Baldor GLC100, GLC60, GLC105, GLC45, GLC20, GLC65, GLC30, GLC15, GLC25 Operation Warning Statements Burn

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Operation Warning Statements Continued

WARNING: Never connect or disconnect loads during operation. Always connect load circuits before starting the engine and use external branch disconnects etc. to switch loads On/Off.

WARNING: Be sure that you understand how to stop the engine quickly in case of an emergency situation. Become familiar with the controls and safety systems provided with this generator set.

WARNING: Always wear safety glasses with side shields and hearing protection when working near the generator.

WARNING: Improper operation may cause violent motion of connected equipment. Be certain that unexpected movement will not cause injury to personnel or damage to equipment.

WARNING: Never operate the generator set indoors or in a poorly ventilated area such as a tunnel or cave. Exhaust fumes are extremely dangerous to all personnel that are in or in contact with that area.

WARNING: Never permit anyone to operate the generator without proper instructions. Be sure to keep a copy of this manual with the generator so that all users can be properly informed of its safe operation.

WARNING: Never allow children or pets to be in the area where the generator is running. The generator and the equipment being powered by the generator may cause injury or death.

WARNING: Never operate the generator unless all guards, covers, shields and other safety items are properly installed.

WARNING: Do not put hands, feet, tools clothing or other objects near 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: When operating this generator remain alert at all times. Never operate machinery when physically or mentally fatigued, or while under the influence of alcohol, drugs or medication.

WARNING: Never operate the engine when the air cleaner is removed. An engine backfire can cause serious burns.

WARNING: 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 battery to explode and cause severe injury or death to anyone in the area.

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.

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: Do not smoke near generator during operation or when close to fuel source. LPG and natural gas fuels are flammable and can cause fire, explosions, injury or death.

WARNING: Keep generator at least three feet away from buildings and other structures.

WARNING: Keep generator away from flammable or hazardous materials (trash, rags, lubricants, explosives, paints etc.) and grass or leaf build up.

WARNING: Keep a fire extinguisher near the generator while generator is in use. An extinguisher rated “ABC” by the National Fire Protection Association is appropriate.

Burn

WARNING: Parts of this generator are extremely hot during and after operation. To prevent severe burns, do not touch any part of the generator until you have first determined if the part is hot. Wear protective clothing and after use allow sufficient time for parts to cool before touching any part of the generator.

WARNING: Do not touch the hot exhaust parts or the high voltage spark plug or coil terminals of the engine. Although spark plug voltages are not normally lethal, a sudden involuntary jerk of the hand or body part caused by contact with high voltage or a hot surface can result in injury to yourself or others.

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.

Continued on next page.

MN2408

Product Safety Information 1‐3

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Contents MN2408 GLC GeneratorCalifornia Proposition 65 Warning Table of Contents Appendix a Troubleshooting and Maintenance Problems and SolutionsAppendix B Read This Manual Thoroughly Section Product Safety InformationOperation SymbolsOperation Warning Statements Burn Installation Battery Safety Maintenance Generator Series Labor Parts Limited WarrantyWarranty Period Any warranty coverage‐2 General Information MN2408 Site Planning Installation GuidelinesRoom Air Controls and Transfer SwitchEngine Cooling System Exhaust SystemSetting The Genset On An Existing Concrete Floor Slab Foundation Design Foundation ChecklistVibration Isolators ‐2 Approximate Weight vs. kW Output Weight Of The Genset‐3 Calculate Soil Bearing Load SBL Capacity Designing An Isolated FoundationSoil Type Safe Bearing Capacity Lb per ft Kilo Pascals ‐5 Typical Foundation InstallationExhaust System ‐6 Exhaust System Calculations Exhaust Piping Transfer Switch Checklist Transfer SwitchTransfer Switch Location Battery Location Battery Starting SystemBattery Cables Battery Charger‐14 General Information MN2408 ‐1 Generator Lifting When the Generator is installed outdoorsSound ‐2 Mounting Dimensions‐3 Stub Up Detail Generator OpenVentilation Test Secure the GeneratorBackpressure must not exceed 20 of water column Hot Exhaust GassesGuidelines for Exhaust System Page ‐4 Fuel Consumption Natural and LPV Fuel ConnectionsGeneral Considerations Pipe Iron Pipe Size Length External Supply Piping by installerExample Determining Pipe Size for Natural Gas Natural Gas Connections‐6 LP Vapor Flow Rate Cubic Feet per Hour per Pipe Length Example Determining Pipe Size for LPVCatalog No Rating Single Phase Power Connections Transfer Switch ConsiderationsRemote Start Neutral L1L2 Connections AC Power Connections GroundConnections General Wiring Considerations Battery Charger ConsiderationsGLC125 Recommended Engine Oil and Battery TypeGLC10-25 GLC100Post Installation Checks Post Installation Checks ‐16 Receiving & Installation MN2408 Digital Engine Controller Description EM0046A21 MRS17 ‐8 Alarm & Warning ConditionsDigital Engine Controller Description EM0046A21 MRS17 OFF ModeMAN Mode AUT ModeMenu Status Condition of Transition Action  Next State Adjustment MenuAlarm List ECU Alarm List‐10 Possible Warnings AlarmsSensor fail FLS see ‐10 Shut down SD see ‐10Used for shunt trip Inputs and Outputs‐11 Binary Inputs ‐12 Binary outputs‐13 Analog Inputs Set points‐14 Basic Setpoints ‐15 Engine Setpoints During the first 500ms. ,1s Range 0 3s Delay for Analog Input 2 Wrn Wtemp low. s Range1-180 s‐15 Engine Setpoints ‐16 Engine Protect Setpoints‐17 Generator Protect Setpoints ‐19 IOM/PTM Module Setpoints ‐18 Sensor Spec Setpoints‐11 Controller Connection Diagram Jdic OFF Switch Alarm LEDSpeed Signal LED Run SwitchManual Start/Stop Operator Control PanelAutomatic Start/Stop Automatic Mains Failure AMF Automatic Fault ShutdownLoad Test Push-button Operation Utility Power Failure ConditionsUtility Power Restored Utility Normal ConditionNo Load Test Internal FaultsDigital Input Faults Fault Digital Inputs Name Action Terminal #‐15 Engine Controller Inputs & Outputs Fault Inputs Name Action Signal Analog FaultsFail Programmable Contacts Such as Fuel Rack Solenoids or electronic governorsCrank Engine starter motorAction Description Display Comments Name and remaining time Apply Power Main LCD DisplayReset faults Show Operating Status screensGenerator Average Output Display Generator Phase Voltage Display Line to LineGenerator Phase/Neutral Voltage Display Line to Neutral Generator Phase Current DisplayProgram Menus Navigation Hints Main Menu Loop Zero Calibration Voltage Calibration ProcedureSpan Calibration Repeat for each phaseDisplayed values Displays the type of calibration function Engine Temperature & Oil Pressure CalibrationOil Pressure ‐16 Configuration Data Sheet Toggle Between Psi/Kpa Parameter Setting RangeSystem Voltage Line To Line 120-15000V ACParameter Setting ‐21 Engine Control Connections ‐34 Operation MN2408 Engine General‐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 Options & Accessories A‐1 Battery ChargerInstallation Considerations BatteryFigure A‐2 Battery Heating Pad Installation BTHTR81 Heater Engine Block Heater Options & Accessories A‐3GLC10-25 GLC30-45 GLC60-90 GLC100-105 SilencersFuel Strainers & Fuel Lines Options & Accessories A‐5Fuel Strainer Stop Figure A‐6 InstallationRemote Annuciators Options & Accessories A‐7GLC80-100 Radiator Duct FlangeGenerator GLC30-60GLC60-90 H1=64.2, H2=76.8 Options & Accessories A‐9Enclosures GLC10-25 H1=36.0 L1=11.75 GLC30-45 H1=52.1, H2=66.6‐10 Series GLC MN2408 Series GLC B‐1 Qty per PhaseGLC Circuit Breaker & Electrical Data OSH PlantFigure B‐11 Customer Interface Connection Diagram Series GLC B‐3 Figure B‐13 Single Phase w/o Breaker Connection Diagram Series GLC B‐5 Figure B‐14 Single Phase One Breaker Connection DiagramFigure B‐15 Single Phase Two Breaker Connection Diagram Series GLC B‐7 ‐8 Series GLC MN2408 Series GLC B‐9 ‐10 Series GLC MN2408 Series GLC B‐11 Figure B‐20 Three Phase Connection DiagramFigure 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 Series GLC B‐21 Figure B‐30 Engine Wiring, Woodward 4.3L GMFigure B‐31 Engine Wiring, Woodward 5.7L GM Series GLC B‐23 Figure B‐32 Engine Wiring, Woodward 8.1L GM‐24 Series GLC MN2408 Baldor District Offices Baldor Electric Company MN2408