Baldor Automatic Emergency Pow'r Products manual

OPERATOR'S MANUAL FOR YOUR AUTOMATIC EMERGENCY POW'R PRODUCTS MODEL AE12 GENERATOR BALDOR GENERATORS 3815 Oregon Street • Oshkosh WI 54902 Telephone 236 - 4200 • Fax 920 - 236 - 4219 FORM#: S - PSG - 002 - 13 EFFECTIVE DATE: 4/ 2/97 AE12 COVER MSW'00 REVISION DATE : 8/13/02[...]

Safety Warnings ? Place protective covers and guards over the rotating parts, if rotating parts such as the drive shaft, pulley, belt, etc. are left exposed, they are potentially hazardous. ? When cleaning, repairing or inspecting, make sure all moving parts have stopped. ? Prior to working on the generator set, disconnect the spark plug and batter[...]

? Never permit anyone to operate the generator set without proper instructions. ? Never allow children to operate the g enerator set. ? Children and pets must be kept away from the area of operation due to the possibility of burns from hot engine components or injury from any equipment the generator set is powering. ? Always wear eye protection and[...]

? Always treat the elect rical circuits as if they were energized. ? Disconnect all leads plugged into the unit Prior to working on it. ? Have the electrical circuits serviced only by qualified technicians. ? Inspect wiring frequently and replace frayed, broken or poor leads . ? Do not connect this unit to any building's electrical system unle[...]

? ? ? ? FOR GASOLINE OR DIESEL POWERED GENERATOR SETS ? ? ? ? ? Check all fuel supply piping and their connections on a monthly basis for fuel leaks. ? Use only approved piping and componentry in your fuel supply system. ? A professional, experienced technician should only install the fuel su pply system. ? Do not run the fuel line up against any s[...]

TABLE OF CONTENTS SECTION PAGE Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . Prefix Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Generator Specifications . . . . . . . . . . . . . . . . . . . 2 Location Information . . . . . . . . . . . . . . . . . . . . . . 3 Connection Information . . . . . . . . . . . .[...]

Customer Connection Wiring Diagram . . . . . . . . . . . . 33 AE12 Base Outline Drawing . . . . . . . . . . . . . . . . . . . . 34 AE12 OPEN - Connection Diagram . . . . . . . . . . . . . . . . 35 AE12 Enclosed - Wiring Diagram . . . . . . . . .. . . . . . . . . 36 AE12 Enclosed - Connection Diagram . . . . . . . . . . . . . 37 Gen End Componentry [...]

Page 1 of 45 FORWARD This manual contains the information you need to safely and efficiently operate your generator set. During the preparation of this manual every effort was made to ensure the accuracy of its contents. Never operate this generator set without first carefully reading this manual and observing all the safety warnings it presents. W[...]

Page 2 of 45 NOTE: The enclosed information covers basic installation, operating and maintenance for this specific generator. Installation of this generator is the sole responsibility of the owner. Baldor Generators provides an AE Installation manual with the shipment of your generator which contains more specific information regarding the installa[...]

Page 3 of 45 LOCATION The following information is provided to assure that you get the best service from your Automatic Emergency Generator. Several factors should be taken into consideration in choosing the best location in which to permanently mount this unit. SURFACE: Baldor Generators strongly recommends that your AE Unit be installed on a conc[...]

Page 4 of 45 CONNECTION INFORMATION Your new Baldor Pow'R Gard Generator has all interconnecting wiring, which is terminated at a junction box. All wiring will be clearly labeled as being load, remote start contacts, and AC input terminals and are to be connected as described below: LOAD - These connections are rated and sized according to the[...]

Page 5 of 45 Do no t connect the ground wire from the generator set to a water pipe or a ground used by a radio system. IMPROPER GROUNDING CAN CAUSE EQUIPMENT DAMAGE, SEVERE INJURY OR DEATH. INSPECT AND MAINTAIN THE GROUNDING SYSTEM IN ACCORDANCE WITH AL L APPLICABLE CODES. CONNECTIONS TO HOUSE WIRING: Any electrical generator that is temporarily c[...]

Page 6 of 45 ENGINE INFORMATION This operator 's manual only covers basic day - to - day engine operating instructions. However, the engine manufacturer's manual is included with your generator set and should be referred to for any additional information you may need. Become familiar with and follow all the engine manufacturer's oper[...]

Page 7 of 45 MAINTENANCE MAINTENANCE SHOULD ONLY BE PERFORMED ON THE GENERATOR SET AFTER THE ENGINE HAS STOPPED AND THE GENERATOR SET HAS COOLED DOWN. THE BATTERY AND SPARK PLUG SHOUL D ALSO BE DISCONNECTED PRIOR TO PERFORMING MAINTENANCE. GENERATOR END MAINTENANCE Generator end maintenance consists of cleaning the generator set, inspecting the wir[...]

Page 8 of 45 ADJUSTMENTS: v The engine should be checked for proper speed setting(s). v Adjust the engine speed to 3720 RPM's (62 Hz) with no load applied to the generator set. ENGINE MAINTENANCE MA INTENANCE SHOULD ONLY BE PERFORMED ON THE GENERATOR SET AFTER THE ENGINE HAS STOPPED AND THE GENERATOR SET HAS COOLED DOWN. THE BATTERY AND SPARK [...]

Page 9 of 45 STORAGE OR LONG TERM NON - USAGE If you will not be using the generator set for a significant amount of time (3 months or longer) you should s tore the generator to prevent any problems that could arise from sitting idle. Please fully read the following guidelines prior to storing the unit. 1 Drain the used oil from the engine's c[...]

Page 10 of 45 ORDERING PARTS When Generator repair parts are needed, they may be o btained by calling the Customer Service Department at Baldor Generators or the nearest local office of Baldor Electric Motors, Drives and Generators. Accurate information such as the following will assure that you receive accurate parts for your particula r generator[...]

Page 11 of 45 GENERAL INSTALLATION & SITE SELECTION GUIDELINES This information is for general reference only! It must not be used as the single source of information for installing the generator set. For more specific/detailed information read the installation manual that accompanied the generator set. Incorrect installation of the generator s[...]

Page 12 of 45 COOLING CONSIDERATIONS 1. when installing the generator set, it should be mounted no closer than 5 feet away from any wall or object that would inhibit the cooling air flow that is necessary to operate the unit properly. 2. When installing the generator set inside a non - occupied building, an adequate supply of cooling air must be di[...]

Page 13 of 45 ELECTRICAL INSTALLATION GUIDELINES Incorrect installation of the generator set could result in property damage, injury, or death! Installation of this generator set must be performed by qualified / professional technicians or contractors. This information is for general reference only! It must not be used as the single source of infor[...]

Page 14 of 45 AC POWER CO NNECTIONS These terminal block connections are used to interface the wires/cables from the emergency power supply input terminals located inside the transfer switch. BATTERY CHARGER CONNECTIONS (OPTIONAL) If you purchased a Master Control Systems Inc. Battery charger with your generator set you must run two sets of wires f[...]

Page 15 of 45 UNITS WITHOUT ENCLOSURE The wires from the terminals labeled DK1 and DK2 on the battery charger must be connected across the starter motor. One lead must go to ground and the other must go to the starter motor (or the 'switched' B+ on the Starter Solenoid). DK1 and DK2 are not polarity sensitive and are therefore interchange[...]

Page 16 of 45 Baldor Generators strongly recommends that all electrical devices share a common ground (i.e. Generator Set, Transfer Switch, Battery Charger, Load Devices, etc.). The grounding stud for the generator set is located under customer connection box.[...]

Page 17 of 45 GASEOUS FUEL INFORMA TION INCORRECT INSTALLATION OF THIS GENERATOR SET COULD RESULT IN PROPERTY DAMAGE, INJURY, OR DEATH! INSTALLATION OF THIS GENERATOR SET MUST BE PERFORMED BY A QUALIFIED, PROFESSIONAL TECHNICIAN OR CONTRACTOR. THIS INFORMATION IS FOR GENERAL REFERENCE ONLY! IT MUST NO T BE USED AS THE SINGLE SOURCE OF INFORMATION F[...]

Page 18 of 45 natural gas. A pressure drop of 0.3' (water column) is used to account for a nominal nu mber of fittings and metering equipment. Referring to the fuel consumption figures, we can use this chart to calculate proper sizing. For example, if the engine is located 30 feet from the main fuel source's primary regulator and the engi[...]

Page 19 of 45 Because tank press ures range from 0 to 200 PSI in LPG tanks, these tanks cannot be filled to capacity. ASME tanks are filled to 90% capacity to allow for expansion of gases during increases in temperature. The recommendation of the local certified professional fuel suppli er should be followed when installing storage vessels and fuel[...]

Page 20 of 45 PROPANE GAS FLOW CHART Pipe Capacity in Cubic Feet An engine needs 10,000 BTU's / HP For Propane there are 91,547 BTU's /Gal For Propane there are 2,516 BTU's / Cubic Ft.[...]

Page 21 of 45 NATURAL GAS FLOW CHART Pipe Capacity in Cubic Feet An Engine needs 10,000 BTU's / HP For Natural Gas there are 1,000 BTU's / Cubic Ft.[...]

Page 22 of 45 OPERATION PRIOR TO STARTING THE UNIT: 1. Locate and set up the generator set in an open, dry , well ventilated and reasonably level location. OPERATING THIS UNIT IN AN AREA NOT SUITABLE FOR IT'S PROPER USE MAY CAUSE DAMAGE TO THE UNIT, SEVERE INJURY, OR DE ATH. SEE "LOCATION INFORMATION" SECTION LOCATED ELSEWHERE IN THI[...]

Page 23 of 45 Remote/Auto Mode : This is the position you need to have the Master Control Switch set in when you wish to operate the Generator Set automatically in conjunc tion with a Transfer Switch. This way, the generator set can only be started by making a connection across the remote start connection points on the terminal block located in the[...]

Page 24 of 45 SIMPLE TROUBLESHOOTING Listed below are the more simp le solutions to some of the more common problems that are reported to the Customer Service Department at Baldor Generators. These troubleshooting solutions are meant to be an aid for a person who has minimal electrical knowledge and experience. More in - dep th, detailed troublesho[...]

Page 25 of 45 Alternate Method With the generator running and the end cover removed, momentarily connect a 12 VDC batter y across the capacitor's terminals for a fraction of a second (Having the battery across the capacitor longer than a fraction of a second may damage the windings of the generator). This is called "flashing the generator[...]

Page 26 of 45 TROUBLESHOOTING FOR GASEOUS FU EL SYSTEM GASEOUS FUELS ARE HIGHLY COMBUSTIBLE AND CAN CAUSE EXPLOSIONS, FIRE, INJURY, OR DEATH! THE FUEL SUPPLY SYSTEM MUST ONLY BE INSTALLED AND ADJUSTED BY AN EXPERIENCED, PROFESSIONAL TECHNICIAN USING APPROVED PIPING AND COMPONENTRY. PR IOR TO MAKING ANY ADJUSTMENTS THAT WILL TAKE THE GENERATOR SET O[...]

Page 27 of 45 PROBLEMS AND POSSIBLE SOLUTIONS In Order of Occurrence Inadequate Fuel Supply v Undersized piping - check pressure at se condary regulator, 6 oz. Minimum. v Condensation in line - check for flow potential, water traps and lines that run in and out of buildings. Improper Fuel Mixture v Check main adjustment - see adjustment section (be[...]

Page 28 of 45 Begin by locating the auto prime adjustment wheel. It protrudes from the secondary regulator mounted on the generator and is often covered by a red vinyl cap. The adjustment knob is orange and just below the knob is a gold colored washer. To adjust, hold the wa sher and rotate the orange knob counterclockwise to lean the adjustment. T[...]

Page 29 of 45 GENERATOR FAILS TO START Test each of the following and record actual findings. If your findings do not match the values listed, contact Baldor Generators for Technical Support at ( 920) 236 - 4200. 1. With generator in “OFF” position, place meter on battery terminals in control box (Red to B+, Black to B - ). Should have 12 VDC R[...]

Page 30 of 45 GENERATOR RUNS CONTINUOUSLY OR FAILS TO STOP AFTER RETRANSFER Basic Theory – Publi c Service power energizes ATS ATS holds “R” terminals open Generator test switch or exerciser can start generator, as programmed. Public Service power drops, ATS closes “R” terminals, generator starts. Ground fault problems in the conduit lead[...]

Page 31 of 45 AE SERIES INTERCONNECTION THE FOLLOWING ARE PRINCIPLES OF INSTALLATI ON. PLEASE NOTE: LOCAL, FEDERAL, OR NEC CODES PREVAIL OVER THESE SUGGESTIONS. Abbreviations: GEN = Generator Assembly ATS = Automatic Transfer Switch Load Center = Customer's Normal Panel Emergency Load Center = Those circuits in a separate load box that will be[...]

Page 32 of 45 Normal Operation : ? Public Service power feeds the ATS which connects to the Emergen cy Load Center. ? When Public Service power fails, the ATS closes a contact causing GEN to start. Once AC power from generator is observed at the ATS, the ATS will switch the Emergency Load Center over to the GEN. ? When Public Service power returns [...]

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FOR AE12 UNITS WITHOUT ENCLOSURE OLD PART # NEW PART # DESCRIPTION 120.00500 EA0000A00SP KN Gaseous Fuel Regulator 47.0 0121A 62SA0008A00 Stator assembly 67.00120 62RA0015A00 Rotor Assembly 230.80010 HA3188A01 Bolt, Rotor attaching 387.09056 BA0330A00L* Base 400.21300A HB6181A00* Engine Adaptor Casting 440.92000 HB6022A10* Heat Shield 480.10000 10X[...]

Limited W arranty Unless otherwise provided, Baldor generators are warranted against defects in Baldor workmanship an d materials for a period of time as set forth in the W arranty Period chart below . I f a Baldor product is defective due to Baldor workmanship or materials and the defect occurs during the warranty period, then Baldor will either r[...]

Limited W arranty Continued Notes for W arranty Period: 1. Labor coverage for warrantable repairs is provided for the applicable period not to exceed published rates as contained in the Baldor Generators W arranty Policy . Mileage is allowed only for permanent installations not to exceed published rates as contained in the Baldor Generators W arran[...]

Owner ’ s Responsibilities: The owner is obligated to operate and maintain the generator in accordance with the recommendations published by Baldor Generators in the Operator . The owner is responsible for the costs associated with maintenance and any adjustments that may be required. The owner is responsible for payment of any of the following e[...]

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: Diesel engine exhaust and some constituents are known to the state of California to cause cancer , birth defects[...]