0 or...

Page 44: ...pens outputs GCB CLOSE OPEN FUEL SOLENOID STARTER and PRESTART to stop the engine immediately Alarm outputs and common shutdown output are closed Active or not reset protection disables start Table 4...

Page 45: ...engine run AUT mode only Table 4 12 Binary outputs Starter relay output The closed relay energizes the starter motor The relay opens if The firing speed is reached or Maximum time of cranking is excee...

Page 46: ...rator in three phases connection Step 1 kW Range 1 3000 kW Nomin power 1ph Nominal power of the generator in single phase connection Step 1 kW Range 1 3000 kW CT Ratio Gen set phases current transform...

Page 47: ...on the governor set the Idle time nevertheless to minimum 5s to avoid Underspeed possibly caused by instability of the engine short after start GCB CloseDelay GCB can be closed earliest GCB CloseDela...

Page 48: ...start of the gen set some engine protections have to be blocked e g Oil pressure The protections are unblocked after the Protection del time The time starts after reaching Start RPM Step 1s Range 0 30...

Page 49: ...overvoltage All three phases are checked Maximum out of three is used Step 1 of Nominal voltage Range Gen V Wrn 200 Gen V Wrn Warning level for generator overvoltage All three phases are checked Maxi...

Page 50: ...AnlInIOM2 lev2 The level for IOM ANALOG INPUT 2 alarm detection Step 1 Range 100 to 10000 AnlInIOM2 del Delay for IOM ANALOG INPUT 2 alarm Step 1 s Range 0 180 s AnlInIOM3 lev1 The level for IOM ANALO...

Page 51: ...E START ER BATTERY FUEL SOLENOID GENERATOR BINARY OUTPUTS STARTER L1 L2 L3 N PRESTART PE ALARM BINARY INP UTS RPM RPM IN COM BO3 BO4 BO5 BO6 BO1 START BO2 FUEL AI1 OIL AI2 TEMP RPM GND PO W ER 8 36VDC...

Page 52: ...GENERATOR G BINARY OUTPUTS STARTER L1 L2 L3 N PRESTART PE ALARM BINARY INP UTS RPM RPM IN COM BO3 BO4 BO5 BO6 BO1 START BO2 FUEL AI1 OIL AI2 TEMP RPM GND PO W ER 8 36VDC RS 232 GENER ATOR V O LTA G E...

Page 53: ...s are detected Speed Signal LED On when the engine speed signal is detected i e the engine is cranking Emergency Stop LED On when the Emergency Stop Switch is used to stop the engine Emergency Stop Sw...

Page 54: ...nnect speed is reached the crank signal is terminated While the engine accelerates to normal speed the controller continuously monitors the engines speed signal Should the engine speed exceed the maxi...

Page 55: ...shutdown fault can be programmed with a definite time transient delay period that must expire before the shutdown is activated The stop sequence will cause the controllers RUN output to be immediatel...

Page 56: ...Utility voltage sensor contact opens 2 After the Return Delay timer expires the Generator Ready to Load output de energizes and the Neutral Delay timer is initiated 3 After the Neutral Delay timer exp...

Page 57: ...ng prompts for overspeed are located in the main menu programming loop Loss of Speed Loss Of Speed is initiated when the engine s speed sensing circuit does not detect a speed signal for a period more...

Page 58: ...4 18 Operation MN2408 Figure 4 15 Engine Controller Inputs Outputs...

Page 59: ...other functions Low Oil Pressure 2 An analog DC signal is provided from an engine mounted sender The low oil pressure shutdown fault is activated when the oil pressure is below a pre determined setpo...

Page 60: ...xpires After the output has energized it will remain on regardless of voltage frequency levels until the controller either has a stop shutdown signal or the engine s speed drops below crank disconnect...

Page 61: ...the remote start contact is open The Main LCD Display will be shown Action Description Display Comments Apply Power and Reset faults Main LCD Display Vavg 000 Aavg 000 Freq 000 Press Enter key Show O...

Page 62: ...g sequence countdown display or return to the original system status menu Action Description Display Comments Apply Power and Reset faults Main LCD Display Vavg 000 Aavg 000 Freq 000 Show Operating St...

Page 63: ...es A to B 1 phase system LINE TO LINE VOLTAGE Phases A to B Vbc Displays the generator s output voltage 3 phase system LINE TO LINE VOLTAGE Phases B to C 1 phase system LINE TO NEUTRAL VOLTAGE Phases...

Page 64: ...led between YES and NO by pressing the INCREMENT push button NO Programming sub menus are disabled when NO is displayed YES Programming sub menus are enabled when YES is displayed and a valid password...

Page 65: ...f multiple crank attempts are selected Note This value will be ignored if only one attempt has been programmed Starter Re Engage Duration This feature checks for a speed signal during cranking If no s...

Page 66: ...e start signal is removed signaling utility power is available After the Return Delay timer expires the Generator Ready To Load output is removed and the Utility Ready To Load output energizes to sign...

Page 67: ...re it is required to do an automatic timed No Load Test of the engine generator set A contact from an external exercise clock timer is required to be connected to the digital input circuit which is pr...

Page 68: ...on factor until 0 amps is displayed With the correct current displayed press the ENTER push button to accept the correction factor number Record the correction factor number on the programming sheet f...

Page 69: ...eading as measured with the external temperature gauge With the correct temperature displayed press the Enter push button to accept the correction factor number Record the correction factor on the pro...

Page 70: ...4 30 Operation MN2408 Figure 4 16 Configuration Data Sheet j j j j j j j j j...

Page 71: ...99 Times 0 Continuous Bypass Delay XX Seconds 0 99 Seconds Cool down Delay XX Seconds 0 9999 Seconds Nominal RPM XXXX RPM 0 4000RPM Flywheel Teeth Engine Speed Sensing Magnetic Pick Up XXX Teeth 0 99...

Page 72: ...2 0 Indicates parameter is non programmable Figure 4 19 Digital Fault Menu Loop Parameters Fault Name Input Action S Shutdown A Alarm Alarm Latch Y Yes N No Polarity O Open C Close Bypass On Start Y Y...

Page 73: ...VC VB VA VC VB VA 1A 1A 1A N GRD GENERATOR OUTPUT CURRENT SENSING TRANSFORMERS 5 Aac SECONDARY DELETE PHASE C FOR SINGLE PHASE SYSTEMS 10A GENERATOR OUTPUT VOLTAGE DELETE PHASE VC FOR SINGLE PHASE SYS...

Page 74: ...4 34 Operation MN2408...

Page 75: ...maximum 6 Inspect and clean all governor and carburetor linkages so they operate properly 7 Inspect the recoil starting rope for any damage and replace it if necessary if applicable 8 Clean the trash...

Page 76: ...es to allow cooling No output voltage Ciruit Breaker tripped or failed Internal failure of Alternator Reset circuit breaker or replace if required Return to factory for repair Output voltage varies Ir...

Page 77: ...y the controller programmed values are correct for the number of flywheel teeth nominal RPM and overspeed setpoint percentage Replace controller if failed Voltage or current metering is incorrect Cont...

Page 78: ...values for corresponding input temperature or pressure Overspeed shutdown occurs at normal speed Controller has failed or input from Magnetic pickup is incorrect Verify the adjustments Replace contro...

Page 79: ...available 120VAC or 240VAC to power the battery charger and other components that may be installed Shore power outlets or wiring must be located close to Battery Charger BTCGR6 Charger refer to charge...

Page 80: ...81 Heater 1 Carefully disconnect the Negative battery terminal from the battery 2 Carefully disconnect the Positive battery terminal from the battery 3 Remove battery hold down bracket 4 Remove batter...

Page 81: ...outlets or wiring must be located close to block heater Figure A 3 Catalog G10A Block Heater refer to block heater manual for specific details 1 Mount the block heater refer to Figure A 3 to determin...

Page 82: ...enuation Kit includes engine adapters flex pipe clamps silencer and rain cap Figure A 4 Industrial Silencer GLCIS 3SU GLC10 25 GLCIS 4SU GLC30 45 GLCIS 6SU GLC60 90 GLCIS 7SU GLC100 105 Critical Silen...

Page 83: ...4 NPT Female fittings 12 long GLCFFL2 1 1 4 NPT Female fittings 18 long GLCFFL3 2 NPT Female fittings 12 long GLCFFS1 3 4 NPT Fuel Strainer female Inlet male outlet GLCFFLS3 2 NPT Fuel Strainer female...

Page 84: ...to Remote Run Terminals on genset Must be adapted for remote mounting when used with open skid mount units Figure A 6 1 3 Installation 1 Locate and drill 4 holes shown in Figure A 6 2 Mount the E Stop...

Page 85: ...t and alarm horn silence pushbuttons are provided Each fault is individually programmable for audible horn operation and alarm labels are field configurable Requires 12VDC 100mA power supply to operat...

Page 86: ...Provides easy connection to air ducting to carry away hot air from engine radiator Duct flange mounts to front of engine radiator Add 3 to length Figure A 9 Table A 1 Mounting Dimensions Generator A...

Page 87: ...uty 12 gauge hot rolled steel with welded corners and baked powder coat finish includes sound deadening insulation for 15 dB of attenuation Fasteners are zinc chromate plated and the locking latches a...

Page 88: ...A 10 Series GLC MN2408...

Page 89: ...1 1 1 EPDM PER PHASE 265 225 1 1 0 1 1 EPDM PER PHASE 265 250 1 2 0 1 1 0 EPDM PER PHASE 305 300 1 4 0 1 2 0 EPDM PER PHASE 355 350 1 4 0 1 3 0 EPDM PER PHASE 410 400 2 1 1 4 0 EPDM PER PHASE 475 450...

Page 90: ...B 2 Series GLC MN2408 Figure B 11 Customer Interface Connection Diagram MEC20 MEC2...

Page 91: ...Series GLC B 3 MN2408 Figure B 12 Customer Interface w o Breaker Power Connection Diagram...

Page 92: ...B 4 Series GLC MN2408 Figure B 13 Single Phase w o Breaker Connection Diagram...

Page 93: ...Series GLC B 5 MN2408 Figure B 14 Single Phase One Breaker Connection Diagram...

Page 94: ...B 6 Series GLC MN2408 Figure B 15 Single Phase Two Breaker Connection Diagram...

Page 95: ...Series GLC B 7 MN2408 Figure B 16 Single Phase Connection Diagram Wire 1 0 and Larger w Breaker...

Page 96: ...B 8 Series GLC MN2408 Figure B 17 Single Phase Connection Diagram Wire 1 0 and Smaller w Breaker...

Page 97: ...Series GLC B 9 MN2408 Figure B 18 Single Phase Connection Diagram Wire 1 0 and Smaller w o Breaker...

Page 98: ...B 10 Series GLC MN2408 Figure B 19 Single Phase Connection Diagram Wire Larger than 1 0 w o Breaker...

Page 99: ...Series GLC B 11 MN2408 Figure B 20 Three Phase Connection Diagram...

Page 100: ...B 12 Series GLC MN2408 Figure B 21 Three Phase Connection Diagram with PMG...

Page 101: ...Series GLC B 13 MN2408 Figure B 22 Three Phase Connection Diagram Wire 1 0 and larger...

Page 102: ...B 14 Series GLC MN2408 Figure B 23 Three Phase Connection Diagram Wire Larger than 1 0 w Breaker...

Page 103: ...Series GLC B 15 MN2408 Figure B 24 Three Phase Connection Diagram Wire 1 0 and Smaller w Breaker...

Page 104: ...B 16 Series GLC MN2408 Figure B 25 Three Phase Connection Diagram Wire Larger than 1 0 w o Breaker...

Page 105: ...Series GLC B 17 MN2408 Figure B 26 Three Phase Connection Diagram Wire 1 0 and Smaller w o Breaker...

Page 106: ...B 18 Series GLC MN2408 Figure B 27 Control Box Connections with MEC20 Controller...

Page 107: ...Series GLC B 19 MN2408 Figure B 28 Control Box Connections with MEC20 Controller Governor...

Page 108: ...B 20 Series GLC MN2408 Figure B 29 Control Box Connections with MEC2 Controller...

Page 109: ...Series GLC B 21 MN2408 Figure B 30 Engine Wiring Woodward 4 3L GM...

Page 110: ...B 22 Series GLC MN2408 Figure B 31 Engine Wiring Woodward 5 7L GM...

Page 111: ...Series GLC B 23 MN2408 Figure B 32 Engine Wiring Woodward 8 1L GM...

Page 112: ...B 24 Series GLC MN2408...

Page 113: ...Baldor District Offices...

Page 114: ...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...

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