Page 2 - Safety Warnings
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 g...
Page 4 - FOR GASOLINE OR DIESEL POWERED GENERATOR SETS
? Always treat the electrical 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 un...
Page 6 - TABLE OF CONTENTS; SECTION
TABLE OF CONTENTS SECTION PAGE Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . Prefix Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Generator Specifications . . . . . . . . . . . . . . . . . . . 2 Location Information . . . . . . . . . . . . . . . . . . . . . ...
Page 8 - Page 1 of 45; FORWARD; severe injury or even death.
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 an...
Page 9 - Page 2 of 45; specific generator.; SPECIFICATIONS FOR YOUR AE12 bBALDOR GENERATOR SET
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 contain...
Page 10 - Page 3 of 45; LOCATION; DIRT; inadequate, a fan to boost circulation should be utilized.; EXHAUST; This unit must not be operated in a confined space or an enclosed
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 r...
Page 11 - Page 4 of 45; CONNECTION INFORMATION; LOAD; If you are not sure of the gauge wire needed for your; REMOTE START CONTACTS -; This two wire connection, once connected to an appropriate
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 con...
Page 12 - Page 5 of 45; Do not; Any electrical generator that is temporarily connected; only by a competent electrician and only after the main service
Page 5 of 45 Do not 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 ALL APPLICABLE CODES. CONNECTIONS TO HOUSE WIRING...
Page 13 - Page 6 of 45; ENGINE INFORMATION; obtain the electrical power it was built to produce.
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 al...
Page 14 - Page 7 of 45; MAINTENANCE; GENERATOR END MAINTENANCE; Repair or replace any problems prior to using the unit.
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 SHOULD ALSO BE DISCONNECTED PRIOR TO PERFORMING MAINTENANCE. GENERATOR END MAINTENANCE Generator end maintenance consists ...
Page 15 - Page 8 of 45; The engine should be checked for proper speed setting(s).; ENGINE MAINTENANCE
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 MAINTENANCE SHOULD ONLY BE PERFORMED ON THE GENERATOR SET AFTER THE ENGINE HAS STOPPED AND THE GENERATOR...
Page 16 - Page 9 of 45; STORAGE OR LONG TERM NON-USAGE; do not; reconnect it. This will help prevent
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 store the generator to prevent any problems that could arise from sitting idle. Please fully read the following guidelines prior to storing the unit...
Page 17 - Page 10 of 45; ORDERING PARTS; Provide the serial number of the generator set.; SERVICE; contacting the factory:
Page 10 of 45 ORDERING PARTS When Generator repair parts are needed, they may be obtained 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 rece...
Page 18 - Page 11 of 45; GENERAL INSTALLATION & SITE SELECTION GUIDELINES; an LP fume concentration.
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 genera...
Page 19 - Page 12 of 45; COOLING CONSIDERATIONS; as not to be re-circulated with the cool intake air.; NOISE CONSIDERATIONS
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 buildi...
Page 20 - Page 13 of 45; ELECTRICAL INSTALLATION GUIDELINES; REMOTE START CONNECTIONS
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!...
Page 21 - Page 14 of 45; AC POWER CONNECTIONS; power supply input terminals located inside the transfer switch.; BATTERY CHARGER CONNECTIONS
Page 14 of 45 AC POWER CONNECTIONS 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 yo...
Page 22 - Page 15 of 45; UNITS WITHOUT ENCLOSURE
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...
Page 23 - Page 16 of 45
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 24 - Page 17 of 45; GASEOUS FUEL INFORMATION; THIS INFORMATION IS FOR GENERAL REFERENCE ONLY! IT MUST NOT; and proper installation.; considered when installing the gaseous fuel supply piping:
Page 17 of 45 GASEOUS FUEL INFORMATION 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 N...
Page 25 - Page 18 of 45; LP Tanks
Page 18 of 45 natural gas. A pressure drop of 0.3' (water column) is used to account for a nominal number 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 ...
Page 26 - Page 19 of 45; installing storage vessels and fuel piping.; Fuel valves
Page 19 of 45 Because tank pressures 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 supplier should be f...
Page 27 - Page 20 of 45; PROPANE GAS FLOW CHART
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 28 - Page 21 of 45; NATURAL GAS FLOW CHART
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 29 - Page 22 of 45; OPERATION; PRIOR TO STARTING THE UNIT:; the level that is recommended by the engine manufacturer.; CONTROLS AND THEIR FUNCTIONS; position for a minimum of 10 seconds.
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 DEATH. SEE "LOCATION INFORMAT...
Page 30 - Page 23 of 45; Fault Indicator Light:; whenever a fault condition develops.; Fuse for the Control Logic Board; current from getting to the circuit board.; Circuit Breaker
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 conjunction with a Transfer Switch. This way, the generator set can only be started by making a connection across the remote start connec...
Page 31 - Page 24 of 45; SIMPLE TROUBLESHOOTING; NO OUTPUT; The generator speed is too slow; . If the generator is turning too slow the generator set; Bad circuit breaker; . Loss of residual magnetism will not allow the generator's
Page 24 of 45 SIMPLE TROUBLESHOOTING Listed below are the more simple 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 ...
Page 32 - Page 25 of 45; Alternate Method; LOW VOLTAGE OUTPUT; Generator speed too slow; . If the generator is turning too slow, the generator set will; Broken wires or loose connections.; Broken wires or loose connections can cause the; HIGH VOLTAGE OUTPUT; Generator speed too fast.; If the generator is turning too fast the generator set will
Page 25 of 45 Alternate Method With the generator running and the end cover removed, momentarily connect a 12 VDC battery 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)....
Page 33 - Page 26 of 45; PRIOR TO MAKING ANY ADJUSTMENTS THAT WILL TAKE THE; in the engine control circuitry or the engine itself.; BASIC DESCRIPTION; Fuel supply is on and available at the fuel valve.
Page 26 of 45 TROUBLESHOOTING FOR GASEOUS FUEL 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. PRIOR TO MAKING AN...
Page 34 - Page 27 of 45; PROBLEMS AND POSSIBLE SOLUTIONS; ADJUSTMENTS
Page 27 of 45 PROBLEMS AND POSSIBLE SOLUTIONS In Order of Occurrence Inadequate Fuel Supply v Undersized piping - check pressure at secondary 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 C...
Page 35 - Page 28 of 45; Check that all fuel supply lines are turned on (where applicable).; the output terminals and anywhere the generator is connected.; applied load) is smooth. This will most likely be a slight rotation
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 washer and rotate the orang...
Page 36 - Page 29 of 45; GENERATOR FAILS TO START; when; ELECTRICAL SYSTEM
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 ...
Page 37 - Page 30 of 45; GENERATOR RUNS CONTINUOUSLY OR FAILS TO STOP AFTER RETRANSFER
Page 30 of 45 GENERATOR RUNS CONTINUOUSLY OR FAILS TO STOP AFTER RETRANSFER Basic Theory – Public 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. Gr...
Page 38 - Page 31 of 45; AE SERIES
Page 31 of 45 AE SERIES INTERCONNECTION THE FOLLOWING ARE PRINCIPLES OF INSTALLATION. 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 ...
Page 39 - Page 32 of 45
Page 32 of 45 Normal Operation: ? Public Service power feeds the ATS which connects to the Emergency 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 ...
Page 50 - Limited Warranty; Notes for Warranty Period:; Owner ’s Responsibilities:; specifically included within the terms of specific warranty.
Limited Warranty Continued Notes for Warranty Period: 1. Labor coverage for warrantable repairs is provided for the applicable periodnot to exceed published rates as contained in the Baldor GeneratorsWarranty Policy. Mileage is allowed only for permanent installations not toexceed published rates as...
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