Tier 2/3 Towable Generators (Trailer and Skid Mounted) (Diesel Liquid Cooled) TS25, 35, 45, 60, 80, 130, 175, 250 and 400 Installation & Operating Manual 10/06 MN2417
WARNING: CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects and other reproductive harm. WARNING: CALIFORNIA PROPOSITION 65 WARNING: Battery posts, terminals and related accessories are known to the state of California to cause cancer, birth defects and other reproductive harm.
Table of Contents Section 1 Product Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii Table of Contents MN2417
Section 1 Product Safety Information Safety Notice Be sure that you are completely familiar with the safe operation of this equipment. This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment. Improper use can cause serious or fatal injury. Always disconnect all electrical loads before starting the generator. Installation and repair procedures require specialized skills with electrical generating equipment and liquid cooled engine systems.
Precaution Statements Used In This Manual There are three classifications of precautionary statements used in this manual. The most critical is a WARNING statement, then the Caution statement and the least critical is the Note statement. The usage of each statement is as follows: WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in injury or death. Caution: Indicates a potentially hazardous situation which, if not avoided, could result in damage to property.
Operation Statements Continued WARNING: Gasoline and diesel fuel are flammable and can cause fire, explosions, injury or death. For storage or refueling handle fuel with care and only in clean, approved, properly marked safety fuel containers. WARNING: Do not overfill the fuel tank. Only fill the tank to within 1/2, of the top of the tank to allow space for fuel expansion. Overfilling of tank may cause fuel to spill out onto engine and cause fire or explosion.
Operation Statements Continued 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: 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.
Installation Statements Continued WARNING: Circuit overload protection must be provided in accordance with the National Electrical Code and local regulations. WARNING: Check Ground Fault Circuit Interrupt (GFCI) receptacles monthly by using the “Test” and “Reset” buttons. WARNING: Have electrical circuits and wiring installed and checked by licensed electrician or qualified technician. Electrical shock can cause serious or fatal injury.
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.
Section 2 General Information Thank you for purchasing your Baldor Generator Set. This manual contains information you need to safely and efficiently install and operate your generator set. During the preparation of this manual every effort was made to ensure the accuracy of its contents. This manual describes only very basic engine information. A separate owner’s manual for the engine is supplied with this unit for your use.
2-2 General Information MN2417
Section 3 Receiving & Installation Receiving & Inspection When you receive your generator, there are several things you should do immediately. 1. Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered your system. 2. Verify that the part number of the system you received is the same as the part number listed on your purchase order. 3.
Several other factors should be carefully evaluated when selecting a location for installation: 1. For effective cooling and maintenance, the system should be mounted on a flat, smooth, noncombustible level surface. A concrete pad is ideal and provides a secure installation. 2. Installation should prevent water levels from reaching the generator. Drainage must be adequate to keep concrete pad free from standing water. 3. Installation should prevent obstructions by buildup of leaves, grass, sand, snow, etc.
Hot Exhaust Gasses WARNING: Exhaust fumes/gases are extremely dangerous and can cause severe illness or death. Never breath exhaust fumes produced by a running engine. Only run the engine outdoors where ventilation is plentiful. Exhaust gases contain carbon monoxide, a colorless, odorless and extremely dangerous gas that can cause unconsciousness or death. Symptoms of carbon monoxide poisoning include: dizziness, nausea, headaches, sleepiness, vomiting or incoherence.
Electrical Connections Class 1 wiring methods must be used for field wiring connections to terminals of a class 2 circuit. It is the responsibility of the owner/operator to arrange for these procedures to be performed by a licensed electrical contractor and ensure conformance to all applicable codes including local codes peculiar to your municipality/city/county and state. Wire size and insulation type should be as required by NEC (National Electrical Code) and local codes.
Single Phase Connections Single phase connections are made at load receptacles located by the operator panel, see Figure 3-3. Simply open the rear panel access door and make the connections. When the panel door is closed, the connections are weather tight. Figure 3-3 Receptacle Panel (Single Phase) Circuit Breakers (Single or Double pole) Circuit Breakers provides protection on some units. To reset a breaker, place it in the OFF then the ON position.
Three Phase Connections Three phase connections are made at L1, L2, L3 and N connections shown in Figure 3-5. Figure 3-5 Three Phase Connections TS250/TS400 Connections For power to be applied to these terminals, the Output Voltage Selector Switch must be in the 120/208V, 120/240V or 277/480V positions. Customer Connections L1, L2, L3 and N Earth Ground Connection (to Driven Earth Ground Rod) Transfer Switch Considerations The following are general considerations for the safe use of a transfer switch: 1.
Frame Ground Connection WARNING: Be sure the system is properly grounded before applying power. Do not apply AC power before you ensure that grounds are connected. Electrical shock can cause serious or fatal injury. NEC requires that the frame and exposed conductive surfaces (metal parts) be connected to an approved earth ground. Local codes may also require proper grounding of generator systems.
WARNING: A battery presents a risk of fire because they generate hydrogen gas. Hydrogen gas is extremely explosive. Never jump start a battery, smoke in the area around the battery or cause any spark to occur in the area around the battery. The following precautions are to be followed when working on batteries: 1. Do not smoke when near batteries. 2. Do not cause flame or spark in battery area. 3. Discharge static electricity from body before touching batteries by first touching a grounded metal surface.
Recommended Engine Oil and Battery Type When replacing batteries, use only the recommended battery for your generator, see Table 3-5. Table 3-5 Oil & Battery Recommendations MODEL TS25 TS35 TS45 TS60 TS80 TS130 TS175 TS250 TS400 SUMMER OIL SAE. 20W/50 SAE. 20W/50 SAE. 20W/50 SAE. 20W/50 SAE. 20W/50 SAE. 20W/50 SAE. 20W/50 SAE. 20W/50 SAE. 20W/50 WINTER OIL 5W/30 5W/30 5W/30 5W/30 5W/30 5W/30 5W/30 5W/30 5W/30 OIL CAPACITY 8.6 QTS 8.5 QTS 11.8 QTS 11.8 QTS 14.0 QTS 18.0 QTS 34.0 QTS 34.0 QTS 45.
Post Installation Checks Continued 16. Place the voltage output selector switch in the appropriate position. 17. Verify all loads are disconnected. 18. Verify the Master Control is in the “Stop” position. Connect the engine starting battery to the starter. Verify it is installed correctly. 19. Verify the fuel source is available. 20. Remove all tools, rags, etc. from inside the generator enclosure. Close all enclosure doors and be sure no hands are inside the generator enclosure when it starts. 21.
Section 4 Operation Towing the Generator WARNING: Never allow a person to ride in or on a trailer that is being towed. All states prohibit passengers in towed vehicles. A person can fall off and be struck be another vehicle or run over by the towed trailer. Failure to observe this warning can result in death. WARNING: Before using a tow vehicle, verify that the vehicle is designed for the load. Using a vehicle that is too small is very dangerous. Be certain that it can handle the M.G.V.W.
Selecting the Proper Towing Equipment Continued Electrical Trailer Wiring All trailers must have taillights, brake lights and turn signals connected to the towing vehicle’s electrical system. It is also recommended that a heavy duty turn signal flasher and emergency flasher (if separate) be installed since the trailer lights place an extra load on car flasher units. Towing Heavy Trailer Loads 1. Trailer brakes.
Figure 4-1 Trailer Component Identification Lift Hook Battery Compartment Jack Coupler Handle Coupler Tow Vehicle Mounted Pintle Hook Trailer Brake Pintle Safety Chains Ball Coupler Safety Chains Jack Trailer Single or Double Axle Engine Compartment Caution: Large “Engine Compartment Doors” on each side of enclosure must remain closed during operation. If doors remain open, engine will overheat due to insufficient air flow around engine.
See Figure 4-1 for component identification. 1. Be sure the generator is off. 2. Shut all enclosure doors and latch the locks. 3. Back the tow vehicle to within a few inches of the trailer coupler (Pintle or Ball). 4. Be sure the Coupler Handle is in the “UP” (open) position or the Pintle Hook is Open. 5. Adjust the trailer jack for the height of the hitch on the tow vehicle. 6. Back the tow vehicle so the trailer coupler is directly over the tow vehicle ball hitch or the Pintle hook. 7.
Trailer Setup See Figure 4-1 for component identification. Carefully read all instructions before starting. 1. Locate a suitable, level location. Also be sure there are no overhead wires or obstructions. The trailer is balanced so the majority of the weight rests on the tow bar (Jack). If on a minor incline, the safest way to position the tailer is to have the tow bar facing down the incline (front of the trailer lower than the rear of the trailer). 2. Install tire chocks if used.
Table 4-2 Three/Single Phase Operation Switch Position Alternator Winding Connection 480/277 Series High Wye 208/120 Parallel Low Wye 240/120 Parallel Low ZigZag Voltage Adjust Position Minimum Middle Maximum Minimum Middle Maximum Minimum Middle Maximum Voltage at Terminal Lugs Line To Line Voltage L1−L2 416 460 480 208 230 240 L2−L3 416 460 480 208 230 240 Line To Neutral Voltage L1−L3 416 460 480 208 230 240 200 220 240 L1−N 240 266 277 120 133 139 100 110 120 L2−N 240 266 277
Figure 4-5 Operator Control Panel Components Volts Battery Displays the voltage of the engine starting battery. Analog display of generator output voltage in RMS volts. Water Temp Displays the temperature of the engine coolant. AMPS Analog display of generator output current in RMS amps. Oil Press Displays engine oil pressure. Horn A Horn (annunciator or buzzer) sounds an alarm when operator attention is needed. HERTZ Analog display of generator RPM which relates to the output frequency in Hertz.
Before attempting to start the generator set, several things must first be verified or performed. These are: 1. Fill system fuel tank with clean, fresh diesel fuel. 2. Fill engine crankcase to full mark with clean, fresh lubricating oil per engine manufacturer operating guide. 3. Radiator coolant should be checked at the beginning of each day and filled in compliance with the engine manufacturer’s guidelines. 4. Secure the generator for operation. a.
Digital Engine Controller Description EM0046A21 (MRS17) Figure 4-6 Operator Control Panel Operating Modes and Horn & Fault Reset Manual Run Display Stop Menu Group LED Indicators LED Indicators Note: The operator control panel is equyipped with a heater element that allows the LCD display to operate to −40°C (not the entire generator set, see generator specifications). This heater operates from the main battery power. Alarm (red) − Alarm (shutdown) condition occurred.
Digital Engine Controller Description EM0046A21 (MRS17) Continued Operating Mode Press Mode or to scroll though the list of operating modes: Off, Manual and Automatic. The control mode is shown in the highlighted area at the top of the display, Figure 4-7. When the desired Control Mode is highlighted, press Start to begin operation. Press Stop to terminate operation. OFF − Generator set operation is not allowed. MAN − Press Start to manually start the generator set immediately.
Digital Engine Controller Description EM0046A21 (MRS17) Continued Table 4-4 Manual Mode Sequence Description Menu Status Condition of Transition Start request Ready Prestart RPM > 2 or Oil pressure detected or Gen voltage > 10V OFF mode selected or Shut down alarm active RPM < 2, Oil pressure not detected, Vgen < 10V, no shutdown alarm active, other than OFF mode selected Prestart time elapsed Cranking RPM> Start RPM D+ input activated or oil pressure detected or Gen voltage > 25% Vgnom MaxCrank time
Following alarms are available: Alarms Sensor fail (FLS) see Table 4-5 Sensor fail is detected when measured value is 6% out of selected sensor characteristic. Sensor fail is indicated by ##### symbol instead measured value. Warning (WRN) see Table 4-5 When warning comes up, only alarm outputs and common warning output are closed. Shut down (SD) see Table 4-5 When the shut−down alarm comes up, InteliLite opens outputs GCB CLOSE/OPEN, FUEL SOLENOID, STARTER and PRESTART to stop the engine immediately.
Inputs and Outputs Any Binary input or output can be configured to any controller terminal Inputs are BI1 − BI6, Outputs are BO1 − BO6) or changed to different function by LiteEdit software. There is fixed 1 sec delay when any binary input is configured as protection. Table 4-6 Binary Inputs Alarm Alarm type Warning or Shut down Alarm active All the time, or Engine running only External request for engine run. AUT mode only. If the input is opened, shut down is immediately activated.
Analog Inputs Three analog inputs for resistive sensor 0 to 2400 ohms measuring are available on IL controller. Use LiteEdit software to modify configuration. The Analog inputs values assignment (AI1 = Oil press, AI2 = Water temp, AI3 = Fuel level) is fix. It is possible to configure on each Analog input: Reading from IL Analog inputs or from Engine Control Unit via CAN bus (J1939) Sensor characteristics − from the list, Value dimension (e.g.
Table 4-10 Engine Setpoints Start RPM Starting POil Prestart time MaxCrank time CrnkFail pause Crank attemps Idle time GCB CloseDelay Stabil time MinStpValvTime “Firing” speed when iL controller stops cranking (starter goes OFF). Step: 1% of nominal RPM; Range: 5 − 50 % When reached controller stops cranking (starter goes OFF). Step: 0,1 psi; Range: −100 − 10000 Note: There are three conditions for stop cranking: Starting RPM, StartingPOil and D+ (when enabled).
Table 4-10 Engine Setpoints Continued Cooling time AfterCoolTime CoolingSpeed D+ function Runtime of the unloaded gen−set to cool the engine before stop. Step: 1s; Range: 0 − 3600 s Runtime of engine after cooling pump. Binary output Cooling pump is closed when the engine starts and opens AfterCool time delayed after gen−set stops. Step: 1s Range: 0 − 3600s Selects the function of the Binary output IDLE/NOMINAL during engine Cooling state.
Table 4-12 Generator Protect Setpoints Overload Overload Wrn Overload del Ishort 2Inom del Curr unbal Curr unbal del Gen >V Gen >V Wrn Gen f Gen >f Wrn Gen
Table 4-13 Sensor Spec Setpoints Calibr AI1,AI2, AI3 AnOut−kW/20mA Calibrating constant to adjust the measured value of IL analog inputs. Physical dimension of calibrating constant is corresponding to Analog input. Step: 1; Range: −1000 to +1000 Conversion coefficient from gen−set power to iG−IOM or PTM analog output.
Digital Engine Controller Description EM0046A21 (MRS17) Continued Figure 4-9 Controller Connection Diagram LOAD DI ESE L /GAS ENGIN E GENERATOR L1 L2 G L3 FUEL SOLENOID N BI6 BI5 BI4 BI3 EMERGENCY STOP REMOTE SSTART/STOP BI1 BINARY INP UTS LB 1 GENER ATOR V O LTA G E 3 x 230 / 400 V GENERATOR CURRENT 0− 5A BI2 L3 L2 N L1 L3l L2l CO M START ER PE RPM L1l BATTERY OIL PRESSURE FUELLEVEL + WATER TEMP − Remote Start RS 232 CAN + − D+ BO6 BO5 BO4 PRESTART PO W ER
Digital Engine Controller Description EM0046A21 (MRS17) Continued Figure 4-10 Controller Connection Diagram LOAD DI ESE L /GAS ENGIN E GENERATOR L1 L2 G L3 BI6 BI5 BI1 L3 L2 N L1 BINARY INP UTS LB 1 L2l L1l CO M L3l GENER ATOR V O LTA G E 3 x 230 / 400 V GENERATOR CURRENT 0− 5A BI4 TO BATTERY START ER BI3 + BATTERY EMERGENCY STOP PE REMOTE SSTART/STOP − JDIC +− BI2 FUEL SOLENOID N Remote Start RS 232 CAN PO W ER 8−36VDC + − D+ BO6 BO5 BO4 BI NA RY OUTPUTS
Section 5 Troubleshooting and Maintenance 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. Caution: If a dead battery is suspected charge battery (or replace), and then attempting starting. Damage to engine control may result from jump starting.
Problems and Solutions Some of the more common problems are listed in Table 5-1. This information is intended to be a check or verification that simple causes can be located and fixed. It is not an exhaustive “how to” for all types of problems. Procedures that require in depth knowledge or skills (like flashing the field) should be referred to an authorized service department. Table 5-1 Troubleshooting Guide Problem Engine will not start Possible Cause No fuel. Restricted air flow.
Table 5-1 Troubleshooting Guide Continued Problem Genset will not pull load Possible Cause Incorrect Engine Speed Load not connected properly Load too large for unit Electrical shock when frame is touched Mechanical noise (alternator) Trailer lights inoperable Static charge. Grounded armature or field coil.
5-4 Troubleshooting and Maintenance MN2417
Appendix A Wiring Diagrams Replacement Parts Replacement parts information is provided in Replacement Parts Catalog CA2401. Engine parts are identified in the engine manual that was provided with your generator set. IMPORTANT: Fuses are installed in the control box to protect the engine controller and associated control circuits. When replacing fuses, use the exact replacement fuse (manufacturer and part number).
Figure A-1 TS25 Connection Diagram A-2 Wiring Diagrams MN2417
Figure A-2 TS25 Connection Diagram MN2417 Wiring Diagrams A-3
Figure A-3 TS25 Connection Diagram A-4 Wiring Diagrams MN2417
Figure A-4 TS25 Connection Diagram MN2417 Wiring Diagrams A-5
Figure A-5 TS25 Connection Diagram A-6 Wiring Diagrams MN2417
Figure A-6 TS25 Connection Diagram MN2417 Wiring Diagrams A-7
Figure A-7 TS35 Connection Diagram A-8 Wiring Diagrams MN2417
Figure A-8 TS35 Connection Diagram MN2417 Wiring Diagrams A-9
Figure A-9 TS35 Connection Diagram A-10 Wiring Diagrams MN2417
Figure A-10 TS35 Connection Diagram MN2417 Wiring Diagrams A-11
Figure A-11 TS35 Connection Diagram A-12 Wiring Diagrams MN2417
Figure A-12 TS35 Connection Diagram MN2417 Wiring Diagrams A-13
Figure A-13 TS35 Power Connection Diagram A-14 Wiring Diagrams MN2417
Figure A-14 TS60 Connection Diagram MN2417 Wiring Diagrams A-15
Figure A-15 TS60 Connection Diagram A-16 Wiring Diagrams MN2417
Figure A-16 TS60 Connection Diagram MN2417 Wiring Diagrams A-17
Figure A-17 TS60 Connection Diagram A-18 Wiring Diagrams MN2417
Figure A-18 TS60 Connection Diagram MN2417 Wiring Diagrams A-19
Figure A-19 TS60 Connection Diagram A-20 Wiring Diagrams MN2417
Figure A-20 TS60 Connection Diagram MN2417 Wiring Diagrams A-21
Figure A-21 TS80 Connection Diagram A-22 Wiring Diagrams MN2417
Figure A-22 TS80 Connection Diagram MN2417 Wiring Diagrams A-23
Figure A-23 TS80 Connection Diagram A-24 Wiring Diagrams MN2417
Figure A-24 TS80 Connection Diagram MN2417 Wiring Diagrams A-25
Figure A-25 TS80 Connection Diagram A-26 Wiring Diagrams MN2417
Figure A-26 TS80 Connection Diagram MN2417 Wiring Diagrams A-27
Figure A-27 TS80 Connection Diagram A-28 Wiring Diagrams MN2417
Figure A-28 TS80 Connection Diagram MN2417 Wiring Diagrams A-29
Figure A-29 TS80 Connection Diagram A-30 Wiring Diagrams MN2417
Figure A-30 TS80 Connection Diagram MN2417 Wiring Diagrams A-31
Figure A-31 TS400 Connection Diagram A-32 Wiring Diagrams MN2417
Figure A-32 TS400 Connection Diagram MN2417 Wiring Diagrams A-33
Figure A-33 TS400 Connection Diagram A-34 Wiring Diagrams MN2417
Figure A-34 TS400 Connection Diagram MN2417 Wiring Diagrams A-35
Figure A-35 TS400 Connection Diagram A-36 Wiring Diagrams MN2417
Figure A-36 TS400 Connection Diagram MN2417 Wiring Diagrams A-37
Figure A-37 TS400 Connection Diagram A-38 Wiring Diagrams MN2417
Figure A-38 TS400 Connection Diagram MN2417 Wiring Diagrams A-39
Figure A-39 TS400 Connection Diagram A-40 Wiring Diagrams MN2417
Baldor District Offices
WARNING: CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects and other reproductive harm. WARNING: CALIFORNIA PROPOSITION 65 WARNING: Battery posts, terminals and related accessories are known to the state of California to cause cancer, birth defects and other reproductive harm. BALDOR ELECTRIC COMPANY P.O. Box 2400 Ft. Smith, AR 72902−2400 (479) 646−4711 Fax (479) 648−5792 www.baldor.
