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