Baldor TS25 Installation & Operating Manual Download

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Tier 2/3 Towable Generators

(Trailer and Skid Mounted)

(Diesel Liquid Cooled)

TS25, 35, 45, 60, 80, 130, 175, 250 and 400

Installation & Operating Manual

8/06

MN2417

Summary of Contents for TS25

Page 1: ...Tier 2 3 Towable Generators Trailer and Skid Mounted Diesel Liquid Cooled TS25 35 45 60 80 130 175 250 and 400 Installation Operating Manual 8 06 MN2417...

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: ...ctions 3 4 Battery Connections 3 7 Recommended Engine Oil and Battery Type 3 9 Post Installation Checks 3 9 Section 4 Operation 4 1 Towing the Generator 4 1 Selecting the Proper Towing Equipment 4 1 S...

Page 4: ...ii Table of Contents MN2417...

Page 5: ...e 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 o...

Page 6: ...efore use after 25 miles of operation and every 100 miles of operation thereafter Failure to check the lug nuts for proper tightness can result in an accident due to a wheel falling from the trailer W...

Page 7: ...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...

Page 8: ...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...

Page 9: ...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...

Page 10: ...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 pres...

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 MN2417...

Page 13: ...pacity and tires for the terrain to avoid becoming stuck or tipping over If the shipping pallet is intact use a fork lift to move the generator If the shipping pallet has been removed use the Lift Poi...

Page 14: ...to be opened or removed for service and maintenance 7 Maximum Ambient temperature is 122 F 50 C Figure 3 2 Generator Mounting Skid B1 B A A2 A1 TS130 175 only 4 Holes A2 A1 TS25 45 80 only 3 Holes A1...

Page 15: ...hat an exhaust rain cap be used whenever it is possible that rain could get into the system This will help to prevent corrosion and damage to the exhaust system and engine Installation The generator i...

Page 16: ...erator The power output connections are rated and sized according to the KW of the generator Proper lead wire from these points to the automatic transfer switch or load switching device is mandatory S...

Page 17: ...connections are weather tight Figure 3 3 Receptacle Panel Single Phase Single phase power is always available GOLD X GOLD Y G SILVER W CS6369 125 250V 50A X Y W Test Reset CS6365N GFI Outlet 120V 20A...

Page 18: ...h may also be used to start the generator Shore Power Use extension cord with appropriately sized conductors to connect the optional Shore Power receptacle to 120VAC 240VAC for TS400 single phase util...

Page 19: ...nel away from batteries WARNING Do not dispose of battery or batteries in a fire The battery is capable of exploding If the battery explodes electrolyte solution will be released in all directions Bat...

Page 20: ...battery cables from the battery the negative first then the positive 3 Remove the Battery Hold Down Bar and Rods 4 Remove the old battery and place the correct new battery see Table 3 5 on the tray 5...

Page 21: ...e generator to the factory for repair and consequent expense and loss of time Note These precautions are especially necessary in locations such as seaboard installations and other high humidity areas...

Page 22: ...iately and repair the leak before proceeding b Verify there are no coolant or oil leaks If a leak is detected stop the engine set the Master Control in the Stop position immediately and repair the lea...

Page 23: ...ransport passengers in any trailer S Reduce weight in car trunk and rear seat areas by the amount of tongue weight of your trailer S Any alterations or changes made to the trailer void any express or...

Page 24: ...nd weather conditions Avoid sudden stops if possible 3 Passing Accelerating and passing should be done slowly to allow extra distance for passing Signal well in advance when passing and returning to t...

Page 25: ...to drag on ground or roadway 8 Test breakaway system Hydraulic surge brake system normally have a cable or chain connected to the tow vehicle In a break away condition this cable or chain activates t...

Page 26: ...inflation 13 Check wheel lug nuts for correct tightness see Lug Nut Tightness Wheel nuts bolts should be torqued before the first road use and after each wheel removal Check and re torque after the f...

Page 27: ...cords or external devices 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 w...

Page 28: ...ctions see Figure 4 4 1 240 120VAC voltage is present at the receptacle panel at all times when generator is running 2 Carefully inspect all Individual load cables for broken insulation or other signs...

Page 29: ...zer sounds an alarm when operator attention is needed Voltage Select Switch switch Selects 208 120 240 120 or 480 277VAC OFF 1 2 Auto Start Connection for external two wire starting from transfer swit...

Page 30: ...connected and connections are secure 9 Ensure that an external ground connection is made when required for safety 10 Ensure that the Remote Start wires are properly connected if used 11 Use disconnect...

Page 31: ...Warning X High Coolant temperature X Low Oil pressure X Low Fuel level X Generator Over Voltage X Generator Over Frequency X Generator Over Current X Generator Overspeed X Coolant temperature High Lo...

Page 32: ...in Figure 4 7 displays the operating mode and operating parameters such as kW engine RPM etc Figure 4 7 Measurement Menu OFF MAN AUT Ready PF RPM Timer 0 00 0 0 0 kW Control Mode Operating Modes and H...

Page 33: ...ng RPM 0 or any other shutdown condition READY TO LOAD off FUEL SOLENOID off Shutdown Generator CB Closed Loaded Generator CB Opened Running Loaded RPM 0 or any other shutdown condition FUEL SOLENOID...

Page 34: ...ut are closed Active or not reset protection disables start Table 4 5 Possible Warnings Events specification Protection type Binary output available Table 4 7 Wrn Oil press WRN YES Sd Oil press SD YES...

Page 35: ...y energizes the starter motor The relay opens if The firing speed is reached or Maximum time of cranking is exceeded or Request to stop occurs Fuel solenoid relay output Closed output opens the fuel s...

Page 36: ...is not active and FAULT RESET is pressed Note Treshhold level for D input is 80 supply voltage Vgen failed Output is closed if the generator over under voltage shutdown alarm or voltage asymmetry shu...

Page 37: ...loses if the generator over under voltage warning alarm activates fgen warning Output closes if the generator over under frequency warning alarm activates Overload wrn Output closes if the generator o...

Page 38: ...te identification at remote phone or mobile connection Gen set name is max 14 characters long and have to be entered using LiteEdit software Nomin power 3ph Nominal power of the generator in three pha...

Page 39: ...Step 1s Range 1 60 s CrnkFail pause Pause between crank attempts Step 1s Range 5 60 s Crank attemps Max number of crank attempts Step 1 Range 1 10 Idle time Idle time delay starts when RPM exceeds Sta...

Page 40: ...etpoint value Eng prot del During the 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...

Page 41: ...overvoltage All three phases are checked Maximum out of three is used Step 1 of Nominal voltage Range Gen V Wrn Gen V Gen V Wrn Warning level for generator under voltage All three phases are checked M...

Page 42: ...3 lev1 The level for IOM ANALOG INPUT 3 alarm detection Step 1 Range 100 to 10000 AnlInIOM3 lev2 The level for IOM ANALOG INPUT 3 alarm detection Step 1 Range 100 to 10000 AnlInIOM3 del Delay for IOM...

Page 43: ...NOID L1 L2 L3 N Generator C B ANALOG INPUTS BINARY OUTPUTS RPM RPM IN COM BO6 BO3 BO4 BO5 BO1 START BO2 FUEL AI1 OIL AI2 TEMP AI3 FUEL RPM GND POWER 8 36 V DC EXTENSION MODULES GENERATOR CURRENT GENER...

Page 44: ...er at o r C B PRESTART PE RS 232C Int erface Modem or PC C O NT RO L SI GNALS ALARM RE ADY TO L OA D D CHRG ALT ER NATOR BINARY INP UTS RPM RPM IN COM BO3 BO4 BO5 BO6 BO1 START BO2 FUEL AI1 OIL AI2 T...

Page 45: ...air filters per the engine manufacturers guidelines 2 Check oil level regularly at least every 5 to 8 operating hours Maintain the proper oil level 3 Change the oil as is recommended in the engine ma...

Page 46: ...e voltage meter with an accurate voltmeter to verify Check continuity across Breaker Fuse Replace if defective Check wiring including grounds crimps and connection points Repair defects The generator...

Page 47: ...gher than rear of tow vehicle when additional supports have been removed View and make adjustments while vehicle and trailer are on level surface Seek expert advise Reduce tow vehicle speed and use ca...

Page 48: ...5 4 Troubleshooting and Maintenance MN2417...

Page 49: ...tified in the engine manual that was provided with your generator set IMPORTANT Fuses are installed in the control box to protect the engine controller and associated control circuits When replacing f...

Page 50: ...A 2 Wiring Diagrams MN2417 Figure A 1 TS25 Connection Diagram...

Page 51: ...Wiring Diagrams A 3 MN2417 Figure A 2 TS25 Connection Diagram...

Page 52: ...A 4 Wiring Diagrams MN2417 Figure A 3 TS25 Connection Diagram...

Page 53: ...Wiring Diagrams A 5 MN2417 Figure A 4 TS25 Connection Diagram...

Page 54: ...A 6 Wiring Diagrams MN2417 Figure A 5 TS25 Connection Diagram...

Page 55: ...Wiring Diagrams A 7 MN2417 Figure A 6 TS25 Connection Diagram...

Page 56: ...A 8 Wiring Diagrams MN2417 Figure A 7 TS35 Connection Diagram...

Page 57: ...Wiring Diagrams A 9 MN2417 Figure A 8 TS35 Connection Diagram...

Page 58: ...A 10 Wiring Diagrams MN2417 Figure A 9 TS35 Connection Diagram...

Page 59: ...Wiring Diagrams A 11 MN2417 Figure A 10 TS35 Connection Diagram...

Page 60: ...A 12 Wiring Diagrams MN2417 Figure A 11 TS35 Connection Diagram...

Page 61: ...Wiring Diagrams A 13 MN2417 Figure A 12 TS35 Connection Diagram...

Page 62: ...A 14 Wiring Diagrams MN2417 Figure A 13 TS35 Power Connection Diagram...

Page 63: ...Wiring Diagrams A 15 MN2417 Figure A 14 TS60 Connection Diagram...

Page 64: ...A 16 Wiring Diagrams MN2417 Figure A 15 TS60 Connection Diagram...

Page 65: ...Wiring Diagrams A 17 MN2417 Figure A 16 TS60 Connection Diagram...

Page 66: ...A 18 Wiring Diagrams MN2417 Figure A 17 TS60 Connection Diagram...

Page 67: ...Wiring Diagrams A 19 MN2417 Figure A 18 TS60 Connection Diagram...

Page 68: ...A 20 Wiring Diagrams MN2417 Figure A 19 TS60 Connection Diagram...

Page 69: ...Wiring Diagrams A 21 MN2417 Figure A 20 TS60 Connection Diagram...

Page 70: ...A 22 Wiring Diagrams MN2417 Figure A 21 TS80 Connection Diagram...

Page 71: ...Wiring Diagrams A 23 MN2417 Figure A 22 TS80 Connection Diagram...

Page 72: ...A 24 Wiring Diagrams MN2417 Figure A 23 TS80 Connection Diagram...

Page 73: ...Wiring Diagrams A 25 MN2417 Figure A 24 TS80 Connection Diagram...

Page 74: ...A 26 Wiring Diagrams MN2417 Figure A 25 TS80 Connection Diagram...

Page 75: ...Wiring Diagrams A 27 MN2417 Figure A 26 TS80 Connection Diagram...

Page 76: ...A 28 Wiring Diagrams MN2417 Figure A 27 TS80 Connection Diagram...

Page 77: ...Wiring Diagrams A 29 MN2417 Figure A 28 TS80 Connection Diagram...

Page 78: ...A 30 Wiring Diagrams MN2417 Figure A 29 TS80 Connection Diagram...

Page 79: ...Wiring Diagrams A 31 MN2417 Figure A 30 TS80 Connection Diagram...

Page 80: ...A 32 Wiring Diagrams MN2417 Figure A 31 TS400 Connection Diagram...

Page 81: ...Wiring Diagrams A 33 MN2417 Figure A 32 TS400 Connection Diagram...

Page 82: ...A 34 Wiring Diagrams MN2417 Figure A 33 TS400 Connection Diagram...

Page 83: ...Wiring Diagrams A 35 MN2417 Figure A 34 TS400 Connection Diagram...

Page 84: ...A 36 Wiring Diagrams MN2417 Figure A 35 TS400 Connection Diagram...

Page 85: ...Wiring Diagrams A 37 MN2417 Figure A 36 TS400 Connection Diagram...

Page 86: ...A 38 Wiring Diagrams MN2417 Figure A 37 TS400 Connection Diagram...

Page 87: ...Wiring Diagrams A 39 MN2417 Figure A 38 TS400 Connection Diagram...

Page 88: ...A 40 Wiring Diagrams MN2417 Figure A 39 TS400 Connection Diagram...

Page 89: ...Baldor District Offices...

Page 90: ...e 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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