Page 3 - Table of Contents
Table of Contents Table of Contents i MN2417 Section 1 Product Safety Information 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Notice 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 4 - ii Table of Contents
Page 5 - Safety Notice; Symbols
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. Impr...
Page 10 - -6 Product Safety Information
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 ...
Page 11 - General Information 2-1; Limited Warranty; Warranty Period; Generator Series
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 accur...
Page 12 - -2 General Information
Page 13 - Receiving & Inspection; the commercial carrier that delivered your system.; Lifting the Generator; for stock units. Please consult Baldor for custom designs.; Figure 3-1 Generator Lifting; Lift Point; Table 3-1 Mounting Dimensions; Generator; Physical Location; When the Generator is installed outdoors; providing cooling and ventilation.
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 carrie...
Page 14 - Holes each side; Table 3-2 Mounting Dimensions; Secure the Generator; long enough to extend through the generator mounting frame.
3-2 Receiving & Installation MN2417 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 secur...
Page 15 - necessary repaired or reinstalled in a well ventilated area.; could cause dried grass, shrubs, trees or other debris to ignite.; Installation; Electrical Connections; ground lead is removed during installation and maintenance.; of the generator set.
Receiving & Installation 3-3 MN2417 Hot Exhaust GassesWARNING: 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 mon...
Page 17 - Single Phase Connections; door is closed, the connections are weather tight.; Circuit Breakers; Figure 3-4 Remote Start Connections; Remote Start Connections
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. Fig...
Page 18 - Customer Connections
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 theseterminals, the Output VoltageSelector Switch must be in the120/208V, 120/240V or277...
Page 21 - generator can result.; saturated; to the transfer switch.
Receiving & Installation 3-9 MN2417 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 SUMMER WINTER OIL RECOMMENDED (AMPS) COLD MODEL SUMMER OIL WINTER OIL OIL CA...
Page 22 - Post Installation Checks; Continued; engine fails to start, refer to Section 5 Troubleshooting.
3-10 Receiving & Installation MN2417 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. Veri...
Page 23 - gross vehicle weight rating of your trailer.; Tow Vehicle
Section 4 Operation Operation 4-1 MN2417 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 th...
Page 24 - Selecting the Proper Towing Equipment; Electrical Trailer Wiring
4-2 Operation MN2417 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 ...
Page 25 - Figure 4-1 Trailer Component Identification; Ball Coupler; operation. If doors remain open, engine will overhea
Operation 4-3 MN2417 Figure 4-1 Trailer Component Identification Jack Single orDouble Axle Trailer Brake SafetyChains Trailer Pintle Engine Compartment Lift Hook Battery Compartment Jack Coupler Coupler Handle SafetyChains Ball Coupler Tow Vehicle MountedPintle Hook Caution: Large “Engine Compartmen...
Page 26 - Tightening
4-4 Operation MN2417 Towing 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”...
Page 27 - Insert padlock through the hole in the handle.
Operation 4-5 MN2417 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 ...
Page 28 - Receptacle Panel Load Connections; damage. Never use a damaged cable. Replace it before usage.; regardless of where it is located on your panel.
4-6 Operation MN2417 Table 4-2 Three/Single Phase Operation Alternator Voltage Voltage at Terminal Lugs Voltage at Plug Receptacles Switch Position Alternator Winding Connection Voltage Adjust Position Line To Line Voltage Line To Neutral Voltage 120VAC Receptacles 240VAC Receptacles (Twist Lock) Po...
Page 29 - Figure 4-5 Operator Control Panel Components; Voltage Reconnect and Adjustment
Operation 4-7 MN2417 Figure 4-5 Operator Control Panel Components PANEL LIGHTS ON OFF Panel Lights switch (On−Off ) Turns 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 u...
Page 32 - OFF MAN AUT; Ready; kW; Control Mode
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 Contr...
Page 33 - ENGINE PROT
Operation 4-11 MN2417 Digital Engine Controller Description EM0046A21 (MRS17) Continued Table 4-4 Manual Mode Sequence Description Menu Status Condition of Transition Action Next State Start request PRESTART on, Prestart time counter started PRESTART Ready RPM > 2 or Oil pressure detected or Gen ...
Page 34 - Alarms; Following alarms are available:; Table 4-5 Possible Warnings
4-12 Operation MN2417 Alarms Following alarms are available: 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, on...
Page 35 - Inputs and Outputs; Outputs are BO1; Table 4-6 Binary Inputs
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. Table 4-6...
Page 36 - Analog Inputs; Use LiteEdit software to modify configuration.; Table 4-8 Analog Inputs
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 = Water temp, AI3 = Fuel level) is fix. It is possible to con...
Page 37 - Table 4-10 Engine Setpoints; Start RPM; RPM; Idle tim e; Idle Function
Operation 4-15 MN2417 Table 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...
Page 39 - Table 4-12 Generator Protect Setpoints
Operation 4-17 MN2417 Table 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 ...
Page 40 - Table 4-13 Sensor Spec Setpoints
4-18 Operation MN2417 Table 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 g...
Page 42 - JDIC
4-20 Operation MN2417 Digital Engine Controller Description EM0046A21 (MRS17) Continued Figure 4-10 Controller Connection Diagram LOAD E M E RGE NCY S T OP R EM O TE SSTAR T/STO P DI ESE L /GASENGIN E START ER BATTERY − + FU EL SO LEN O ID GENERATOR G BINARY OUTPUTS STARTER L1 L2 L3 N PRESTART PE AL...
Page 43 - Troubleshooting and Maintenance 5-1; Damage to engine control may result from jump starting.; precedence over any of the following general recommendations.
Section 5 Troubleshooting and Maintenance Troubleshooting and Maintenance 5-1 MN2417 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...
Page 44 - -2 Troubleshooting and Maintenance; Problems and Solutions; field) should be referred to an authorized service department.; Table 5-1 Troubleshooting Guide; Problem
5-2 Troubleshooting and Maintenance MN2417 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 t...
Page 45 - Fault Shutdowns
Troubleshooting and Maintenance 5-3 MN2417 Table 5-1 Troubleshooting 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 enginespeed if necessary...
Page 46 - -4 Troubleshooting and Maintenance
Page 47 - Replacement Parts
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. IMPORTANT: Fuses are installed in the control box to prot...
Page 48 - Figure A-1 TS25 Connection Diagram
A-2 Wiring Diagrams MN2417 Figure A-1 TS25 Connection Diagram
Page 49 - Figure A-2 TS25 Connection Diagram
Wiring Diagrams A-3 MN2417 Figure A-2 TS25 Connection Diagram
Page 50 - Figure A-3 TS25 Connection Diagram
A-4 Wiring Diagrams MN2417 Figure A-3 TS25 Connection Diagram
Page 51 - Figure A-4 TS25 Connection Diagram
Wiring Diagrams A-5 MN2417 Figure A-4 TS25 Connection Diagram
Page 52 - Figure A-5 TS25 Connection Diagram
A-6 Wiring Diagrams MN2417 Figure A-5 TS25 Connection Diagram
Page 53 - Figure A-6 TS25 Connection Diagram
Wiring Diagrams A-7 MN2417 Figure A-6 TS25 Connection Diagram
Page 54 - Figure A-7 TS35 Connection Diagram
A-8 Wiring Diagrams MN2417 Figure A-7 TS35 Connection Diagram
Page 55 - Figure A-8 TS35 Connection Diagram
Wiring Diagrams A-9 MN2417 Figure A-8 TS35 Connection Diagram
Page 56 - Figure A-9 TS35 Connection Diagram
A-10 Wiring Diagrams MN2417 Figure A-9 TS35 Connection Diagram
Page 57 - Figure A-10 TS35 Connection Diagram
Wiring Diagrams A-11 MN2417 Figure A-10 TS35 Connection Diagram
Page 58 - Figure A-11 TS35 Connection Diagram
A-12 Wiring Diagrams MN2417 Figure A-11 TS35 Connection Diagram
Page 59 - Figure A-12 TS35 Connection Diagram
Wiring Diagrams A-13 MN2417 Figure A-12 TS35 Connection Diagram
Page 60 - Figure A-13 TS35 Power Connection Diagram
A-14 Wiring Diagrams MN2417 Figure A-13 TS35 Power Connection Diagram
Page 61 - Figure A-14 TS60 Connection Diagram
Wiring Diagrams A-15 MN2417 Figure A-14 TS60 Connection Diagram
Page 62 - Figure A-15 TS60 Connection Diagram
A-16 Wiring Diagrams MN2417 Figure A-15 TS60 Connection Diagram
Page 63 - Figure A-16 TS60 Connection Diagram
Wiring Diagrams A-17 MN2417 Figure A-16 TS60 Connection Diagram
Page 64 - Figure A-17 TS60 Connection Diagram
A-18 Wiring Diagrams MN2417 Figure A-17 TS60 Connection Diagram
Page 65 - Figure A-18 TS60 Connection Diagram
Wiring Diagrams A-19 MN2417 Figure A-18 TS60 Connection Diagram
Page 66 - Figure A-19 TS60 Connection Diagram
A-20 Wiring Diagrams MN2417 Figure A-19 TS60 Connection Diagram
Page 67 - Figure A-20 TS60 Connection Diagram
Wiring Diagrams A-21 MN2417 Figure A-20 TS60 Connection Diagram
Page 68 - Figure A-21 TS80 Connection Diagram
A-22 Wiring Diagrams MN2417 Figure A-21 TS80 Connection Diagram
Page 69 - Figure A-22 TS80 Connection Diagram
Wiring Diagrams A-23 MN2417 Figure A-22 TS80 Connection Diagram
Page 70 - Figure A-23 TS80 Connection Diagram
A-24 Wiring Diagrams MN2417 Figure A-23 TS80 Connection Diagram
Page 71 - Figure A-24 TS80 Connection Diagram
Wiring Diagrams A-25 MN2417 Figure A-24 TS80 Connection Diagram
Page 72 - Figure A-25 TS80 Connection Diagram
A-26 Wiring Diagrams MN2417 Figure A-25 TS80 Connection Diagram
Page 73 - Figure A-26 TS80 Connection Diagram
Wiring Diagrams A-27 MN2417 Figure A-26 TS80 Connection Diagram
Page 74 - Figure A-27 TS80 Connection Diagram
A-28 Wiring Diagrams MN2417 Figure A-27 TS80 Connection Diagram
Page 75 - Figure A-28 TS80 Connection Diagram
Wiring Diagrams A-29 MN2417 Figure A-28 TS80 Connection Diagram
Page 76 - Figure A-29 TS80 Connection Diagram
A-30 Wiring Diagrams MN2417 Figure A-29 TS80 Connection Diagram
Page 77 - Figure A-30 TS80 Connection Diagram
Wiring Diagrams A-31 MN2417 Figure A-30 TS80 Connection Diagram
Page 78 - Figure A-31 TS400 Connection Diagram
A-32 Wiring Diagrams MN2417 Figure A-31 TS400 Connection Diagram
Page 79 - Figure A-32 TS400 Connection Diagram
Wiring Diagrams A-33 MN2417 Figure A-32 TS400 Connection Diagram
Page 80 - Figure A-33 TS400 Connection Diagram
A-34 Wiring Diagrams MN2417 Figure A-33 TS400 Connection Diagram
Page 81 - Figure A-34 TS400 Connection Diagram
Wiring Diagrams A-35 MN2417 Figure A-34 TS400 Connection Diagram
Page 82 - Figure A-35 TS400 Connection Diagram
A-36 Wiring Diagrams MN2417 Figure A-35 TS400 Connection Diagram
Page 83 - Figure A-36 TS400 Connection Diagram
Wiring Diagrams A-37 MN2417 Figure A-36 TS400 Connection Diagram
Page 84 - Figure A-37 TS400 Connection Diagram
A-38 Wiring Diagrams MN2417 Figure A-37 TS400 Connection Diagram
Page 85 - Figure A-38 TS400 Connection Diagram
Wiring Diagrams A-39 MN2417 Figure A-38 TS400 Connection Diagram
Page 86 - Figure A-39 TS400 Connection Diagram
A-40 Wiring Diagrams MN2417 Figure A-39 TS400 Connection Diagram
Page 87 - Baldor District Offices
Page 88 - BALDOR ELECTRIC COMPANY
© Baldor Electric Company MN2417 Printed in USA 10/06 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...