Automatic Emergency Generator AE8, AE10, AE11 and AE25 Installation & Operating Manual 5/05 MN2415
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix A Series AE8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Panel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
Symbols This symbol is shown throughout the manual to indicate a connection to ground reference point. 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. Precaution Statements Used In This Manual There are three classifications of precautionary statements used in this manual.
Operation Warning Statements Continued WARNING: 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. WARNING: Be sure that you understand how to stop the engine quickly in case of an emergency situation. Become familiar with the controls and safety systems provided with this generator set.
Warning Statements Continued Installation WARNING: 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. WARNING: Disconnect the battery’s ground terminal before working in the vicinity of the battery or battery wires. Contact with the battery can result in electrical shock when a tool accidently touches the positive battery terminal or wire.
Warning Statements Continued Maintenance WARNING: Before servicing the generator set, be sure to disconnect the battery terminals to prevent accidental engine rotation or starting. WARNING: Disconnect the battery’s ground terminal before working in the vicinity of the battery or battery wires. Contact with the battery can result in electrical shock when a tool accidently touches the positive battery terminal or wire.
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 MN2415
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.
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.
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 the AC power terminals of the generator set so that when the generator set starts it will provide immediate cooling air flow. The fan will operate until the generator set stops.
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. A carbon monoxide tester may be installed to detect the presence of the deadly gas during times when you are in the building with the engine running (during testing or maintenance).
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. Table 3-2 defines the flow rate required for each fuel type. Note: The AE25 must be ordered for use with Natural gas or LPG.
Natural Gas Connections The incoming pressure must be as indicated in Table 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. Table 3-3 Natural Gas Flow Rate (Cubic Feet per Hour) per Pipe Length Pipe Length (Feet) 15 30 45 60 75 90 105 120 150 180 210 240 270 300 Iron Pipe Size 1/ ″ 2 3/ ″ 4 73 50 41 37 165 115 95 83 74 67 63 1. 2. 3.
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 + 63.5 cubic feet per hour. 2, 516 From Table 3-4, a 60 foot run requires a minimum 1” pipe at full engine load. LP Gas Connections (vapor withdrawal only) The LPG connections should only be made if your generator is setup to run on LPG.
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.
General Wiring Considerations 1. Control wires and Power wires cannot 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 sure that all the electrical components (generator set, transfer switch, battery charger, etc.) share a common hardwired ground. 4.
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.
AE11 Electrical Connections Applies only to AE11 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.
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.
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.
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, AE11, and AE25. The generator is shipped with no battery installed. WARNING: Installation and servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions.
Figure 3-12 Battery Installation 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. Washers & Nut Battery Hold Down Bar (Install away from terminals) Battery Washers & Nut Battery Hold Down Rod Battery Tray 4. 5. 6. 7. 8. Connect the positive lead to the positive (+) battery terminal. Connect the negative lead to the negative (−) battery terminal. Do not lay tools or metal parts on top of batteries.
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−saturated condition. Moisture can cause insulation breakdown, making it necessary to return the generator to the factory for repair, and consequent expense and loss of time.
Post Installation Checks Continued 20. Verify 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 Troubleshooting. 23. With the engine running, several checks must be made: a. Verify there are no fuel leaks.
3-18 Receiving & Installation MN2415
Section 4 Operation 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 and AE10 Master Control Switch (Run Manual −Off − Remote Auto) Run Manual − Immediately energizes the crank cycle to start Master Control the generator set and produce power.
Figure 4-3 Operator Control Panel AE25 WATER HIGH TEMPERATURE LOW OIL PRESSURE OVERSPEED OVERCRANK STOP MANUAL RUN AUTO START MASTER CONTROL Display Lamps Hour Meter Meters DC Control Fuse AC Control Fuse OIL BATTERY Hour Meter DC CONTROL FUSE AC CONTROL FUSE NAT. GAS L.P. GAS High Temperature − Indicates excessive engine coolant temperature. Low Oil Pressure − Indicates low engine oil pressure. Overspeed − Indicates engine speed is greater than preset limit.
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 speed is reached, the crank signal is terminated. While the engine accelerates to normal speed, the controller continuously monitors the engines speed signal.
AE11 Operating Procedures The AE11 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 initiated when the remote start input from the transfer switch or other device is activated. To prevent a false remote start, the Start Delay timer is initiated.
Shutdowns Continued Fail To 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 Shutdown lamp is On.
Table 4-1 Programmable Functions and Values Value (Preset in Bold) ! 1 ! 2 0 Seconds 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 F F F Used to pre−heat the engine prior to cranking. The output is active for the duration of the setting, prior to cranking.
Table 4-1 Programmable Functions and Values Continued Value (Preset in Bold) 1 ! 2 ! 0 Seconds 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 F F F Delay between opening the generator load−switching device and stopping the engine to allow time for the engine to cool down before being stopped. This is particularly useful when used in conjunction with turbo−charged engines.
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 energize the common warning and common alarm output.
Electrical Connections The engine controller is installed into the AE11 from the factory. The information provided here will help you connect external devices to the Auxiliary inputs and outputs.
Figure 4-5 Garretson KN Fuel Valve Outlet Mount Primer (Optional) Lock−Off Adjustment Inlet 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 help is not available Garretson will furnish you a list of repair shops with the proper service information.
Section 5 Troubleshooting and Maintenance Maintenance MN2415 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 engine owner’s manual take precedence over any of the following general recommendations. General: 1. Inspect the fuel system for leaks. Replace all defective components immediately. 2.
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 should be referred to the Baldor Generator Service Department by calling (920) 236−4200.
Table 5-2 Troubleshooting Guide (Digital Controller Only) Problem Controller does not power up even with correct DC power applied Possible Cause Wiring Mistake Loss of DC Supply Remedy Check the battery and wiring to the unit. Check the DC supply. Check the DC fuse. Check DC supply voltage is not above 35 Volts or below 9 Volts. Check the operating temperature is not above 70 °C. Low Oil Pressure fault Low Oil Pressure Defect in sender or wiring Check engine oil pressure.
Note: See Engine Controller manual for additional information. Table 5-3 Troubleshooting Guide (Analog Controller Only) Problem Controller cannot be Reset" Possible Cause Engine not stopped Controller not in OFF mode Remedy Verify the engine is at a complete stop before trying to reset. Set the controller to the OFF mode before trying to reset.
Appendix A Series AE8 Information in this Appendix applies to the AE8 Generator. Operator Panel Configuration Figure A-1 AE8 Operator Panel Master Control Switch RUN OFF REMOTE MANUAL AUTO Controller Fuse CONTROLLER FUSE Circuit Breaker Lamp Master Control Switch − A three position switch allows choice of automatic or manual operating mode. Run Manual − In this position the controller immediately energizes the crank cycle to start the generator set and produce power.
Replacement Parts Replacement parts assembly views for the Generator set are shown in Figure A-2 and A-3. Parts information is provided in Table A-1. Engine parts are identified in the engine manual that was provided with your generator set. Figure A-2 Alternator Assembly 5 15 16 23 23 6 RM1088A01 RM1088A06 RM1088A07 HB6150A01 HB6150A00 1 21 8 22 2 7 3 21 4 Figure A-3 Frame Assembly 20 20 Table A-1 Generator Set Parts List Ref No. 1 2 3 4 5 5 6 6 7 8 15 16 16 20 20 21 22 22 23 23 Part No.
Table A-1 Generator Set Parts List Continued Ref No. Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Part No.
Figure A-4 AE8 Customer Connection Diagram A-4 Series AE8 MN2415
Figure A-5 AE8 Open Frame Wiring Diagram MN2415 Series AE8 A-5
Figure A-6 AE8 Enclosed Wiring Diagram A-6 Series AE8 MN2415
Appendix B Series AE10 Information in this Appendix applies to the AE10 Generator. Operator Panel Configuration Figure B-1 AE10 Operator Panel Master Control Switch RUN OFF REMOTE MANUAL AUTO Controller Fuse CONTROLLER FUSE Circuit Breaker Lamp Master Control Switch − A three position switch allows choice of automatic or manual operating mode. Run Manual − In this position the controller immediately energizes the crank cycle to start the generator set and produce power.
Replacement Parts Replacement parts assembly views for the Generator set are shown in Figure B-2 and B-3. Parts information is provided in Table B-1. Engine parts are identified in the engine manual that was provided with your generator set. Figure B-2 Alternator Assembly 5 15 23 6 7 8 RM1088A07 21 22 21 1 2 3 4 Figure B-3 Frame Assembly 20 20 Table B-1 Generator Set Parts List Ref No. 1 2 3 4 5 6 7 8 Not Shown 15 20 20 21 22 23 Part No.
Table B-1 Generator Set Parts List Continued Ref No. Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Part No.
Figure B-4 AE10 Customer Connection Diagram B-4 Series AE10 MN2415
Figure B-5 AE10 Open Frame Wiring Diagram MN2415 Series AE10 B-5
Figure B-6 AE10 Enclosed Wiring Diagram B-6 Series AE10 MN2415
Appendix C Series AE11 Information in this Appendix applies to the AE11 Generator.
Replacement Parts Replacement parts assembly views for the Generator set are shown in Figure C-2 and C-3. Parts information is provided in Table C-1. Engine parts are identified in the engine manual that was provided with your generator set. Figure C-2 Alternator Assembly 5 15 6 23 7 8 RM1088A15 21 1 2 22 3 4 Figure C-3 Frame Assembly 20 Table C-1 Generator Set Parts List Ref No. 1 2 3 4 5 6 7 8 Not Shown 15 20 21 22 23 Part No.
Table C-1 Generator Set Parts List Continued Ref No. Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Not Shown Part No.
7. 8. Remove the insert from the 90° elbow, Figure C-5. Connect the hose and hose clamp to the 90° elbow. Figure C-5 90° Elbow with LPG Insert removed. Hose (fuel line) and clamp installed Insert 9. Remove the control box cover by removing the six 7/16” bolts. to gain access to the customer connection terminal strips. 10. Remove the jumper assembly attached to the demand regulator. 11. Locate the two terminals labeled FUEL JUMPER and connect the jumper assembly between them. 12.
Figure C-7 AE11 Customer Connection Diagram MN2415 Series AE11 C-5
Figure C-8 AE11 Generator Connection Diagram C-6 Series AE11 MN2415
Figure C-9 AE11 Engine Connection Diagram MN2415 Series AE11 C-7
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.
Figure C-11 AE11 Customer Wiring Interface Diagram MN2415 Series AE11 C-9
C-10 Series AE11 MN2415
Appendix D Series AE25 Information in this Appendix applies to the AE25 Generator. Operator Panel Configuration Figure D-1 AE25 Operator Panel WATER HIGH TEMPERATURE LOW OIL PRESSURE OVERSPEED OVERCRANK STOP MANUAL RUN AUTO START MASTER CONTROL Display Lamps Hour Meter Meters DC Control Fuse AC Control Fuse OIL BATTERY Hour Meter DC CONTROL FUSE AC CONTROL FUSE NAT. GAS L.P. GAS High Temperature − Indicates excessive engine coolant temperature.
Replacement Parts Replacement parts assembly views for the Generator set are shown in Figure D-2 and D-3. Parts information is provided in Table D-1. Engine parts are identified in the engine manual that was provided with your generator set. Figure D-2 Alternator Assembly 5 6 7 1 9 2 8 3 4 Figure D-3 Frame Assembly 15 RM1088A11 (TS25−Green) RM1088A12 (TS45−Red) RM1088A13 (TS80−White) RM1088A25 (TS45−Green) HB6072A05 HB6072A04 21 22 20 Table D-1 Generator Set Parts List Ref No.
Table D-1 Generator Set Parts List Continued Ref No.
Figure D-4 AE25 Receptacle Connection Diagram D-4 Series AE25 MN2415
Figure D-5 AE25 Engine Compartment Connection Diagram MN2415 Series AE25 D-5
Figure D-6 AE25 Control Box Connection Diagram D-6 Series AE25 MN2415
Baldor District Offices UNITED STATES ARIZONA PHOENIX 4211 S 43RD PLACE PHOENIX, AZ 85040 PHONE: 602−470−0407 FAX: 602−470−0464 CALIFORNIA LOS ANGELES 6480 FLOTILLA COMMERCE, CA 90040 PHONE: 323−724−6771 FAX: 323−721−5859 HAYWARD 21056 FORBES STREET HAYWARD, CA 94545 PHONE: 510−785−9900 FAX: 510−785−9910 COLORADO DENVER 2520 W BARBERRY PLACE DENVER, CO 80204 PHONE: 303−623−0127 FAX: 303−595−3772 FAX: 586−978−9969 MICHIGAN Continued GAND RAPIDS 668 3 MILE ROAD NW GRAND RAPIDS, MI 49504 PHONE: 616−785−1784 F
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.
