Manuals / Baldor / Lawn and Garden / Portable Generator

Baldor GLC45, GLC60, GLC105, GLC20 Battery Charger Considerations, General Wiring Considerations

Models: GLC40 GLC25 GLC15 GLC100 GLC30 GLC65 GLC20 GLC45 GLC105 GLC60 GLC10

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Battery Charger Considerations

1.Mount the battery charger on the generator or as close to the generator as possible.

2.If you mount the battery charger inside the building, mount it near the main breaker box or disconnect box.

3.If you mount the battery charger outside, you must protect it from the environment and the elements.

4.Do not mount the battery charger where flammable liquids or vapors are present.

General Wiring Considerations

1.When routing the interface wiring, do not route it up against anything that could cut or chafe the wiring. do not route the wire up against any hot or potentially hot object.

2.Make sure that all the electrical components (generator set, transfer switch, battery charger, etc.) share a common hard wired ground.

3.Check with your local building inspector to determine what you must do to comply with the local regulations for grounding of this type of permanent installation.

3‐12 Receiving & Installation

MN2408

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Baldor GLC45, GLC60, GLC105, GLC20, GLC65, GLC30, GLC100, GLC15 Battery Charger Considerations, General Wiring Considerations

Contents

Installation & Operating Manual GLC GeneratorGaseous Liquid Cooled GLC10, 15, 20, 25 30, 40, 45, 60, 65, 100 andPage Table of Contents SectionSection SectionSection SectionAppendix A Appendix BSection Product Safety Information Read This Manual ThoroughlySymbols IMPORTANT SAFETY INSTRUCTIONSPrecaution Statements Used In This Manual OperationOperation Warning Statements Continued BurnWarning Statements Continued Installation Warning Statements Continued Battery Safety Warning Statements Continued Maintenance Caution StatementsLimited Warranty Section General InformationGenerator Series Labor2‐2 General Information MN2408Installation Guidelines Site PlanningS Controls and Transfer Switch S Engine Cooling SystemS Exhaust System S Room AirFoundation Checklist Setting The Genset On An Existing Concrete Floor SlabFigure 2‐1 Typical Installation of Spring Type Isolator Foundation DesignWeight Of The Genset Figure 2‐2 Approximate Weight vs. kW OutputDesigning An Isolated Foundation Figure 2‐3 Calculate Soil Bearing Load SBL CapacityFigure 2‐5 Typical Foundation Installation Table 2‐1 Approximate Load Bearing Capacities of Various Soil TypesSoil Type Safe Bearing CapacityExhaust Checklist System PlacementMulti-Engine Installations Exhaust SystemFigure 2‐7 Exhaust Pipe Thimble Installation Rain Protection Figure 2‐6 Exhaust System Calculations Exhaust PipingTransfer Switch Transfer Switch ChecklistFigure 2‐8 Typical Emergency power System Installations Transfer Switch LocationBattery Starting System Battery LocationFigure 2‐9 Battery Starting System Battery Size Battery Charger Battery CablesFigure 2‐10 Typical Battery Cable Calculations 2‐14 General Information MN2408Section Receiving & Installation When the Generator is installed outdoorsFigure 3‐1 Generator Lifting Table 3‐2 Mounting Dimensions Figure 3‐2 Generator MountingTable 3‐3 Stub Up Detail Fuel Stub UpSecure the Generator Ventilation TestHot Exhaust Gasses Backpressure must not exceed 20” of water columnGuidelines for Exhaust System MN2408 Fuel Connections Table 3‐4 Fuel Consumption Natural and LPVGeneral Considerations GLC10External Supply Piping by installer Example Determining Pipe Size for Natural GasNatural Gas Connections Table 3‐5 Natural Gas Flow Rate Cubic Feet per Hour per Pipe LengthExample Determining Pipe Size for LPV Table 3‐6 LP Vapor Flow Rate Cubic Feet per Hour per Pipe Length1 Phase Amps 3 Phase Amps 240VAC3 Phase Amps 480VAC Generator RatingTransfer Switch Considerations Figure 3‐4 Basic Power Transfer SystemSingle Phase Power Connections Generator PowerFigure 3‐5 Single Phase Connections From Alternator Factory Wired AC Power ConnectionsFigure 3‐6 Three Phase WYE and DELTA Connections Bond JumperBattery Charger Considerations General Wiring ConsiderationsRecommended Engine Oil and Battery Type Figure 3‐7 Battery InstallationTable 3‐7 Post Installation Checks Post Installation Checks Continued 3‐16 Receiving & Installation MN2408Table 4‐8 Alarm & Warning Conditions Changes menu displayed - Measurement, Adjustment or HistoryHorn Reset Fault ResetMAN AUT Digital Engine Controller Description EM0046A21 MRS17 ContinuedMeasurement Menu Figure 4‐9 Measurement MenuAdjustment Menu Figure 4‐10 Adjustment MenuAlarm List ECU Alarm ListAlarms Sensor fail FLS see Table 4‐10Warning WRN see Table 4‐10 Shut down SD see Table 4‐10Inputs and Outputs Table 4‐11 Binary InputsTable 4‐12 Binary outputs Set points Table 4‐13 Analog InputsTable 4‐14 Basic Setpoints Table 4‐15 Engine Setpoints Start RPMRPM = Idle tim etime. This is because the JD engine passes some erroneous RPM signals Table 4‐15 Engine Setpoints ContinuedTable 4‐16 Engine Protect Setpoints Water temp Low delTable 4‐17 Generator Protect Setpoints MN2408Operation 4‐9 Table 4‐18 Sensor Spec Setpoints Table 4‐19 IOM/PTM Module Setpoints4‐10 Operation MN2408Figure 4‐11 Controller Connection Diagram BATTERY START ERBOOT JUMPER TO BATTERYFigure 4‐12 Controller Connection Diagram BATTERY START ERBOOT JUMPER JDICADJUST Operator Control Panel MICROPROCESSOR Engine Controller OnlyFigure 4‐13 Digital Operator Control Panel MICROPROCESSOR ENGINE CONTROLLERAuto Switch Load Test SwitchReset Voltage AdjustAutomatic Fault Shutdown Figure 4‐14 Auto Mains Failure AMF Connections Transfer SwitchAutomatic Mains Failure AMF Utility Power Failure Conditions Utility Power RestoredUtility Normal Condition Load Test Push-button OperationInternal Faults Digital Input FaultsHigh Engine Temperature No Load TestFigure 4‐15 Engine Controller Inputs & Outputs 4‐18 OperationMN2408 Analog Faults High Engine Temperature #1High Engine Temperature # Low Engine TemperatureOil Bypass Timer Complete fault will be automatically displayed all active faults at a two second rateAction DescriptionApply Power and Reset faultsAction DescriptionGenerator Phase Voltage Display Line to Line Generator Phase/Neutral Voltage Display Line to NeutralGenerator Phase Current Display Generator Average Output DisplayBattery Voltage/Engine Speed Engine Temperature/Oil PressureProgram Menus TachometerNavigation Hints Main Menu Loop Continued Utility Ready To LoadVoltage Calibration Procedure Zero CalibrationCURRENT A ZERO 350ABAT VOLTS SPAN Engine Temperature & Oil Pressure Calibration Oil PressureFigure 4‐16 Configuration Data Sheet 4‐30 OperationMN2408 Setting Figure 4‐17 Main Menu Loop ParametersParameter RangeFigure 4‐18 Analog Fault Menu Loop Parameters Figure 4‐19 Digital Fault Menu Loop Parameters4‐32 Operation MN2408OPERATES ON AN ALARM OR Figure 4‐21 Engine Control ConnectionsCOMMON FAIL CONTACT SHUTDOWN CONDITION4‐34 Operation MN2408Section Troubleshooting and Maintenance GeneralEngine Problems and Solutions Table 5‐1 General Troubleshooting GuideTable 5‐2 Troubleshooting Guide Digital Controller Only Table 5‐3 Troubleshooting Guide Analog Controller Only ServiceParts Battery Charger GLC30-45 Battery ChargerGLC60-105 Battery Charger Installation ConsiderationsInstallation Considerations Figure A‐2 Battery Heating Pad Installation BTHTR81 HeaterInstallation Considerations Options & Accessories A‐3Engine Block Heater Figure A‐3Silencers Figure A‐4Fuel Strainers & Fuel Lines Figure A‐5 Fuel Strainer and Flex Fuel Line ConnectionsInstallation E-StopFigure A‐6 Remote Annuciators Figure A‐7 MEC2 Remote AnnunciatorFigure A‐8 Intelilite Remote Annunciator Figure A‐9 Table A‐1 Mounting Dimensions Radiator Duct FlangeEnclosures Figure A‐10 Generator LiftingA‐10 Series GLC MN2408Appendix B Series GLC Information & Wiring Diagrams GLC Circuit Breaker & Electrical DataFigure B‐11 Customer Interface Connection Diagram MEC20 MEC2Figure B‐12 Customer Interface w/o Breaker Power Connection Diagram Series GLC B‐3Figure B‐13 Single Phase - w/o Breaker Connection Diagram B‐4 Series GLCMN2408 Figure B‐14 Single Phase - One Breaker Connection Diagram Series GLC B‐5Figure B‐15 Single Phase - Two Breaker Connection Diagram B‐6 Series GLCMN2408 Series GLC B‐7 B‐8 Series GLC MN2408Series GLC B‐9 B‐10 Series GLC MN2408Figure B‐20 Three Phase Connection Diagram Series GLC B‐11Figure B‐21 Three Phase Connection Diagram with PMG B‐12 Series GLCMN2408 Figure B‐22 Three Phase Connection Diagram Wire 1/0 and larger Series GLC B‐13B‐14 Series GLC MN2408Series GLC B‐15 B‐16 Series GLC MN2408Series GLC B‐17 Figure B‐27 Control Box Connections with MEC20 Controller B‐18 Series GLCMN2408 Figure B‐28 Control Box Connections with MEC20 Controller & Governor Series GLC B‐19Figure B‐29 Control Box Connections with MEC2 Controller B‐20 Series GLCMN2408 Figure B‐30 Engine Wiring, Woodward 4.3L GM Series GLC B‐21Figure B‐31 Engine Wiring, Woodward 5.7L GM B‐22 Series GLCMN2408 Figure B‐32 Engine Wiring, Woodward 8.1L GM Series GLC B‐23B‐24 Series GLC MN2408Baldor District Offices BALDOR ELECTRIC COMPANY World Headquarters P.O. Box 2400 Fort Smith, AR