Installation & Operating Manual
GLC Generator
Gaseous Liquid Cooled
GLC10, 15, 20, 25 30, 40, 45, 60, 65, 100 and
Page
Table of Contents
Section
Section
Section
Section
Section
Appendix A
Appendix B
Section Product Safety Information
Read This Manual Thoroughly
Symbols
IMPORTANT SAFETY INSTRUCTIONS
Precaution Statements Used In This Manual
Operation
Operation Warning Statements Continued
Burn
Warning Statements Continued Installation
Warning Statements Continued Battery Safety
Warning Statements Continued Maintenance
Caution Statements
Limited Warranty
Section General Information
Generator Series
Labor
2‐2 General Information
MN2408
Installation Guidelines
Site Planning
S Controls and Transfer Switch
S Engine Cooling System
S Exhaust System
S Room Air
Foundation Checklist
Setting The Genset On An Existing Concrete Floor Slab
Figure 2‐1 Typical Installation of Spring Type Isolator
Foundation Design
Weight Of The Genset
Figure 2‐2 Approximate Weight vs. kW Output
Designing An Isolated Foundation
Figure 2‐3 Calculate Soil Bearing Load SBL Capacity
Figure 2‐5 Typical Foundation Installation
Table 2‐1 Approximate Load Bearing Capacities of Various Soil Types
Soil Type
Safe Bearing Capacity
Exhaust Checklist
System Placement
Multi-Engine Installations
Exhaust System
Figure 2‐7 Exhaust Pipe Thimble Installation Rain Protection
Figure 2‐6 Exhaust System Calculations Exhaust Piping
Transfer Switch
Transfer Switch Checklist
Figure 2‐8 Typical Emergency power System Installations
Transfer Switch Location
Battery Starting System
Battery Location
Figure 2‐9 Battery Starting System Battery Size
Battery Charger
Battery Cables
Figure 2‐10 Typical Battery Cable Calculations
2‐14 General Information
MN2408
Section Receiving & Installation
When the Generator is installed outdoors
Figure 3‐1 Generator Lifting
Table 3‐2 Mounting Dimensions
Figure 3‐2 Generator Mounting
Table 3‐3 Stub Up Detail
Fuel Stub Up
Secure the Generator
Ventilation Test
Hot Exhaust Gasses
Backpressure must not exceed 20” of water column
Guidelines for Exhaust System
MN2408
Fuel Connections
Table 3‐4 Fuel Consumption Natural and LPV
General Considerations
GLC10
External Supply Piping by installer
Example Determining Pipe Size for Natural Gas
Natural Gas Connections
Table 3‐5 Natural Gas Flow Rate Cubic Feet per Hour per Pipe Length
Example Determining Pipe Size for LPV
Table 3‐6 LP Vapor Flow Rate Cubic Feet per Hour per Pipe Length
1 Phase Amps
3 Phase Amps 240VAC
3 Phase Amps 480VAC
Generator Rating
Transfer Switch Considerations
Figure 3‐4 Basic Power Transfer System
Single Phase Power Connections
Generator Power
Figure 3‐5 Single Phase Connections From Alternator Factory Wired
AC Power Connections
Figure 3‐6 Three Phase WYE and DELTA Connections
Bond Jumper
Battery Charger Considerations
General Wiring Considerations
Recommended Engine Oil and Battery Type
Figure 3‐7 Battery Installation
Table 3‐7
Post Installation Checks
Post Installation Checks Continued
3‐16 Receiving & Installation
MN2408
Table 4‐8 Alarm & Warning Conditions
Changes menu displayed - Measurement, Adjustment or History
Horn Reset
Fault Reset
MAN AUT
Digital Engine Controller Description EM0046A21 MRS17 Continued
Measurement Menu
Figure 4‐9 Measurement Menu
Adjustment Menu
Figure 4‐10 Adjustment Menu
Alarm List
ECU Alarm List
Alarms
Sensor fail FLS see Table 4‐10
Warning WRN see Table 4‐10
Shut down SD see Table 4‐10
Inputs and Outputs
Table 4‐11 Binary Inputs
Table 4‐12 Binary outputs
Set points
Table 4‐13 Analog Inputs
Table 4‐14 Basic Setpoints
Table 4‐15 Engine Setpoints
Start RPM
RPM =
Idle tim e
time. This is because the JD engine passes some erroneous RPM signals
Table 4‐15 Engine Setpoints Continued
Table 4‐16 Engine Protect Setpoints
Water temp Low del
Table 4‐17 Generator Protect Setpoints
MN2408
Operation 4‐9
Table 4‐18 Sensor Spec Setpoints
Table 4‐19 IOM/PTM Module Setpoints
4‐10 Operation
MN2408
Figure 4‐11 Controller Connection Diagram
BATTERY START ER
BOOT JUMPER
TO BATTERY
Figure 4‐12 Controller Connection Diagram
BATTERY START ER
BOOT JUMPER
JDIC
ADJUST
Operator Control Panel MICROPROCESSOR Engine Controller Only
Figure 4‐13 Digital Operator Control Panel
MICROPROCESSOR ENGINE CONTROLLER
Auto Switch
Load Test Switch
Reset
Voltage Adjust
Automatic Fault Shutdown
Figure 4‐14 Auto Mains Failure AMF Connections Transfer Switch
Automatic Mains Failure AMF
Utility Power Failure Conditions
Utility Power Restored
Utility Normal Condition
Load Test Push-button Operation
Internal Faults
Digital Input Faults
High Engine Temperature
No Load Test
Figure 4‐15 Engine Controller Inputs & Outputs
4‐18 Operation
MN2408
Analog Faults
High Engine Temperature #1
High Engine Temperature #
Low Engine Temperature
Oil Bypass Timer Complete
fault will be automatically displayed
all active faults at a two second rate
Action
Description
Apply Power and
Reset faults
Action
Description
Generator Phase Voltage Display Line to Line
Generator Phase/Neutral Voltage Display Line to Neutral
Generator Phase Current Display
Generator Average Output Display
Battery Voltage/Engine Speed
Engine Temperature/Oil Pressure
Program Menus
Tachometer
Navigation Hints
Main Menu Loop Continued
Utility Ready To Load
Voltage Calibration Procedure
Zero Calibration
CURRENT A ZERO
350A
BAT VOLTS SPAN
Engine Temperature & Oil Pressure Calibration
Oil Pressure
Figure 4‐16 Configuration Data Sheet
4‐30 Operation
MN2408
Setting
Figure 4‐17 Main Menu Loop Parameters
Parameter
Range
Figure 4‐18 Analog Fault Menu Loop Parameters
Figure 4‐19 Digital Fault Menu Loop Parameters
4‐32 Operation
MN2408
OPERATES ON AN ALARM OR
Figure 4‐21 Engine Control Connections
COMMON FAIL CONTACT
SHUTDOWN CONDITION
4‐34 Operation
MN2408
Section Troubleshooting and Maintenance
General
Engine
Problems and Solutions
Table 5‐1 General Troubleshooting Guide
Table 5‐2 Troubleshooting Guide Digital Controller Only
Table 5‐3 Troubleshooting Guide Analog Controller Only
Service
Parts
Battery Charger
GLC30-45 Battery Charger
GLC60-105 Battery Charger
Installation Considerations
Installation Considerations
Figure A‐2 Battery Heating Pad Installation BTHTR81 Heater
Installation Considerations
Options & Accessories A‐3
Engine Block Heater
Figure A‐3
Silencers
Figure A‐4
Fuel Strainers & Fuel Lines
Figure A‐5 Fuel Strainer and Flex Fuel Line Connections
Installation
E-Stop
Figure A‐6
Remote Annuciators
Figure A‐7 MEC2 Remote Annunciator
Figure A‐8 Intelilite Remote Annunciator
Figure A‐9 Table A‐1 Mounting Dimensions
Radiator Duct Flange
Enclosures
Figure A‐10 Generator Lifting
A‐10 Series GLC
MN2408
Appendix B Series GLC Information & Wiring Diagrams
GLC Circuit Breaker & Electrical Data
Figure B‐11 Customer Interface Connection Diagram
MEC20 MEC2
Figure B‐12 Customer Interface w/o Breaker Power Connection Diagram
Series GLC B‐3
Figure B‐13 Single Phase - w/o Breaker Connection Diagram
B‐4 Series GLC
MN2408
Figure B‐14 Single Phase - One Breaker Connection Diagram
Series GLC B‐5
Figure B‐15 Single Phase - Two Breaker Connection Diagram
B‐6 Series GLC
MN2408
Series GLC B‐7
B‐8 Series GLC
MN2408
Series GLC B‐9
B‐10 Series GLC
MN2408
Figure B‐20 Three Phase Connection Diagram
Series GLC B‐11
Figure B‐21 Three Phase Connection Diagram with PMG
B‐12 Series GLC
MN2408
Figure B‐22 Three Phase Connection Diagram Wire 1/0 and larger
Series GLC B‐13
B‐14 Series GLC
MN2408
Series GLC B‐15
B‐16 Series GLC
MN2408
Series GLC B‐17
Figure B‐27 Control Box Connections with MEC20 Controller
B‐18 Series GLC
MN2408
Figure B‐28 Control Box Connections with MEC20 Controller & Governor
Series GLC B‐19
Figure B‐29 Control Box Connections with MEC2 Controller
B‐20 Series GLC
MN2408
Figure B‐30 Engine Wiring, Woodward 4.3L GM
Series GLC B‐21
Figure B‐31 Engine Wiring, Woodward 5.7L GM
B‐22 Series GLC
MN2408
Figure B‐32 Engine Wiring, Woodward 8.1L GM
Series GLC B‐23
B‐24 Series GLC
MN2408
Baldor District Offices
BALDOR ELECTRIC COMPANY World Headquarters
P.O. Box 2400 Fort Smith, AR
