Baldor AE8 manual

Automatic Emergency Generator AE8, AE10, AE1 1 and AE25 Installation & Operating Manual 5/05 MN2415[...]

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[...]

T able of Contents T able of Contents i MN2415 Section 1 Product Safety Information 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Notice 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

ii T able of Contents MN2415 Appendix A Series AE8 A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Panel Configuration A-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

Section 1 Product Safety Information Product Safety Information 1-1 MN2415 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[...]

1-2 Product Safety Information MN2415 This symbol is shown throughout the manual to indicate a connection to ground reference point. Symbols Indicates a potentially hazardous situation which, if not avoided, could result in injury or death. Indicates a potentially hazardous situation which, if not avoided, could result in injury or death. Precautio[...]

Product Safety Information 1-3 MN2415 Operation W arning Statements Continued W ARNING: Never connect or disconnect loads during operation. Always connect load circuits before starting the engine and use external branch disconnects etc. to switch loads On/Off. W ARNING: Be sure that you understand how to stop the engine quickly in case of an emerge[...]

1-4 Product Safety Information MN2415 W arning Statements Continued Installation W ARNING: Installation and servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries. W ARNING: Disconnect the battery’ s ground terminal before workin[...]

Product Safety Information 1-5 MN2415 W arning Statements Continued Maintenance W ARNING: Before servicing the generator set, be sure to disconnect the battery terminals to prevent accidental engine rotation or starting. W ARNING: Disconnect the battery’ s ground terminal before working in the vicinity of the battery or battery wires. Contact wit[...]

1-6 Product Safety Information MN2415 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[...]

Section 2 General Information General Information 2-1 MN2415 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[...]

2-2 General Information MN2415[...]

Section 3 Receiving & Installation Receiving & Installation 3-1 MN2415 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[...]

3-2 Receiving & Installation MN2415 Physical Location The mounting location of the system is important. It should be installed in an area that is protected from direct harmful gases or liquids, dust, metallic particles, shock and vibration. It should be installed in an outdoor location so the exhaust fumes are vented to the atmosphere. W ARNING[...]

Receiving & Installation 3-3 MN2415 Indoor Location Continued It is recommended that the cool air intake have at least three (3) times the cross − sectional area of the power ventilation system. It is also recommended that the cool air intake be located as close as possible to the top of the generator set. The exhaust fan must be connected to[...]

3-4 Receiving & Installation MN2415 Indoor Location Continued 4. Keep all fuel and its associated piping away from all components of the engine exhaust system. 5. The exhaust system should be inspected on a regular basis to assure there are no toxic exhaust gas leaks. In some areas this inspection may be provided by your local public service. 6[...]

Receiving & Installation 3-5 MN2415 Fuel Connections The AE Series generators will run on Natural Gas or LPG (Liquid Propane Gas). If natural gas supply is used, follow the “Natural Gas Connections” procedure. If LPG supply is used, follow the “LP Gas Connections” procedure. T able 3-2 defines the flow rate required for each fuel type. [...]

3-6 Receiving & Installation MN2415 Natural Gas Connections The incoming pressure must be as indicated in T able 3-2. Note: Almost all operation problems are related to the installation techniques used. Do Not guess, be sure pipe size is adequate for required flow rate. T able 3-3 Natural Gas Flow Rate (Cubic Feet per Hour) per Pipe Length Pipe[...]

Receiving & Installation 3-7 MN2415 Example: Determining Pipe Size for LPG An AE8 has a 16Hp engine. For LP fuel, determine the supply pipe size for 60 feet run. 16 x 10,000 = 160,000 BTU’s / per hour for proper operation. 160, 000 2, 516 + 63.5 cubic feet per hour. From T able 3-4, a 60 foot run requires a minimum 1” pipe at full engine lo[...]

3-8 Receiving & Installation MN2415 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[...]

Receiving & Installation 3-9 MN2415 General Wiring Considerations 1. Control wires and Power wires cann ot be located in the same conduit (NEC Article 725). 2. 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. 3. Make sur[...]

3-10 Receiving & Installation MN2415 AE10 Electrical Connections Applies only to AE10 Enclosed and Open Series Generators Single Phase Power Connections The generator has a 240V single phase AC output. These connections are made at the power terminal box shown in Figure 3-5. Figure 3-5 Single Phase Output Power Connections 1 N AE10 Open AE10 wi[...]

Receiving & Installation 3-1 1 MN2415 AE1 1 Electrical Connections Applies only to AE1 1 Enclosed Series Generators Single Phase Power Connections The generator has a 240V single phase AC output. These connections are made at the power terminal box shown in Figure 3-7. Figure 3-7 Single Phase Output Power Connections L1 L2 AE1 1 with Enclosure [...]

3-12 Receiving & Installation MN2415 AE25 Electrical Connections Applies only to AE25 Enclosed Series Generators Single Phase Power Connections The generator has a 240V single phase AC output. These connections are made at the power terminal box shown in Figure 3-9. Figure 3-9 Single Phase Output Power Connections AE25 with Enclosure (Natural G[...]

Receiving & Installation 3-13 MN2415 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 [...]

3-14 Receiving & Installation MN2415 Caution: This generator must have a battery installed for operation. The battery is used during starting and during operation. If engine operation is attempted while the battery is removed, damage to the engine’ s electrical components may result. Battery Connections AE8, AE10, AE1 1, and AE25. The generat[...]

Receiving & Installation 3-15 MN2415 Figure 3-12 Battery Installation W ashers & Nut Battery Battery Hold Down Rod W ashers & Nut Battery T ray The + and − terminals of your battery may be different than shown. Be sure that the Positive lead is connected to the positive (+) terminal of your battery . Battery Hold Down Bar (Install awa[...]

3-16 Receiving & Installation MN2415 Post Installation Checks When the initial installation is complete, these checks must be performed before starting the engine. These checks are not required before each start, only after the initial installation. Caution: Do not apply high voltage to windings (do not start the generator) in a moisture − sa[...]

Receiving & Installation 3-17 MN2415 Post Installation Checks Continued 20. V erify all loads are disconnected. 21. Start the generator . (Refer to Section 4 Operation for details). 22. The engine should begin to crank and start when the fuel moves through the pipe to the carburetor . If the engine fails to start, refer to Section 5 T roublesho[...]

3-18 Receiving & Installation MN2415[...]

Section 4 Operation Operation 4-1 MN2415 Operator Control Panel Each operator panel is slightly different, depending on features of the generator you purchased. The Operator Control Panel of Figure 4-1 is shown because it has most of the available features. This will be used to explain how the controls operate. Figure 4-1 Operator Control Panel AE8[...]

4-2 Operation MN2415 Figure 4-3 Operator Control Panel AE25 OVERSPEED OVERCRANK HIGH TEMPERA TURE LOW OIL PRESSURE MASTER CONTROL MANUAL RUN AUTO ST ART STOP NA T . GAS L.P . GAS W A TER OIL BA TTERY DC CONTROL FUSE AC CONTROL FUSE Hour Meter Display Lamps High T emperature − Indicates excessive engine coolant temperature. Low Oil Pressure − In[...]

Operation 4-3 MN2415 Operating Procedures The engine − generator controller is designed to start and stop an engine from either a local mode “Manual Run” or remote mode “Auto Start”. When a start command is issued, the controller issues a run and crank output signal. The controller then monitors engine speed and when crank disconnect spee[...]

4-4 Operation MN2415 AE1 1 Operating Procedures The AE1 1 engine controller is programmable and it’s internal workings is more complex than the other AE series generators. Auto Start Operation This mode is activated by pressing the Auto pushbutton, see Figure 4-2. An LED indicator beside the button lights in Auto mode. The start sequence is initi[...]

Operation 4-5 MN2415 Shutdowns Continued Fail T o Start − if the engine does not start after 3 start cycles, a shutdown will be initiated and the Fail to Start Shutdown lamp is On. Low Oil Pressure − if engine oil pressure is less than the low oil pressure limit (after the Safety On timer), a shutdown will occur and the Low Oil Pressure Shutdow[...]

4-6 Operation MN2415 T able 4-1 Programmable Functions and V alues Function ! ! ! ! 1 ! ! ! ! 2 V alue (Preset in Bold) Pre − Heat Timer f f f f F f f f 0 Seconds f f f f F f f F 5 Seconds f F f 10 Seconds f F F 15 Seconds F f f 20 Seconds F f F 30 Seconds F F f 60 Seconds F F F 180 Seconds Used to pre−heat the engine prior to cranking. The out[...]

Operation 4-7 MN2415 T able 4-1 Programmable Functions and V alues Continued Function ! ! ! ! 1 ! ! ! ! 2 V alue (Preset in Bold) Cooling Timer ffFFffff 0 Seconds g f f F F f ffF 5 Seconds fFf 10 Seconds fFF 15 Seconds Fff 20 Seconds FfF 30 Seconds FFf 60 Seconds FFF 180 Seconds Delay between opening the generator load−switching device and stoppi[...]

4-8 Operation MN2415 Note 1: Programmable input, can be configured to on of the following: S Immediate warning close on fault − If the input is activated at any time the unit will alarm and energize the common warning and common alarm output. S Immediate warning open on fault − If the input is deactivated at any time the unit will alarm and ene[...]

Operation 4-9 MN2415 Electrical Connections The engine controller is installed into the AE1 1 from the factory . The information provided here will help you connect external devices to the Auxiliary inputs and outputs. T able 4-2 Engine Controller T erminal Identification Pin No Description Cable Size Notes 1 DC Plant Supply Input (−ve) 1.0mm Con[...]

4-10 Operation MN2415 Figure 4-5 Garretson KN Fuel V alve Outlet Mount Inlet Lock − Of f Adjustment Primer (Optional) Mount Service The KN should be periodically checked for leakage past the valve seat and the vents on the cover kept clean and free of obstructions. If the KN needs service we suggest you take it to a qualified serviceman. If that [...]

Section 5 T roubleshooting and Maintenance T roubleshooting and Maintenance 5-1 MN2415 Maintenance This manual contains only very minimal engine maintenance instructions. Refer to the engine manufacturer ’s owner ’s manual for specific engine maintenance instructions for your generator set. Any maintenance instructions or recommendations in the[...]

5-2 T roubleshooting and Maintenance MN2415 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 sho[...]

T roubleshooting and Maintenance 5-3 MN2415 T able 5-2 T roubleshooting Guide (Digital Controller Only) Problem Possible Cause Remedy Controller does not power up even with correct DC power applied Wiring Mistake Loss of DC Supply Check the battery and wiring to the unit. Check the DC supply . Check the DC fuse. Check DC supply voltage is not above[...]

5-4 T roubleshooting and Maintenance MN2415 Note: See Engine Controller manual for additional information. T able 5-3 T roubleshooting Guide (Analog Controller Only) Problem Possible Cause Remedy Controller cannot be Reset" Engine not stopped Controller not in OFF mode V erify the engine is at a complete stop before trying to reset. Set the[...]

Appendix A Series AE8 Series AE8 A-1 MN2415 Information in this Appendix applies to the AE8 Generator . Operator Panel Configuration Figure A-1 AE8 Operator Panel RUN MANUAL OFF REMOTE AUTO CONTROLLER FUSE Master Control Switch Controller Fuse Lamp Circuit Breaker Master Control Switch − A three position switch allows choice of automatic or manua[...]

A-2 Series AE8 MN2415 Replacement Parts Replacement parts assembly views for the Generator set are shown in Figure A-2 and A-3. Parts information is provided in T able A-1. Engine parts are identified in the engine manual that was provided with your generator set. Figure A-2 Alternator Assembly 21 22 21 23 1 2 3 5 6 4 7 8 23 HB6150A00 HB6150A01 RM1[...]

Series AE8 A-3 MN2415 T able A-1 Generator Set Parts List Continued Ref No. Part No. Description Open Enclosed Not Shown EH0279A00 Enclosure, T op X Not Shown EH0280A00 Enclosure, Door X Not Shown EH0281A00 Enclosure, End Cap X Not Shown EH0290A00 Enclosure, Right Side X Not Shown EH0291A00 Enclosure, Left Side X Not Shown HB2400A00 Enclosure, Latc[...]

A-4 Series AE8 MN2415 Figure A-4 AE8 Customer Connection Diagram[...]

Series AE8 A-5 MN2415 Figure A-5 AE8 Open Frame Wiring Diagram[...]

A-6 Series AE8 MN2415 Figure A-6 AE8 Enclosed Wiring Diagram[...]

Appendix B Series AE10 Series AE10 B-1 MN2415 Information in this Appendix applies to the AE10 Generator . Operator Panel Configuration Figure B-1 AE10 Operator Panel RUN MANUAL OFF REMOTE AUTO CONTROLLER FUSE Master Control Switch Controller Fuse Lamp Circuit Breaker Master Control Switch − A three position switch allows choice of automatic or m[...]

B-2 Series AE10 MN2415 Replacement Parts Replacement parts assembly views for the Generator set are shown in Figure B-2 and B-3. Parts information is provided in T able B-1. Engine parts are identified in the engine manual that was provided with your generator set. Figure B-2 Alternator Assembly 21 22 21 23 1 2 3 5 7 6 4 RM1088A07 15 8 Figure B-3 F[...]

Series AE10 B-3 MN2415 T able B-1 Generator Set Parts List Continued Ref No. Part No. Description Open Enclosed Not Shown EH0279A00 Enclosure, T op X Not Shown EH0280A00 Enclosure, Door X Not Shown EH0281A00 Enclosure, End Cap X Not Shown EH0290A00 Enclosure, Right Side X Not Shown EH0291A00 Enclosure, Left Side X Not Shown HB2400A00 Enclosure, Lat[...]

B-4 Series AE10 MN2415 Figure B-4 AE10 Customer Connection Diagram[...]

Series AE10 B-5 MN2415 Figure B-5 AE10 Open Frame Wiring Diagram[...]

B-6 Series AE10 MN2415 Figure B-6 AE10 Enclosed Wiring Diagram[...]

Appendix C Series AE1 1 Series AE1 1 C-1 MN2415 Information in this Appendix applies to the AE1 1 Generator . Operator Panel Configuration Figure C-1 AE1 1 Operator Panel Stop Manual Run Auto Start Hour Meter (fuel solenoid energized Low Oil Pressure Shutdown High Coolant T emperature Shutdown Over Speed Shutdown Alternator Charge Failure W arning [...]

C-2 Series AE1 1 MN2415 Replacement Parts Replacement parts assembly views for the Generator set are shown in Figure C-2 and C-3. Parts information is provided in T able C-1. Engine parts are identified in the engine manual that was provided with your generator set. Figure C-2 Alternator Assembly 21 23 1 2 3 5 7 6 4 RM1088A15 15 8 22 Figure C-3 Fra[...]

Series AE1 1 C-3 MN2415 T able C-1 Generator Set Parts List Continued Ref No. Part No. Description Not Shown EH0491A02 Enclosure, T op Not Shown EH0491A1 1 Enclosure, Access Panel Not Shown EH0491A01 Enclosure, Front Not Shown EH0491A10 Enclosure, Right Side (Hinge) & Rear Not Shown EH0491A13 Enclosure, Left Side (Latch) & Front Not Shown H[...]

C-4 Series AE1 1 MN2415 7. Remove the insert from the 90 ° elbow , Figure C-5. 8. Connect the hose and hose clamp to the 90 ° elbow . Figure C-5 90 ° Elbow with LPG Insert removed. Insert Hose (fuel line) and clamp installed 9. Remove the control box cover by removing the six 7/16” bolts. to gain access to the customer connection terminal stri[...]

Series AE1 1 C-5 MN2415 Figure C-7 AE1 1 Customer Connection Diagram[...]

C-6 Series AE1 1 MN2415 Figure C-8 AE1 1 Generator Connection Diagram[...]

Series AE1 1 C-7 MN2415 Figure C-9 AE1 1 Engine Connection Diagram[...]

C-8 Series AE1 1 MN2415 Figure C-10 AE1 1 Connection Diagram Notes: 1. Remove jumper if LP fuel is used. 2. Remove bullet connector from BLK/WHT wire. Substitute WD1000F23. 3. No Bonding wire. 4. (GRN) wires have green colored insulation. (Red) wires have Red colored insulation.[...]

Series AE1 1 C-9 MN2415 Figure C-1 1 AE1 1 Customer Wiring Interface Diagram[...]

C-10 Series AE1 1 MN2415[...]

Appendix D Series AE25 Series AE25 D-1 MN2415 Information in this Appendix applies to the AE25 Generator . Operator Panel Configuration Figure D-1 AE25 Operator Panel OVERSPEED OVERCRANK HIGH TEMPERA TURE LOW OIL PRESSURE MASTER CONTROL MANUAL RUN AUTO ST ART STOP NA T . GAS L.P . GAS W A TER OIL BA TTERY DC CONTROL FUSE AC CONTROL FUSE Hour Meter [...]

D-2 Series AE25 MN2415 Replacement Parts Replacement parts assembly views for the Generator set are shown in Figure D-2 and D-3. Parts information is provided in T able D-1. Engine parts are identified in the engine manual that was provided with your generator set. Figure D-2 Alternator Assembly 1 2 3 5 7 6 4 8 9 Figure D-3 Frame Assembly 20 RM1088[...]

Series AE25 D-3 MN2415 T able D-1 Generator Set Parts List Continued Ref No. Part No. Description Not Shown EH0278A78 Enclosure, T op Not Shown EH0278B72 Enclosure, Door Not Shown EH0386A02 Enclosure, Front Not Shown EH0386A03 Enclosure, Rear Not Shown EA0006A08 Radiator Not Shown FN0027A00 Fan, Radiator Cooling Not Shown EA0005A08 Upper Radiator H[...]

D-4 Series AE25 MN2415 Figure D-4 AE25 Receptacle Connection Diagram[...]

Series AE25 D-5 MN2415 Figure D-5 AE25 Engine Compartment Connection Diagram[...]

D-6 Series AE25 MN2415 Figure D-6 AE25 Control Box Connection Diagram[...]

Baldor District Offices UNITED ST ATES ARIZONA PHOENIX 421 1 S 43RD PLACE PHOENIX, AZ 85040 PHONE: 602−470−0407 F AX: 602−470−0464 CALIFORNIA LOS ANGELES 6480 FLOTILLA COMMERCE, CA 90040 PHONE: 323−724−6771 F AX: 323−721−5859 HA YWARD 21056 FORBES STREET HA YWARD, CA 94545 PHONE: 510−785−9900 F AX: 510−785−9910 COLORADO DENV[...]

© Baldor Electric Company MN2415 P r i n t e di nU S A 5/05 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 ar[...]