Baldor AE12 User Manual

4 (1)
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 battery to prevent accidental
starting.
? Use only original equipment or authorized replacement parts. Use of correct parts will assure the operator
of the safety integrity that was designed into the unit.
? Unauthorized modifications to the generator set may impair the function and/or safety of the unit. ? Do not operate the generator set without a muffler. Inspect periodically and replace if necessary. ? Do not touch the hot exhaust components or the high voltage spark plug and coil terminals. While Spark
Plug Voltages are not normally lethal, an involuntary jerk of the hand caused by a hot surface or by an electrical shock can result in injury.
? Repair of electrical generating equipment requires specialized skills. Repair personnel must have a
thorough understanding of generator and small engine repair procedures.
? Never inhale exhaust gases. They contain carbon monoxide; a colorless, odorless and extremely
dangerous gas that can cause unconsciousness or death. Symptoms of carbon monoxide poisoning can include: dizziness, nausea, headaches, sleepiness, vomiting or incoherency. If you or anyone else experiences any of these symptoms, get out into the fresh air immediately. Shut the unit down and do not operate it until it has been inspected and, if necessary, repaired.
? Never Operate the generator set indoors or in a poorly ventilated area such as a tunnel or cave. ? CALIFORNIA PROPOSITION 65 WARNING: engine exhaust from this product contains chemicals known
to the state of California to cause cancer, birth defects or other reproductive harm.
? Know how to stop the engine quickly and understand the operation of all controls.
? Never permit anyone to operate the generator set without proper instructions. ? Never allow children to operate the generator 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 Hearing protection when working near the generator set. ? Operate the generator set only with the guards, shields and other safety items in place and working
properly.
? Do not put hands, feet, tools or other objects near rotating parts. ? Use reasonable care when moving or lifting the unit. The generator set may move around inside the wrap
frame creating "Pinch Points".
? Do not run the generator set while it is being moved. ? Do not support the generator set from the top of the wrap frame. ? Do not operate the generator set while under the influence of alcohol, drugs or medication. ? When transporting or using a generator set with the wheel option, secure the unit to prevent it from moving
around.
? Do not tamper with or change the engine speed as it has been preset at the factory for proper operation. ? Keep hands and face away from the carburetor when the air cleaner is being moved. A sudden backfire
can cause serious burns.
? Be careful of hot parts. The muffler and other generator parts become very hot while the engine is running. ? Do not "jump start" the generator set. ? Sulfuric acid can cause severe injury and can give off gases, which are corrosive and potentially explosive.
Avoid contact with skin, eyes, and clothing. In case of contact, flush area immediately with water.
? When transporting a generator set, secure it to prevent it from moving or shifting.
? Know how to stop the engine quickly and understand the operation of all controls. ? Do not operate electrical equipment while standing in water, on wet ground or with wet hands or shoes. ? Use extreme caution when working on electrical components. Potentially dangerous voltage is present
when the engine is running.
? 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 unit to any building's electrical system unless you utilize an approved transfer switch or
the main service entrance switch has been disconnected and locked open.
? Circuit overload protection must be provided in accordance with national electrical codes and local
regulations.
? Check GFCI Receptacles monthly by using the "Test" and "Reset" buttons designed into them. ? Depending on your application it may be mandatory to ground or not ground this unit to earth ground.
Comply with local electrical codes.
? ? ? ? FOR GASOLINE OR DIESEL POWERED GENERATOR SETS ? ? ? ?
? Operate the generator set on a level surface. If the generator set is tilted, fuel spillage may result. ? Handle fuel with care. It is highly flammable. Use only clean, properly marked and approved safety
containers for refueling and storing fuel.
? Stop the engine and allow it to cool before refueling. ? Do not overfill the fuel tank. Only fill the tank to within 1/2" of the top of the tank to allow space for fuel
expansion.
? If fuel is spilled, wipe it up carefully and wait until the fuel has dried before starting the engine. ? Make sure the fuel cap is properly closed after refueling. ? Never operate the generator set while smoking. ? Never operate the generator set near an open flame. ? Never store the generator set with fuel in the tank indoors or in an enclosed, poorly ventilated enclosure
where fuel fumes may reach an open flame, electrical spark or pilot light as on a furnace, water heater, clothes dryer, etc.
? When transporting over long distances or rough roads, drain the fuel tank to prevent leakage and spillage.
? ? ? ? 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 supply system. ? Do not run the fuel line up against any sharp objects. ? Comply with NFPA regulations and your local codes in regard to shut-off valves, regulators, etc. and any
other recommendations or requirements they may have.
? Keep the generator set at least three feet away from buildings or other structures. ? Keep the generator set away from flammable and other hazardous materials (trash, rags, lubricants,
explosives, paints, etc.)
? Keep the generator set free of grass, leaves and excessive grease and oils. ? Allow the generator set to cool before transporting it or storing it indoors. ? Have fire extinguisher accessible and nearby while operating the generator set. ? This generator set must not be used on or near any forest covered brush covered or grass covered land
unless the engine's exhaust system is equipped with a spark arrester and it must be maintained in effective working order by the operator.
? Operation inside an enclosed compartment or building is a potential fire hazard and should not be done
unless approval is obtained from Baldor Generators. Engine/Generator overheating can cause severe damage due to restricted, obstructed or improper air-flow that is necessary for the proper cooling of the unit.
? Hot exhaust gases being discharged by the engine must never be directed toward anything that could
catch fire or explode.
TABLE OF CONTENTS
SECTION PAGE
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . Prefix
Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Generator Specifications . . . . . . . . . . . . . . . . . . . 2 Location Information . . . . . . . . . . . . . . . . . . . . . . 3
Connection Information . . . . . . . . . . . . . . . . . . . 4
Engine Information . . . . . . . . . . . . . . . . . . . . . . . 6
Basic Generator Maintenance . . . . . . . . . . . . . . 7
Basic Engine Maintenance . . . . . . . . . . . . . . . . . . 8
Storage or Long Term Non-Use Instructions . . . . . 9
Parts & Service Information . . . . . . . . . . . . . . . . . . 10
General Installation & Site Selection Guidelines . . . 11
Electric Installation Guidelines . . . . . . . . . . . . . . . . 13
AE8 Enclosed Assembly Diagram . . . . . . . . . . . . . . 16
Connection Box for AE8/10 Units with Enclosure. . . . 17
AE8 and AE10 Installation Diagram. . . . . . . . . . . . . 16
Basic Gaseous Fuel Information. . . . . . . . . . . . . . . . 17
Propane Gas Flow Chart . . . . . . . . . . . . . . . . . . . . . 20
Natural Gas Flow Chart. . . . . . . . . . . . . . . . . . . . . . 21
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Simple Electrical Troubleshooting . . . . . . . . . . . . . . 24
Gaseous Fuel System Troubleshooting . . . . . . . . . . . 26
Electrical System Troubleshooting . . . . . . . . . . . . . . 29
AE Series Interconnection . . . . . . . . . . . . . . . . . . . . 31
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 Diagram . . . . . . . . . . . . . . .. . 40
Parts Break Down for AE12 . . . . . . . . . . . . . . . . . . 41
Warranty Information . . . . . . . . . . . . . . . . . . . . . . 43
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. While safety is built into every Baldor Pow'R Gard generator set, careless or improper operation could possibly result in mechanical failure, property damage, severe injury or even death.
Note that this manual covers only very basic information in regards to the engine. A separate owner's manual for the engine is supplied with this unit for your use. Please refer to this manual for information relative to engine operation, maintenance, recommendations, and additional safety warnings.
As soon as you receive your generator set, inspect it closely for shipping damage. If you find some damage notify the transportation company immediately and file a freight damage claim.
Think of this manual as a tool to help you get the most out of your generator set. We strongly suggest that you keep this manual with your generator set and refer to it when questions arise in regards to its operation.
Baldor Generators has been in business since 1965. The generator sets we manufacture have earned the reputation of being of high quality and dependability. We take pride in this fact and continue to keep our quality standards high on the list of priorities. We are also constantly researching new technological ideas to determine if they could be used to make our generator sets even better.
Thank you for purchasing your Baldor generator set.
Effective: February 26, 1998 Revised, August 12,2002 Form#: S-PSG-001-25
Page 1 of 45
SPECIFICATIONS FOR YOUR AE12 bBALDOR GENERATOR SET
RATINGS: 12 KW ENGINE CHARACTERISTICS: FUEL TYPE: LP/Natural Gas Make: ONAN ELECTRICAL CHARACTERISTICS: Model: P224 Voltage: 120/240 Cooling: Air Phase: 1 No. Cylinders 2 Power Factor: 1 H.P. 24.0 Amps: 100/50 R.P.M.: 3600 Hertz: 60 Voltage Regulation (+/-): 1% FUEL CONSUMPTION (Full Load): Frequency Regulation: 5% LP Gas: 96 C.F.H Total Harmonic Distortion: <8% Natural Gas: 260 C.F.H. Motor Starting (HP): 6
Dimensions w/ enclosure - IN. (LxWxH) : 44 1/2 x 29 x 38 3/4 Weight: 585 Lbs. Dimensions w/o enclosure - IN. (LxWxH) : 33 x 27 x 30 Weight: 389 Lbs.
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 installation of your AE Unit.
Any questions regarding this information may be directed to the Customer Service department at Baldor Generators.
This information is designed to be a guide for an experienced electrician. Those not qualified should not attempt installation.
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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 concrete or cement slab of appropriate size relative to the generator's base which is at least five (5) feet from any building, structure, shrubbery, or any other obstruction that could possibly catch fire due to the extreme heat output of this generator set.
MOISTURE: All electrical equipment should be protected from excessive moisture. Failure to do so will result in deterioration of the wiring insulation and may result in short circuits and a possible electrocution hazard.
OPERATING ELECTRICAL EQUIPMENT IN WET ENVIRONMENTAL
CONDITIONS CREATES A POTENTIAL ELECTROCUTION HAZARD. DO NOT OPERATE ELECTRICAL EQUIPMENT WHILE STANDING IN WATER, ON WET GROUND, OR WITH WET HANDS OR SHOES.
DIRT: Foreign materials such as dust, sand, and other abrasive materials have a tendency to
cause excessive wear to both engine and generator parts. It is important that the unit be permanently located and operated in a reasonable clean environment.
HEAT: All engines give off considerable heat when running. Since the engine and your generator set uses air to keep it cool it is important that the temperature of the area in which it is located does not exceed 100 degrees F (Even while it is running). Where natural ventilation is inadequate, a fan to boost circulation should be utilized.
EXHAUST: Exhaust gases from internal combustion engines are extremely poisonous. We recommend that this unit not be placed in an indoor environment. However, if this is the application you choose, the engine exhaust fumes must be vented to the outside.
EXHAUST FUMES CAN CAUSE SEVERE INJURY OR DEATH. ALWAYS
OPERATE IN A WELL VENTILATED AREA.
CONFINED SPACE: This unit must not be operated in a confined space or an enclosed
compartment/area. Running the generator set in this environment is a potential fire hazard and is not authorized. Engine and generator overheating damage could also occur due to restricted cooling air flow to and from the unit.
OPERATING THIS UNIT IN AN AREA WITHOUT ADEQUATE
VENTILATION CREATES A POTENTIAL FIRE HAZARD. ALWAYS OPERATE THIS UNIT IN A WELL VENTILATED AREA.
Page 3 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 KW of the generator. Proper lead wire from these points to the automatic transfer switch (or load switching device)
is mandatory. See enclosed transfer switch information for corresponding generator input terminals.
WIRING - Use sufficiently large insulated wire to connect the generator set to the load. The gauge of wire will depend largely on the distance, the permissible voltage drop, and the
size and type of load. If you are not sure of the gauge wire needed for your
application, consult a competent electrician.
FRAYED, CUT, BROKEN, LOOSELY CONNECTED, OR IMPROPERLY SIZED POWER CORDS OR WIRES CAN CAUSE EQUIPMENT DAMAGE, FIRE, SEVERE INJURY OR DEATH. INSPECT AND MAINTAIN ALL POWER CORDS ON A REGULAR BASIS.
REMOTE START CONTACTS - This two wire connection, once connected to an appropriate
switch will start the generator and perform as described in the remote start/stop
literature. These contacts are connected to the "Engine Start Contacts" of the
automatic transfer switch. A Two Pole normally open, closed to operate switch may also be used to start the generator. AC INPUT - These connections are for units with float type battery chargers or engine block
heater combinations. A constant supply of 120 volts AC (or as specified) is needed at
these terminals to power these devices. NOTE - Power is not required when the unit is in operation. Internal battery charging
and radiant heat during operation eliminate the need for these devices. NOTE - It is recommended that units utilizing an automatic transfer switch with adjustable
time delay have the initial adjustments made prior to startup.
Factory recommendations are to allow a 2 second delay on startup, and a 15 second delay on emergency to normal (so if your public service power is interrupted, the automatic
transfer switch will tell your generator to start after two seconds of power loss. Then, once Public Service Power is restored, the generator will continue to operate for an additional fifteen minutes just in case there is yet another outage of power).
GROUNDING: If grounding is necessary in your application according to National Electric
Code and/or local codes, drive a 3/4" or 1" pipe into the ground as close to the
Generator Set as is possible. This pipe must penetrate moist earth (minimum of 8
feet). Connect a ground clamp to this pipe and run a No. 10 wire or larger from it to
the ground stud on the generator set.
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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: Any electrical generator that is temporarily connected
to a building or home (where the building is also supplied electricity by a local utility)
shall be connected only by a competent electrician and only after the main service
entrance switch has been disconnected and locked open. This will isolate the building's
electrical system from the local utility's electrical transmission wires and prevent the
hazard of electrical back-feed to utility service workers. Any generator set that is permanently connected to a building or home (where the building is
also supplied electricity by a local utility) shall be connected only by means of a double- throw transfer switch. This will isolate the building's electrical system from the local utility's electrical transmission wires and prevent the hazard of electrical back-feed to utility service workers.
DO NOT CONNECT THIS GENERATOR SET TO ANY BUILDING'S ELECTRICAL
SYSTEM UNLESS YOU USE AN APPROVED TRANSFER SWITCH OR THE MAIN SERVICE ENTRANCE SWITCH HAS BEEN DISCONNECTED AND LOCKED OPEN.
ANY TEMPORARY OR PERMANENT WIRING CONNECTIONS MADE BETWEEN GENERATOR SET AND AN EXISTING ELECTRICAL SYSTEM MUST ONLY BE DONE BY A QUALIFIED COMPETENT ELECTRICIAN. IMPROPER WIRING/ CONNECTIONS COULD CAUSE EQUIPMENT DAMAGE, PROPERTY DAMAGE, INJURY OR DEATH.
CHECK ALL NATIONAL ELECTRIC CODES AND ALL LOCAL CODES IN REGARDS TO YOUR SPECIFIC APPLICATION. ANY NATIONAL ELECTRIC CODE OR LOCAL CODE WILL TAKE PRECEDENCE OVER ANY OF OUR GUIDELINES OR RECOMMENDATIONS.
Page 5 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 operation, safety and maintenance guidelines.
OIL: Use a high quality oil of the type specified in the engine owner's manual for your specific
operating conditions. Check the oil regularly, or at minimum every 5-8 hours of
operation.
TO HELP PREVENT ENGINE DAMAGE, CHECK THE OIL LEVEL OF THE
ENGINE REGULARLY AND MAKE SURE IT IS MAINTAINED AT THE PROPER LEVEL.
FUEL: (LP or Natural Gas): Make sure the gaseous fuel being supplied to the unit is in vapor
form and that it is being delivered to the engine's gaseous fuel regulator at the pressure specified on it.
An engine needs 10,000 BTU's of fuel per each engine horsepower to operate properly.
GASEOUS FUEL IS EXTREMELY FLAMMABLE AND CAN CAUSE PROPERTY
DAMAGE, SEVERE INJURY OR DEATH. CHECK THE GASEOUS FUEL SUPPLY SYSTEM ON A MONTHLY BASIS FOR LEAKS. HAVE ANY LEAKS REPAIRED BY AN EXPERIENCED PROFESSIONAL PRIOR TO STARTING YOUR GENERATOR SET.
OPERATING SPEED: This generator set must be run at it's proper designed speed in order to
obtain the electrical power it was built to produce. All engines have a tendency to slow down when a load is applied to it. The governor on the
engine is designed to hold the operating speed as nearly constant as possible. When the load connected to the generator set is increased, the engine is more heavily loaded and as a result the engine speed drops slightly. This slight decrease in engine speed results in a slight decrease in generator voltage and frequency output. This voltage and frequency variation has no appreciable effect in the operation of motors, lights, and most appliances and tools. However, timing devices and clocks will not keep perfect time when used on this generator.
Page 6 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 of cleaning the generator set, inspecting the wiring and fuel system, and making any necessary adjustments. Generator end maintenance should be performed on a monthly basis (or sooner if needed).
CLEANING: v Clean the generator set and remove any and all dust, dirt, or other foreign material.
v Inspect and clean the cooling air intake and exhaust louvers of the generator end. Make
sure they are free of 'caked -on' dirt or any other material that may restrict the cooling air flow through the generator windings.
v Clean the generator set and its components with a damp cloth or sponge.
Do not use sprayed water or compressed air to clean the generator set or it's components.
INSPECTING: v Inspect the external wires of the generator set for cuts, fraying, or loose connections.
Repair or replace any problems prior to using the unit.
CUT, FRAYED, BROKEN, OR LOOSELY CONNECTED WIRES CAN
CAUSE EQUIPMENT DAMAGE, SEVERE INJURY, OR DEATH.
v Inspect and clean the battery posts and the associated battery cable terminals. v Inspect and replace any control box components that are broken or not working properly
(receptacles, circuit breakers, switches, etc…).
v Inspect the fuel system for leaks. v Inspect and replace any fuel line that shows signs of deterioration. v Make sure all the fuel clamps are tight. v Make sure the fuel cap fits snugly on the fuel tank and that the fuel tank contains no leaks.
REPAIR ANY FUEL SYSTEM LEAKS
PRIOR TO RUNNING THE UNIT.
Page 7 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 SET HAS COOLED DOWN. THE BATTERY AND SPARK PLUG SHOULD ALSO BE DISCONNECTED PRIOR TO PERFORMING MAINTENANCE.
REPAIRS AND/OR ANY ADJUSTMENTS MADE TO THE GENERATOR SET SHOULD ONLY BE PERFORMED BY A COMPETENT MECHANIC FAMILIAR WITH THE OPERATION, SERVICING, AND SAFETY PRECAUTIONS RELEVENT TO THE ENGINE BEING WORKED ON.
This manual contains only very minimal engine maintenance instructions. You should refer to the engine manufacturer's owner's manual for specific maintenance instructions for the engine on your generator set. Any maintenance instructions or recommendations in the engine owner's manual take precedence over any of the following general recommendations.
1. Clean and/or replace any fuel, oil, and/or air filters per the engine manufacturers' guidelines.
2. Check oil level regularly; at least every 5 to 8 hours of operation. Be sure the proper oil level is maintained.
3. Change the oil as is recommended in the engine manufacturer's owner's manual.
4. Replace the spark plug(s) as is recommended by the engine manufacturer (if applicable to the engine).
5. Clean the cooling fins on the engine to keep the engine's heat dissipation potential at it's maximum.
6. Inspect and clean all governor and carburetor linkages and make sure they operate properly.
7. Inspect the recoil rope for any damage and replace it if necessary (if applicable).
8. Clean the trash screen around the recoil or other cooling air intake.
Page 8 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.
1 Drain the used oil from the engine's crankcase and refill it with fresh, clean oil (if your engine is diesel proceed to step 4).
2. Remove the spark plug and pour1 oz. of clean engine oil into the cylinder. Put a rag over the spark plug port and turn the engine over approximately 5 times to distribute the oil in the cylinder. Replace the spark plug but do not reconnect it. This will help prevent accidental or unauthorized starting.
4. Provide maintenance to the engine and generator set as described in the engine and generator maintenance sections of this manual.
5. Cover any bare metal spots with paint or another type of rust preventative.
6. Disconnect and remove the battery if your generator set is so equipped.
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