Baldor GLC100 Installation & Operating Manual Download

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GLC Generator

(Gaseous Liquid Cooled)

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

Installation & Operating Manual

5/04

MN2408

Summary of Contents for GLC100

Page 1: ...GLC Generator Gaseous Liquid Cooled GLC30 35 45 50 60 80 100 and 125 Installation Operating Manual 5 04 MN2408...

Page 2: ...hemicals 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...

Page 3: ...tion 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 Bat...

Page 4: ...u 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 Pres...

Page 5: ...afe 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 engin...

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: ...cally 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 th...

Page 10: ...n 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...

Page 11: ...ldor 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...

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: ...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 ho...

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: ...e 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...

Page 22: ...f 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...

Page 23: ...iping 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 l...

Page 24: ...2 14 General Information MN2408 Figure 2 11 Valves Fittings and Fluid Flow in Pipe Figure 2 12 Hot Well Installation...

Page 25: ...ce 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 u...

Page 26: ...e 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 c...

Page 27: ...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 radi...

Page 28: ...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 o...

Page 29: ...ng 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 Locatio...

Page 30: ...ity 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...

Page 31: ...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 b...

Page 32: ...2 22 General Information MN2408...

Page 33: ...g 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 To lift the gener...

Page 34: ...er break to protect the unit from accumulation of debris 4 Installation should place the generator as close as possible to the fuel supply and transfer switch 5 At least forty eight 48 inches clearanc...

Page 35: ...t is also recommended that the cool air intake be located as close as possible to the top of the generator set The exhaust fan must be connected to the AC power terminals of the generator set so that...

Page 36: ...ows tend to resist the flow of gases and accumulate carbon deposits Each pipe fitting and elbow will further restrict the exhaust flow Guidelines for Exhaust System 1 If you are using a remote muffler...

Page 37: ...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 38: ...8 GLC125 46 8 16 5 General Considerations 1 A generator set needs the engine to deliver 2 hp of energy to the alternator for every 1000 watts of electric output power example an 8000 watt generator n...

Page 39: ...5 991 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...

Page 40: ...236 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...

Page 41: ...nerator set is to provide emergency power when the main utility power supply is interrupted Therefore it is important that all the wiring that connects the generator set with your house transfer switc...

Page 42: ...3 10 Receiving Installation MN2408 Figure 3 4 Three Phase WYE and DELTA Connections...

Page 43: ...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 L...

Page 44: ...lled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of one pound 500 grams bicarbonate of soda to one gallon four liters of water The bicarbona...

Page 45: ...LC35 SAE 30 5W 30 6 0 QTS BCI Group 31 925 GLC45 SAE 30 5W 30 6 0 QTS BCI Group 31 925 GLC50 SAE 30 5W 30 6 2 QTS BCI Group 31 925 GLC60 SAE 30 5W 30 6 2 QTS BCI Group 31 925 GLC80 SAE 30 5W 30 6 5 QT...

Page 46: ...ands are inside the generator enclosure when it starts Post Installation Checks Continued 19 Verify all loads are disconnected 20 Start the generator Refer to Section 4 Operation for details 21 The en...

Page 47: ...faults 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 St...

Page 48: ...nect 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 maxim...

Page 49: ...specific 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 im...

Page 50: ...tility 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 expi...

Page 51: ...g 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 52: ...4 6 Operation MN2408 Figure 4 3 Engine Controller Inputs Outputs...

Page 53: ...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 setpoi...

Page 54: ...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 55: ...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 Op...

Page 56: ...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 57: ...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 58: ...gled 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 passwor...

Page 59: ...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 sp...

Page 60: ...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 61: ...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 62: ...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 63: ...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 64: ...4 18 Operation MN2408 Figure 4 4 Configuration Data Sheet j j j j j j j j j...

Page 65: ...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 66: ...A S Y Y 2 0 Indicates parameter is non programmable Figure 4 7 Digital Fault Menu Loop Parameters Fault Name Input Action S Shutdown Alarm Latch Y Yes Polarity O Open Bypass On Start Transient Delay...

Page 67: ...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 68: ...of the engine starting battery Engine Temperature meter Displays the temperature of the engine coolant Oil Pressure meter Displays engine oil pressure Run Time Hours meter Total elapsed time indicato...

Page 69: ...tart signal is activated the engine will start as per the sequence of operation described for the manual start sequence 3 The automatic stop sequence will be initiated by removal of the remote start s...

Page 70: ...SM160 Analog Engine Controller Connections 15 14 16 12 13 8 7 6 5 4 3 1 10 11 9 Fuel Relay Remote Start Contact 15A Start Relay Display LED s Low Oil Pressure High Water Temperature Overcrank Overspee...

Page 71: ...the KN when the engine is not running A properly adjusted KN requires a vacuum of only 0 25 to 0 35 of water column to start the opening sequence Due to this sensitivity most installations do not need...

Page 72: ...ce at least as big as the orifice in the KN Flexible piping to the inlet should be used to prevent cracking from vibration if the KN is mounted on the engine or other vibrating surface Note Thread sea...

Page 73: ...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 74: ...engine surfaces 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 vol...

Page 75: ...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 76: ...ssure Overspeed shutdown occurs at normal speed Controller has failed or input from Magnetic pickup is incorrect Verify the adjustments Replace controller if failed Service Service for your generator...

Page 77: ...071A00 FU0071A00 FU0071A00 FU0071A00 FUSE 10A FU0070A00 FU0070A00 FU0070A00 FU0070A00 FU0070A00 FUSE BUSS AGC 15 FU0066A07 FU0066A07 FU0066A07 FU0066A07 FU0066A07 RHEOSTAT 1K 2W ENCLOSED SP9134 SP9134...

Page 78: ...1A FU0071A00 FUSE 10A FU0070A00 FUSE AGC 2 FU0066A03 FU0066A03 FUSE AGC 15 FU0066A07 FU0066A07 FU0066A07 SWITCH TOGGLE SP9079 SWITCH DPDT SP9094 SWITCH E 3PH SP9095 RELAY RE5031A01 RE5031A01 RE5031A0...

Page 79: ...the old Magnetic Pickup sensor 2 Ensure that a tooth on the flywheel gear ring is centered directly in the hole for the Magnetic Pickup If not rotate the engine generator to center a tooth by placing...

Page 80: ...30 3 WYE 240 139 391 450 450 500 5 2 1 0 GLC125 UCI274F 12 311 Nat Gas GM 8 1L 125 3 Series WYE 380 220 237 273 300 300 5 1 2 0 GLC125 UCI274F 12 311 Nat Gas 3 416 GLC125 UCI274F 12 311 Nat Gas GM 8 1...

Page 81: ...9 301 346 350 400 5 1 3 0 GLC100 UCI274E 12 311 LPG GM 8 1L 98 3 Series Wye 380 220 186 214 225 250 5 1 1 GLC100 UCI274E 12 311 LPG 3 416 GLC100 UCI274E 12 311 LPG GM 8 1L 100 3 Series Wye 480 277 150...

Page 82: ...9 180 207 225 200 5 1 1 GLC60 UCI224E 12 311 LPG GM 5 7L 49 3 Series Wye 380 220 93 107 110 125 5 1 6 GLC60 UCI224E 12 311 LPG 3 416 0 GLC60 UCI224E 12 311 LPG GM 5 7L 60 3 Series Wye 480 277 90 104 1...

Page 83: ...39 135 156 175 150 5 1 1 GLC45 UCI224D 12 311 LPG GM 4 3L 45 3 Series Wye 380 220 85 98 100 100 5 1 6 GLC45 UCI224D 12 311 LPG 3 416 0 GLC45 UCI224D 12 311 LPG GM 4 3L 45 3 Series Wye 480 277 68 78 80...

Page 84: ...240 139 90 104 110 125 5 1 6 GLC30 UCI224C 12 311 Nat Gas GM 4 3L 30 3 Series Wye 380 220 57 66 70 75 5 1 8 GLC30 UCI224C 12 311 Nat Gas 3 416 0 GLC30 UCI224C 12 311 Nat Gas GM 4 3L 30 3 Series Wye 4...

Page 85: ...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 2 1 0 2 1 0 EPDM PER...

Page 86: ...A 10 Series GLC MN2408 Figure A 2 Customer Interface Connection Diagram MEC20 MEC2...

Page 87: ...Series GLC A 11 MN2408 Figure A 3 Customer Interface w o Breaker Power Connection Diagram...

Page 88: ...A 12 Series GLC MN2408 Figure A 4 Single Phase w o Breaker Connection Diagram...

Page 89: ...Series GLC A 13 MN2408 Figure A 5 Single Phase One Breaker Connection Diagram...

Page 90: ...A 14 Series GLC MN2408 Figure A 6 Single Phase Two Breaker Connection Diagram...

Page 91: ...Series GLC A 15 MN2408 Figure A 7 Single Phase Connection Diagram Wire 1 0 and Larger w Breaker...

Page 92: ...A 16 Series GLC MN2408 Figure A 8 Single Phase Connection Diagram Wire 1 0 and Smaller w Breaker...

Page 93: ...Series GLC A 17 MN2408 Figure A 9 Single Phase Connection Diagram Wire 1 0 and Smaller w o Breaker...

Page 94: ...A 18 Series GLC MN2408 Figure A 10 Single Phase Connection Diagram Wire Larger than 1 0 w o Breaker...

Page 95: ...Series GLC A 19 MN2408 Figure A 11 Three Phase Connection Diagram...

Page 96: ...A 20 Series GLC MN2408 Figure A 12 Three Phase Connection Diagram with PMG...

Page 97: ...Series GLC A 21 MN2408 Figure A 13 Three Phase Connection Diagram Wire 1 0 and larger...

Page 98: ...A 22 Series GLC MN2408 Figure A 14 Three Phase Connection Diagram Wire Larger than 1 0 w Breaker...

Page 99: ...Series GLC A 23 MN2408 Figure A 15 Three Phase Connection Diagram Wire 1 0 and Smaller w Breaker...

Page 100: ...A 24 Series GLC MN2408 Figure A 16 Three Phase Connection Diagram Wire Larger than 1 0 w o Breaker...

Page 101: ...Series GLC A 25 MN2408 Figure A 17 Three Phase Connection Diagram Wire 1 0 and Smaller w o Breaker...

Page 102: ...A 26 Series GLC MN2408 Figure A 18 Control Box Connections with MEC20 Controller Without Governor...

Page 103: ...Series GLC A 27 MN2408 Figure A 19 Control Box Connections with MEC20 Controller Governor With Governor...

Page 104: ...A 28 Series GLC MN2408 Figure A 20 Control Box Connections with MEC2 Controller...

Page 105: ...Series GLC A 29 MN2408 Figure A 21 Engine Wiring Woodward 4 3L GM...

Page 106: ...A 30 Series GLC MN2408 Figure A 22 Engine Wiring Woodward 5 7L GM...

Page 107: ...Series GLC A 31 MN2408 Figure A 23 Engine Wiring Woodward 8 1L GM...

Page 108: ...A 32 Series GLC MN2408...

Page 109: ...or Information End User Owner Information Name Name Address Address Phone Phone Model Number Job Number _______ RPM _______ Hz _______ P F Standby Continuous _______ kW _______ Volts _______ KVA _____...

Page 110: ...e speed to 60 50Hz if equipped with electronic governor or 63 53 Hz with mechanical governor Gas solenoid valve is properly functioning If speed is unstable adjust per engine or governor manual Exhaus...

Page 111: ...STER ROAD MEMPHIS TN 38118 PHONE 901 365 2020 FAX 901 365 3914 TEXAS HOUSTON 4647 PINE TIMBERS SUITE 135 HOUSTON TX 77041 PHONE 713 895 7062 FAX 713 690 4540 DALLAS 3040 QUEBEC DALLAS TX 75247 PHONE 2...

Page 112: ...0 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 CALIF...

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