Baldor GLC40, GLC60, GLC105, GLC45, GLC20, GLC65, GLC30, GLC100, GLC15, GLC25 manual Maintenance

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Warning Statements Continued

Maintenance

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.

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 for repair.

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

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Contents GLC Generator MN2408California Proposition 65 Warning Table of Contents Appendix a Troubleshooting and Maintenance Problems and SolutionsAppendix B Section Product Safety Information Read This Manual ThoroughlySymbols OperationOperation Warning Statements Burn Installation Battery Safety Maintenance Any warranty coverage Limited WarrantyWarranty Period Generator Series Labor Parts‐2 General Information MN2408 Installation Guidelines Site PlanningExhaust System Controls and Transfer SwitchEngine Cooling System Room AirSetting The Genset On An Existing Concrete Floor Slab Foundation Design Foundation ChecklistVibration Isolators Weight Of The Genset ‐2 Approximate Weight vs. kW OutputDesigning An Isolated Foundation ‐3 Calculate Soil Bearing Load SBL Capacity‐5 Typical Foundation Installation Soil Type Safe Bearing Capacity Lb per ft Kilo PascalsExhaust System ‐6 Exhaust System Calculations Exhaust Piping Transfer Switch Checklist Transfer SwitchTransfer Switch Location Battery Starting System Battery LocationBattery Charger Battery Cables‐14 General Information MN2408 When the Generator is installed outdoors ‐1 Generator LiftingGenerator Open ‐2 Mounting Dimensions‐3 Stub Up Detail SoundSecure the Generator Ventilation TestBackpressure must not exceed 20 of water column Hot Exhaust GassesGuidelines for Exhaust System Page ‐4 Fuel Consumption Natural and LPV Fuel ConnectionsGeneral Considerations Natural Gas Connections External Supply Piping by installerExample Determining Pipe Size for Natural Gas Pipe Iron Pipe Size LengthExample Determining Pipe Size for LPV ‐6 LP Vapor Flow Rate Cubic Feet per Hour per Pipe LengthCatalog No Rating Single Phase Power Connections Transfer Switch ConsiderationsRemote Start Neutral L1L2 Connections AC Power Connections GroundConnections Battery Charger Considerations General Wiring ConsiderationsGLC100 Recommended Engine Oil and Battery TypeGLC10-25 GLC125Post Installation Checks Post Installation Checks ‐16 Receiving & Installation MN2408 ‐8 Alarm & Warning Conditions Digital Engine Controller Description EM0046A21 MRS17AUT Mode OFF ModeMAN Mode Digital Engine Controller Description EM0046A21 MRS17ECU Alarm List Adjustment MenuAlarm List Menu Status Condition of Transition Action  Next StateShut down SD see ‐10 AlarmsSensor fail FLS see ‐10 ‐10 Possible Warnings‐12 Binary outputs Inputs and Outputs‐11 Binary Inputs Used for shunt trip‐13 Analog Inputs Set points‐14 Basic Setpoints ‐15 Engine Setpoints ‐16 Engine Protect Setpoints Delay for Analog Input 2 Wrn Wtemp low. s Range1-180 s‐15 Engine Setpoints During the first 500ms. ,1s Range 0 3s‐17 Generator Protect Setpoints ‐18 Sensor Spec Setpoints ‐19 IOM/PTM Module Setpoints‐11 Controller Connection Diagram Jdic Run Switch Alarm LEDSpeed Signal LED OFF SwitchManual Start/Stop Operator Control PanelAutomatic Start/Stop Automatic Fault Shutdown Automatic Mains Failure AMFUtility Normal Condition Utility Power Failure ConditionsUtility Power Restored Load Test Push-button OperationFault Digital Inputs Name Action Terminal # Internal FaultsDigital Input Faults No Load Test‐15 Engine Controller Inputs & Outputs Analog Faults Fault Inputs Name Action SignalEngine starter motor Such as Fuel Rack Solenoids or electronic governorsCrank Fail Programmable ContactsAction Description Display Comments Show Operating Status screens Apply Power Main LCD DisplayReset faults Name and remaining timeGenerator Phase Current Display Generator Phase Voltage Display Line to LineGenerator Phase/Neutral Voltage Display Line to Neutral Generator Average Output DisplayProgram Menus Navigation Hints Main Menu Loop Voltage Calibration Procedure Zero CalibrationSpan Calibration Repeat for each phaseDisplayed values Displays the type of calibration function Engine Temperature & Oil Pressure CalibrationOil Pressure ‐16 Configuration Data Sheet 120-15000V AC Parameter Setting RangeSystem Voltage Line To Line Toggle Between Psi/KpaParameter Setting ‐21 Engine Control Connections ‐34 Operation MN2408 General Engine‐1 General Troubleshooting Guide Problems and SolutionsProblem Possible Cause Remedy ‐2 Troubleshooting Guide Digital Controller Only Service ‐3 Troubleshooting Guide Analog Controller OnlyVerify the adjustments. Replace controller if failed Battery Battery ChargerInstallation Considerations Options & Accessories A‐1Figure A‐2 Battery Heating Pad Installation BTHTR81 Heater Options & Accessories A‐3 Engine Block HeaterSilencers GLC10-25 GLC30-45 GLC60-90 GLC100-105Fuel Strainers & Fuel Lines Options & Accessories A‐5Fuel Strainer Figure A‐6 Installation StopOptions & Accessories A‐7 Remote AnnuciatorsGLC30-60 Radiator Duct FlangeGenerator GLC80-100GLC10-25 H1=36.0 L1=11.75 GLC30-45 H1=52.1, H2=66.6 Options & Accessories A‐9Enclosures GLC60-90 H1=64.2, H2=76.8‐10 Series GLC MN2408 OSH Plant Qty per PhaseGLC Circuit Breaker & Electrical Data Series GLC B‐1Figure B‐11 Customer Interface Connection Diagram Series GLC B‐3 Figure B‐13 Single Phase w/o Breaker Connection Diagram Figure B‐14 Single Phase One Breaker Connection Diagram Series GLC B‐5Figure B‐15 Single Phase Two Breaker Connection Diagram Series GLC B‐7 ‐8 Series GLC MN2408 Series GLC B‐9 ‐10 Series GLC MN2408 Figure B‐20 Three Phase Connection Diagram Series GLC B‐11Figure B‐21 Three Phase Connection Diagram with PMG Series GLC B‐13 ‐14 Series GLC MN2408 Series GLC B‐15 ‐16 Series GLC MN2408 Series GLC B‐17 Figure B‐27 Control Box Connections with MEC20 Controller Series GLC B‐19 Figure B‐29 Control Box Connections with MEC2 Controller Figure B‐30 Engine Wiring, Woodward 4.3L GM Series GLC B‐21Figure B‐31 Engine Wiring, Woodward 5.7L GM Figure B‐32 Engine Wiring, Woodward 8.1L GM Series GLC B‐23‐24 Series GLC MN2408 Baldor District Offices Baldor Electric Company MN2408