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Baldor TS400 manual

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Table of contents for the manual

  • Page 1

    T ier 2/3 T owable Generators (T railer and Skid Mounted) (Diesel Liquid Cooled) TS25, 35, 45, 60, 80, 130, 175, 250 and 400 Installation & Operating Manual 10/06 MN2417[...]

  • Page 2

    W ARNING: CALIFORNIA PROPOSITION 65 W ARNING: Engine exhaust from this product contains chemicals known to the state of California to cause cancer , birth defects and other reproductive harm. W ARNING: CALIFORNIA PROPOSITION 65 W ARNING: Battery posts, terminals and related accessories are known to the state of California to cause cancer , birth de[...]

  • Page 3

    T able of Contents T able of Contents i MN2417 Section 1 Product Safety Information 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Notice 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

  • Page 4

    ii T able of Contents MN2417[...]

  • Page 5

    Section 1 Product Safety Information Product Safety Information 1-1 MN2417 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 . Alway[...]

  • Page 6

    1-2 Product Safety Information MN2417 Precaution Statements Used In This Manual There are three classifications of precautionary statements used in this manual. The most critical is a W ARNING statement, then the Caution statement and the least critical is the Note statement. The usage of each statement is as follows: W ARNING: Indicates a potentia[...]

  • Page 7

    Product Safety Information 1-3 MN2417 Operation Statements Continued W ARNING: 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. W ARNING: Do not overfill the fuel tank. Only fill the tank to with[...]

  • Page 8

    1-4 Product Safety Information MN2417 Operation Statements Continued W ARNING: 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[...]

  • Page 9

    Product Safety Information 1-5 MN2417 Installation Statements Continued W ARNING: Circuit overload protection must be provided in accordance with the National Electrical Code and local regulations. W ARNING: Check Ground Fault Circuit Interrupt (GFCI) receptacles monthly by using the “T est” and “Reset” buttons. W ARNING: Have electrical ci[...]

  • Page 10

    1-6 Product Safety Information MN2417 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 fa[...]

  • Page 11

    Section 2 General Information General Information 2-1 MN2417 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 ve[...]

  • Page 12

    2-2 General Information MN2417[...]

  • Page 13

    Section 3 Receiving & Installation Receiving & Installation 3-1 MN2417 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. V erify that th[...]

  • Page 14

    3-2 Receiving & Installation MN2417 Several other factors should be carefully evaluated when selecting a location for installation: 1. For eff ective 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 wa[...]

  • Page 15

    Receiving & Installation 3-3 MN2417 Hot Exhaust Gasses W ARNING: 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 dange[...]

  • Page 16

    3-4 Receiving & Installation MN2417 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[...]

  • Page 17

    Receiving & Installation 3-5 MN2417 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) Single pha[...]

  • Page 18

    3-6 Receiving & Installation MN2417 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 For power to be applied to these terminals, the Output V oltage Selector Switch must be in the 120/208V , 120/240V or 277/480V positions. Customer Connections L1, L2[...]

  • Page 19

    Receiving & Installation 3-7 MN2417 Frame Ground Connection W ARNING: 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 a[...]

  • Page 20

    3-8 Receiving & Installation MN2417 W ARNING: 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 batte[...]

  • Page 21

    Receiving & Installation 3-9 MN2417 Recommended Engine Oil and Battery T ype When replacing batteries, use only the recommended battery for your generator , see T able 3-5. T able 3-5 Oil & Battery Recommendations MODEL SUMMER WINTER OIL RECOMMENDED (AMPS) COLD MODEL SUMMER OIL WINTER OIL OIL CAP ACITY RECOMMENDED BA TTERY (AMPS) COLD CRANK[...]

  • Page 22

    3-10 Receiving & Installation MN2417 Post Installation Checks Continued 16. Place the voltage output selector switch in the appropriate position. 17. V erify all loads are disconnected. 18. V erify the Master Control is in the “Stop” position. Connect the engine starting battery to the starter . V erify it is installed correctly . 19. V eri[...]

  • Page 23

    Section 4 Operation Operation 4-1 MN2417 T owing the Generator W ARNING: 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. W ARNING: Befor[...]

  • Page 24

    4-2 Operation MN2417 Selecting the Proper T owing Equipment Continued Electrical T railer 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 light[...]

  • Page 25

    Operation 4-3 MN2417 Figure 4-1 T railer Component Identification Jack Single or Double Axle T railer Brake Safety Chains T railer Pintle Engine Compartment Lift Hook Battery Compartment Jack Coupler Coupler Handle Safety Chains Ball Coupler T ow V ehicle Mounted Pintle Hook Caution: Large “Engine Compartment Doors” on each side of enclosure mu[...]

  • Page 26

    4-4 Operation MN2417 T owing Instructions 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. [...]

  • Page 27

    Operation 4-5 MN2417 T railer 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 [...]

  • Page 28

    4-6 Operation MN2417 T able 4-2 Three/Single Phase Operation Alternator V oltage V oltage at T erminal Lugs V oltage at Plug Receptacles Switch Position Alternator Winding Connection V oltage Adjust Position Line T o Line V oltage Line T o Neutral V oltage 120VAC Receptacles 240V AC Receptacles (T wist Lock) Position C onnec ti on P os iti on L1−[...]

  • Page 29

    Operation 4-7 MN2417 Figure 4-5 Operator Control Panel Components P ANEL LIGHTS ON OFF Panel Lights switch (On−Off ) T urns on the panel lights. FUSE Fuse Fuses provides protection on some units. (Do not remove while generator is running). BREAKER Breaker Circuit Breakers provides protection on some units. T o reset a breaker , simply press the c[...]

  • Page 30

    4-8 Operation MN2417 Pre − Start Procedure 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 [...]

  • Page 31

    Operation 4-9 MN2417 Digital Engine Controller Description EM0046A21 (MRS17) Figure 4-6 Operator Control Panel Stop Manual Run Display Menu Group LED Indicators Operating Modes and Horn & Fault Reset Note: The operator control panel is equyipped with a heater element that allows the LCD display to operate to − 40 ° C (not the entire generato[...]

  • Page 32

    4-10 Operation MN2417 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 b[...]

  • Page 33

    Operation 4-1 1 MN2417 Digital Engine Controller Description EM0046A21 (MRS17) Continued T able 4-4 Manual Mode Sequence Description Menu Status Condition of T ransition Action  Next State Start request PREST ART on, Prestart time counter started PREST ART Ready RPM > 2 or Oil pressure detected or Gen voltage > 10V Stop (Stop fail) OFF mod[...]

  • Page 34

    4-12 Operation MN2417 Alarms Following alarms are available: Sensor fail (FLS) see T able 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. W arning (WRN) see T able 4-5 When warning comes up, only alarm outputs and common warning output are [...]

  • Page 35

    Operation 4-13 MN2417 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. T able 4-6 Binary Inputs Alarm Alarm type W arning or S[...]

  • Page 36

    4-14 Operation MN2417 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 = W ater temp, AI3 = Fuel level) is fix. It is possible to configure on each Analog input:  Reading from IL[...]

  • Page 37

    Operation 4-15 MN2417 T able 4-10 Engine Setpoints Start RPM “Firing” speed when iL controller stops cranking (starter goes OFF). Step: 1% of nominal RPM; Range: 5 − 50 % Starting POil When reached controller stops cranking (starter goes OFF). Step: 0,1 psi; Range: − 100 − 10000 Note: There are three conditions for stop cranking: Starting[...]

  • Page 38

    4-16 Operation MN2417 T able 4-10 Engine Setpoints Continued Cooling time Runtime of the unloaded gen − set to cool the engine before stop. Step: 1s; Range: 0 − 3600 s AfterCoolT ime 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: 1[...]

  • Page 39

    Operation 4-17 MN2417 T able 4-12 Generator Protect Setpoints Overload Threshold for generator overload (in % of Nominal power) Step: 1% of Nominal power; Range: 0 − 200% Overload Wrn Threshold for generator overload warning (in % of Nominal power) Step: 1% of Nominal power; Range: 0 − 200% Overload del Delay for generator overload alarm. Step:[...]

  • Page 40

    4-18 Operation MN2417 T able 4-13 Sensor Spec Setpoints Calibr AI1,AI2, AI3 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 AnOut − kW/20mA Conversion coefficient from gen − set power to iG − IOM or PTM analog [...]

  • Page 41

    Operation 4-19 MN2417 Digital Engine Controller Description EM0046A21 (MRS17) Continued Figure 4-9 Controller Connection Diagram OIL PRESSURE WA TER TEMP FUELLEVEL RPM LOAD EMERGENCY  STOP REMOTE SSTART/STO P DI ESE L /GASENGIN E START ER BATTERY − + FUEL SOLENOID GENERATOR BINARY OUTPUTS STARTER L1 L2 L3 N PRE[...]

  • Page 42

    4-20 Operation MN2417 Digital Engine Controller Description EM0046A21 (MRS17) Continued Figure 4-10 Controller Connection Diagram LOAD EMERGENCY  STOP REMOTE SSTART/STO P DI ESE L /GASENGIN E START ER BATTERY − + FUEL SOLENOID GENERATOR G BINARY OUTPUTS STARTER L1 L2 L3 N PRESTART PE ALARM BINARY INP UTS RPM RP[...]

  • Page 43

    Section 5 T roubleshooting and Maintenance T roubleshooting and Maintenance 5-1 MN2417 W ARNING: 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 deat[...]

  • Page 44

    5-2 T roubleshooting and Maintenance MN2417 Problems and Solutions Some of the more common problems are listed in T able 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 (li[...]

  • Page 45

    T roubleshooting and Maintenance 5-3 MN2417 T able 5-1 T roubleshooting Guide Continued Problem Possible Cause Remedy Genset will not pull load Incorrect Engine Speed Load not connected properly Load too large for unit Remove electrical load, output should be 61−62 Hertz adjust engine speed if necessary . V erify voltage at the load and the conne[...]

  • Page 46

    5-4 T roubleshooting and Maintenance MN2417[...]

  • Page 47

    Appendix A Wiring Diagrams Wiring Diagrams A-1 MN2417 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. IMPORT ANT : Fuses are installed in the control box to protect the engine controller and associated control[...]

  • Page 48

    A-2 Wiring Diagrams MN2417 Figure A-1 TS25 Connection Diagram[...]

  • Page 49

    Wiring Diagrams A-3 MN2417 Figure A-2 TS25 Connection Diagram[...]

  • Page 50

    A-4 Wiring Diagrams MN2417 Figure A-3 TS25 Connection Diagram[...]

  • Page 51

    Wiring Diagrams A-5 MN2417 Figure A-4 TS25 Connection Diagram[...]

  • Page 52

    A-6 Wiring Diagrams MN2417 Figure A-5 TS25 Connection Diagram[...]

  • Page 53

    Wiring Diagrams A-7 MN2417 Figure A-6 TS25 Connection Diagram[...]

  • Page 54

    A-8 Wiring Diagrams MN2417 Figure A-7 TS35 Connection Diagram[...]

  • Page 55

    Wiring Diagrams A-9 MN2417 Figure A-8 TS35 Connection Diagram[...]

  • Page 56

    A-10 Wiring Diagrams MN2417 Figure A-9 TS35 Connection Diagram[...]

  • Page 57

    Wiring Diagrams A-1 1 MN2417 Figure A-10 TS35 Connection Diagram[...]

  • Page 58

    A-12 Wiring Diagrams MN2417 Figure A-1 1 TS35 Connection Diagram[...]

  • Page 59

    Wiring Diagrams A-13 MN2417 Figure A-12 TS35 Connection Diagram[...]

  • Page 60

    A-14 Wiring Diagrams MN2417 Figure A-13 TS35 Power Connection Diagram[...]

  • Page 61

    Wiring Diagrams A-15 MN2417 Figure A-14 TS60 Connection Diagram[...]

  • Page 62

    A-16 Wiring Diagrams MN2417 Figure A-15 TS60 Connection Diagram[...]

  • Page 63

    Wiring Diagrams A-17 MN2417 Figure A-16 TS60 Connection Diagram[...]

  • Page 64

    A-18 Wiring Diagrams MN2417 Figure A-17 TS60 Connection Diagram[...]

  • Page 65

    Wiring Diagrams A-19 MN2417 Figure A-18 TS60 Connection Diagram[...]

  • Page 66

    A-20 Wiring Diagrams MN2417 Figure A-19 TS60 Connection Diagram[...]

  • Page 67

    Wiring Diagrams A-21 MN2417 Figure A-20 TS60 Connection Diagram[...]

  • Page 68

    A-22 Wiring Diagrams MN2417 Figure A-21 TS80 Connection Diagram[...]

  • Page 69

    Wiring Diagrams A-23 MN2417 Figure A-22 TS80 Connection Diagram[...]

  • Page 70

    A-24 Wiring Diagrams MN2417 Figure A-23 TS80 Connection Diagram[...]

  • Page 71

    Wiring Diagrams A-25 MN2417 Figure A-24 TS80 Connection Diagram[...]

  • Page 72

    A-26 Wiring Diagrams MN2417 Figure A-25 TS80 Connection Diagram[...]

  • Page 73

    Wiring Diagrams A-27 MN2417 Figure A-26 TS80 Connection Diagram[...]

  • Page 74

    A-28 Wiring Diagrams MN2417 Figure A-27 TS80 Connection Diagram[...]

  • Page 75

    Wiring Diagrams A-29 MN2417 Figure A-28 TS80 Connection Diagram[...]

  • Page 76

    A-30 Wiring Diagrams MN2417 Figure A-29 TS80 Connection Diagram[...]

  • Page 77

    Wiring Diagrams A-31 MN2417 Figure A-30 TS80 Connection Diagram[...]

  • Page 78

    A-32 Wiring Diagrams MN2417 Figure A-31 TS400 Connection Diagram[...]

  • Page 79

    Wiring Diagrams A-33 MN2417 Figure A-32 TS400 Connection Diagram[...]

  • Page 80

    A-34 Wiring Diagrams MN2417 Figure A-33 TS400 Connection Diagram[...]

  • Page 81

    Wiring Diagrams A-35 MN2417 Figure A-34 TS400 Connection Diagram[...]

  • Page 82

    A-36 Wiring Diagrams MN2417 Figure A-35 TS400 Connection Diagram[...]

  • Page 83

    Wiring Diagrams A-37 MN2417 Figure A-36 TS400 Connection Diagram[...]

  • Page 84

    A-38 Wiring Diagrams MN2417 Figure A-37 TS400 Connection Diagram[...]

  • Page 85

    Wiring Diagrams A-39 MN2417 Figure A-38 TS400 Connection Diagram[...]

  • Page 86

    A-40 Wiring Diagrams MN2417 Figure A-39 TS400 Connection Diagram[...]

  • Page 87

    Baldor District Offices[...]

  • Page 88

    © Baldor Electric Company MN2417 Printed in USA 10/06 W ARNING: CALIFORNIA PROPOSITION 65 W ARNING: Engine exhaust from this product contains chemicals known to the state of California to cause cancer , birth defects and other reproductive harm. W ARNING: CALIFORNIA PROPOSITION 65 W ARNING: Battery posts, terminals and related accessories are know[...]