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Baldor Electric Company

MN2417

Printed in USA

8/06

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.

BALDOR ELECTRIC COMPANY

P.O. Box 2400

Ft. Smith, AR 72902

−

2400

(479) 646

−

4711

Fax (479) 648

−

5792

www.baldor.com

Содержание TS130

Страница 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 ...

Страница 2: ...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 ...

Страница 3: ...ections 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 Safe Driving Tips 4 2 Safety Checks 4 3 Towing Instructions 4 4 Lug Nut Tightness 4 4 Trailer Setup 4 5 Voltage Selection 4 5 Pre Start Procedure 4 8 Operating Procedures 4 8 Digital Engine Controller...

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

Страница 5: ...ne that operates this equipment at all times Keep non qualified personnel at a safe distance from this equipment Only qualified personnel familiar with the safe installation operation and maintenance of this device should attempt start up or operating procedures Always stop engine before making or removing any connections Always stop engine and allow it to cool before refueling Responsibility When...

Страница 6: ...before 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 WARNING Never operate a trailer or tow vehicle that has a loose missing or broken lug nut The trailer is designed for safe operation with all lug nuts installed and all at the proper torque rating Ope...

Страница 7: ...g 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 Be sure that you understand how to stop the engine quickly in case of an emergency situation Become familiar with the...

Страница 8: ...e 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 un...

Страница 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 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 leak...

Страница 10: ...t 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...

Страница 11: ...nstallation shipment or otherwise Problems with Baldor products can be due to improper maintenance faulty installation non Baldor additions or modifications or other problems not due to defects in Baldor workmanship or materials If a Baldor Generator repair facility determines that the problem with a Baldor product is not due to defects in Baldor workmanship or materials then the customer will be ...

Страница 12: ...2 2 General Information MN2417 ...

Страница 13: ...apacity 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 Point hole at the top of the generator Figure 3 1 The lift point is designed only for the weight of the generator and factory trailer Do not lift by these points if the generator is mounted to a trailer...

Страница 14: ...s 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 A2 A2 TS250 only 4 Holes A2 A1 A2 A1 TA0000C10 BA0236A00 BA0236A02 TS400 only 6 Holes A1 48 Holes each side 21 24 27 10 85401 G10 Table 3 2 Mounting Dimensions Generator A A1 A2 B B1 TS25 74 8 12 23...

Страница 15: ...that an exhaust rain cap be used whenever it is possible that rain could get into the system This will help to prevent corrosion and damage to the exhaust system and engine Installation The generator is completely assembled tested and adjusted at the factory before it is shipped The procedures presented in this manual are suggestions and it is the responsibility of the Owner Operator to arrange fo...

Страница 16: ...nerator 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 See transfer switch information for corresponding generator input terminals Three phase circuit protection is provided by the generator When connecting the generator output to an electrical load a UL ...

Страница 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 STD Outlet 120V 20A 240V 50A Circuit Breakers Single or Double pole Circuit Breakers provides protection on some units To reset a breaker place it in the OFF then the ON position Single pole breaker ...

Страница 18: ...ch 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 utility power This powers battery chargers block heaters etc when the generator is not in operation A single phase 20 amp breaker is provided for circuit protection AC Input These connections are for uni...

Страница 19: ...nnel away from batteries WARNING Do not dispose of battery or batteries in a fire The battery is capable of exploding If the battery explodes electrolyte solution will be released in all directions Battery electrolyte solution is caustic and can cause severe burns and blindness If electrolyte contacts skin or eyes immediately flush the area with water and seek medical attention quickly WARNING Do ...

Страница 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 Install the Battery Hold Down Bar and Rods as shown in Figure 3 5 a Place the bent end of the Battery Hold Down Rod through the hole in the Battery Tray b Place the threaded end of the Battery Hold D...

Страница 21: ...he 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 Some installations will be in atmospheres that are much more corrosive than others Prevention of a failure is better than being forced to make a repair 2 Verify that the transfer switch is in Utility...

Страница 22: ...diately 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 leak before proceeding c Verify that operation is smooth If squeals vibrations or other abnormal sources of noise exist stop the engine set the Master Control in the Stop position immediately and repair...

Страница 23: ...transport 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 implied warranties on the trailer or towing equipment Selecting the Proper Towing Equipment When selecting the proper towing equipment the two most important factors that must be considered are the M...

Страница 24: ...and 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 the proper lane Allow for the extra length of the trailer before changing lanes Never change lanes abruptly as this may cause the trailer to sway and push the tow vehicle into a jack knife condition 4...

Страница 25: ...m 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 the master cylinder and operates the brakes as the trailer stops An electric brake system the emergency breakaway system has a battery charger breakaway switch with a pull pin and cable connected to t...

Страница 26: ...r 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 first 50 miles and again at 100 miles Check periodically thereafter 14 Verify that all jacks pins cables and doors are secured and trailer tongue is level 15 Remove tire chocks if used These prevent t...

Страница 27: ...r 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 wet ground or with wet hands feet or shoes or while barefoot Hard Wire Load Terminal Block shown in Figure 3 4 1 Ensure the generator is off 2 Place voltage select switch in the correct position 208 1...

Страница 28: ...ections 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 of damage Never use a damaged cable Replace it before usage 3 Individual load cables may be routed into the receptacle compartment through the Enclosure Electrical Access Panel 4 Individual load cab...

Страница 29: ...zzer 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 switch or other controller Strip the insulation from the remote start wires Simply press while inserting the wire then release to secure the connection Panel Lights Lamps to illuminate the operator panel...

Страница 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 at the load to turn off the load Do not start engine with load switched on Allow engine to come up to speed and warm up before load is switched on Caution Large Engine Compartment Doors on each side...

Страница 31: ...m 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 Low X Starting battery Over Under Voltage Manual Run Immediately energizes the crank cycle to start the generator set and produce power Start Start generator set operation Stop Stops the Engine and gen...

Страница 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 Horn Fault Reset Ready Status kW Active power produced by generator PF Power Factor RPM Engine speed in revolutions per minute Timer Event counting time e g prestart cooling etc L OFF MAN AUT Control ...

Страница 33: ...ing 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 off STOP SOLENOID on READY TO LOAD off Shutdown Cooling time elapsed FUEL SOLENOID off STOP SOLENOID on Stop Cooling RPM 0 or any other shutdown condition FUEL SOLENOID off STOP SOLENOID on Shutdown ...

Страница 34: ...put 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 Wrn Water temp WRN YES Sd Water temp SD YES Wrn Wtemp Low WRN YES Wrn Fuel Level WRN YES Sd Fuel Level SD YES Analog inp IOM PTM Wrn WRN YES Analog inp IOM PTM Sd SD YES Binary input Configurable YE...

Страница 35: ...ay 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 solenoid and enables the engine start The output opens if Emergency stop occurs or Cooled gen set is stopped or In pause between repeated starts GCB Close Open The output controls the generator circui...

Страница 36: ...m 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 shutdown alarm activates The output opens if alarm is not active and FAULT RESET is pressed fgen failed Output is closed if the generator over under frequency shutdown alarm activates The output opens i...

Страница 37: ...closes 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 overload warning alarm activates Running Output closes if the engine is in Running state ServiceTime Output closes if the ServiceTime alarm activates The output opens if alarm is not active and FAULT ...

Страница 38: ...Lite 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 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 transformers ratio Step 1...

Страница 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 Start RPM Start fail is detected when during Idle state RPM decreases below 2 During the Idle time timer running the binary output IDLE NOMINAL is opened when it elapses the IDLE NOMINAL output closes B...

Страница 40: ...setpoint 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 reaching Start RPM Step 1s Range 0 300 s Horn timeout Max time limit of horn sounding Set to zero if you want to leave the output HORN open Step 1s Range 0 600 s Overspeed Threshold for over speed p...

Страница 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 Minimum out of three is used Step 1 of Nominal voltage Range Gen V Gen V Wrn Gen V Shutdown level for generator under voltage All three phases are checked Minimum out of three is used Step 1 of Nomina...

Страница 42: ...M3 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 ANALOG INPUT 3 alarm Step 1 s Range 0 180 s AnlInIOM4 lev1 The level for IOM ANALOG INPUT 4 alarm detection Step 1 Range 100 to 10000 AnlInIOM4 lev2 The level for IOM ANALOG INPUT 4 alarm detection S...

Страница 43: ...ENOID 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 GENERATOR VOLTAGE N L1 L2 L3 L3l L2l L1k L1l BINARYINPUTS BINARYINPUTS RS 232 BI1 BI2 BI3 BI4 BI5 BI6 BOOT JUMPER Ground RPM Remote Start Stop Access Lock Emergency Stop Remote Off Sprinkler Not Used HORN...

Страница 44: ...n 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 TEMP RPM GND PO W ER 8 36VDC RS 232 GENER ATOR V O LTA G E 3 x 230 400 V N L1 L2 L3 BI1 BI2 BI3 BI4 BI5 BI6 L3l L2l L1l LB 1 BI NA RY OUTPUTS D BOOT JUMPER CO M AI3 FUEL EXTENSION M ODULE EDC 87654321...

Страница 45: ...r 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 manufacturer s owner s manual 4 Clean the cooling fins on the engine to keep the engine s heat dissipation potential at it s maximum 5 Inspect and clean all governor and fuel supply linkages so they op...

Страница 46: ...he 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 needs to be flashed Contact service center to perform this procedure Replace switch contact service center to perform this procedure Contact service center to perform this procedure Low Voltage 15 20...

Страница 47: ...igher 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 caution while braking Obey all local laws and regulations never exceed the posted speed limit and use reasonable care when towing any type of trailer Contact local authority having jurisdiction Note Af...

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

Страница 49: ...ntified 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 fuses use the exact replacement fuse manufacturer and part number Wiring Diagrams Wiring diagrams for these generators are contained on the following pages of this appendix ...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 89: ...Baldor District Offices ...

Страница 90: ...te 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 BALDOR ELECTRIC COMPANY P O Box 2400 Ft Smith AR 72902 2400 479 646 4711 Fax 479 648 5792 www baldor com ...

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