Baldor AE25 - Manuals

Product Safety Information 1-3 MN2415 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 ...

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 ...

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 accur...

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 carrie...

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 ex...

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 inspecti...

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. Table 3-2 defines th...

3-6 Receiving & Installation MN2415 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 ...

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 Table 3-4, a 60 foot run...

Receiving & Installation 3-9 MN2415 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 again...

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 Ph...

Receiving & Installation 3-11 MN2415 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. Figure 3-7 Single Phase Outpu...

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 Outpu...

Receiving & Installation 3-13 MN2415 Frame Ground ConnectionWARNING: 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 cond...

Receiving & Installation 3-15 MN2415 Figure 3-12 Battery Installation Washers & Nut Battery Battery Hold Down Rod Washers & Nut Battery Tray 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...

Receiving & Installation 3-17 MN2415 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 f...

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 contr...

4-2 Operation MN2415 Figure 4-3 Operator Control Panel AE25 OVERSPEED OVERCRANK HIGH TEMPERATURELOW OIL PRESSURE MASTER CONTROL MANUAL RUN AUTO START STOP NAT. GAS L.P. GAS WATER OIL BATTERY DC CONTROL FUSE AC CONTROL FUSE Hour Meter Display Lamps High Temperature − Indicates excessive engine coolan...

4-6 Operation MN2415 Table 4-1 Programmable Functions and Values Function !!!! 1 !!!! 2 Value (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 ...

Operation 4-7 MN2415 Table 4-1 Programmable Functions and Values Continued Function !!!! 1 !!!! 2 Value (Preset in Bold) Cooling Timer f f F F f f f f 0 Seconds g 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 Delay be...

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 deacti...

Operation 4-9 MN2415 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. Table 4-2 Engine Controller Terminal Identification Pin No Description Cable Size N...

Section 5 Troubleshooting and Maintenance Troubleshooting 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 maintena...

5-2 Troubleshooting and Maintenance MN2415 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...

Troubleshooting and Maintenance 5-3 MN2415 Table 5-2 Troubleshooting Guide (Digital Controller Only) Problem Possible Cause Remedy Controller does not power up even withcorrect DC power applied Wiring MistakeLoss of DC Supply Check the battery and wiring to the unit. Check the DC supply.Check the DC...

5-4 Troubleshooting and Maintenance MN2415 Note: See Engine Controller manual for additional information. Table 5-3 Troubleshooting Guide (Analog Controller Only) Problem Possible Cause Remedy Controller cannot be Reset" Engine not stoppedController not in OFF mode Verify the engine is at a comp...

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 posi...

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 Table A-1. Engine parts are identified in the engine manual that was provided with your generator set. Figure A-2 Alternator Assembly 21 22...

Series AE8 A-3 MN2415 Table A-1 Generator Set Parts List Continued Ref No. Part No. Description Open Enclosed Not Shown EH0279A00 Enclosure, Top 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,...

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 ...

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 Table B-1. Engine parts are identified in the engine manual that was provided with your generator set. Figure B-2 Alternator Assembly 21 2...

Series AE10 B-3 MN2415 Table B-1 Generator Set Parts List Continued Ref No. Part No. Description Open Enclosed Not Shown EH0279A00 Enclosure, Top 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...

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 AE11 Series AE11 C-1 MN2415 Information in this Appendix applies to the AE11 Generator. Operator Panel Configuration Figure C-1 AE11 Operator Panel Stop Manual Run AutoStart Hour Meter (fuel solenoid energized Low Oil Pressure Shutdown High Coolant Temperature Shutdown Over Speed S...

C-2 Series AE11 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 Table C-1. Engine parts are identified in the engine manual that was provided with your generator set. Figure C-2 Alternator Assembly 21 2...

Series AE11 C-3 MN2415 Table C-1 Generator Set Parts List Continued Ref No. Part No. Description Not Shown EH0491A02 Enclosure, Top Not Shown EH0491A11 Enclosure, Access Panel Not Shown EH0491A01 Enclosure, Front Not Shown EH0491A10 Enclosure, Right Side (Hinge) & Rear Not Shown EH0491A13 Enclos...

Series AE11 C-5 MN2415 Figure C-7 AE11 Customer Connection Diagram

C-6 Series AE11 MN2415 Figure C-8 AE11 Generator Connection Diagram

Series AE11 C-7 MN2415 Figure C-9 AE11 Engine Connection Diagram

C-8 Series AE11 MN2415 Figure C-10 AE11 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 AE11 C-9 MN2415 Figure C-11 AE11 Customer Wiring Interface Diagram

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 TEMPERATURELOW OIL PRESSURE MASTER CONTROL MANUAL RUN AUTO START STOP NAT. GAS L.P. GAS WATER OIL BATTERY DC ...

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 Table D-1. Engine parts are identified in the engine manual that was provided with your generator set. Figure D-2 Alternator Assembly 1 2 ...

Series AE25 D-3 MN2415 Table D-1 Generator Set Parts List Continued Ref No. Part No. Description Not Shown EH0278A78 Enclosure, Top Not Shown EH0278B72 Enclosure, Door Not Shown EH0386A02 Enclosure, Front Not Shown EH0386A03 Enclosure, Rear Not Shown EA0006A08 Radiator Not Shown FN0027A00 Fan, Radia...

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 STATES ARIZONA PHOENIX4211 S 43RD PLACEPHOENIX, AZ 85040PHONE: 602−470−0407FAX: 602−470−0464 CALIFORNIA LOS ANGELES6480 FLOTILLACOMMERCE, CA 90040PHONE: 323−724−6771FAX: 323−721−5859 HAYWARD21056 FORBES STREETHAYWARD, CA 94545PHONE: 510−785−9900FAX: 510−785−9910 COLORA...

© Baldor Electric Company MN2415 Printed in USA 5/05 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,...