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Baldor AE11 Portable Generator User Manual

1. 1 gt 5 9 8 8 30 L ara 86 82 21 SNOISIA3y 3215 lMVd 133HS NG 3lvG wos Alva 35 313 4 PPL 40 NOISSIAM3d LNOHLIM 18 0530 ava 827516 ON AVM NI 0321101 38 LON s138v1 667 571 v _ a IVILN3GIJNOO ATLOINIS SI 1 340200 SIHL ara sesrit NUIOVINUO S138V1 Q3ADH3N 66 41 71 8 y 380105 31 0 48 dev 00991 0S6 3 S3IN3S WVNOVIG ININIM MOTIOS OL SNOUYOlID3dS LNIVd m E em m em SLO BAOH AMSTE NDLLO3NNDO AIWOLSNI ssvio 3389 AF STIONV 10 XX zz z 0
2. ANO NO Q3138V1 Zh LP S LNO dn 19415 NO 235 01 OOV OL Zh 17 100 XNVMO 31042 zl als OL 183ANOO OL 2123135 S 91 38 OL S3MIM TOMINOD vl 38 OL S3MIM TV 2 xovi8 TW OS 43130395 3SId3HlO SS3nNn LON OFT 3snd T 2 0555 NO 9 9 5 9 ld 249715 0014 UNO 5667 NN 0755 D S N Nid 0009 Lva veZ ANIONS 319v14393M 0 1 SVg NO wo B E 19015 QN9 8 yx 8 Xs 0097 lt ow 9001 ano UND oos 317 Wavy ou amp 9 9 jo vis 01 35010 0219 HOLIMS 3LON3Y 3sn4 0519 B i 0072 0012 T 8 181 aioNa08 3797193039 z 5077 0009 0007 93105 05 m oH IS HOLIMS d 9 le P 2 Sla 9015 1809 ca 504 ae E en YOLON YSLYVIS OL org er 9115 N URL e 3 OLNY ow 0415 5 0 19 ze A OI3NOVN S lt lt p KON L 065
3. 588 CELEM 703 595662 ual 002761750 75195590 ISNS E ECEE To 8 MOLVH3N39 ES Jololn6ey 20303 Al GIONS TOS ov 3115 eo eg a RN E S A A oV S 2 3 Nua TA e npow Ps o TA T OION310S 8 o S 9 5 4 9 5 pue Q e E xl he k a or 5d zs amp Xl gt JepuaS _NOLVINOIY iiu S Zd kal led 1900 20000020 094 Ajddns 10 pejbJ 5320309 deeq 0 2415 Figure C 8 AE11 Generator Connection Diagram GW0026D LN LL 3V NOILO3NNOO YOLVY3N3O 90 002 22 0 52 62 11 03SA3y Z8 S0000 W9d 314 609027000000 901 10 NL ODRLLOWIM OUTIVS lN3W3ONVHHV 381 035 33 0530 AJY
4. Figure D 5 AE25 Engine Compartment Connection Diagram pasllddnS pee dX 53 uo pesog M 19470 9 3 3 uo pesog 3182 3N3HdO3N XISSI OMY 2959 AeHo8 YOLVNYSLT 1 15 3604 X8 2 0 H LN30 iHM n 259 VN YNI m OMY 91 1900 di dWnd 1303 voL aay 1926 Ile suction Suis die SIM 02130 N3349 034 5 c uo1vNu3L TY Q3H N33N9 06 S AVTI3N 331915 704 MOTA 268 B 049 OL v zw30 7 E 8 T 6 8 4 9 S Z 1 8 LvOL 3 430 ov18 MoT34 24 8 IN 6209 3uHW NMONB da gr AAA m ly lo ly ke ls ly SN3S_dW3L_LNV1000 8 N30 6 m EE Ei SNIS dW3L 14 1009 a vse MOSN3S 504 OSEH amp MOSN3S 504 54 1 vil 1109 BONVYO NVL 96 KT 7109 91 8 ponos 5 30 109 ALIHM NVL S6 1S 2
5. YSWOLSND 3 4002 22 70 v SZ EL 03538 06SNS0000NY9dN 3715 6090 000000 391 10 NOISN3A V cul ORLLOWIM HOGIVG 281 A9078 TWNINYAL 0351434 0530 N3dNnn MOLO3NNOO 3HM INO S3LON 91 q u 91 91 9 91 q u 91 qiu 91 91 4 91 3npaol 2 SION YIYNLIVANNYN WIJI INY NT V N V N ONIN M3d N3L3AVIO 310H VAN V N MIYOS gf NYAL Z 3ION 2 310N 8 0 3ONVH Y N Y N 3215 YOLONGNOD X2018 Z 2 LON V N V N ONm 012342 C M no no no no no SYOLONAGNOD SN INS 25 os ase os asia Z LON Z 3009 2519313 V N 3 W907 325 AMLIOVdAV 18915 19915 N3OUVHO 7304 fans 3ioW3u iva 9 iva n iva ri 931 N3OISnO NOILVOLIILN3O 1 98L 9 81 S Oo8L 28 81 1 OGL 1 5 YINOLSNO TYnNYA ULSNI SONMVEO 335 30odlo31 Ji 3008193713 L qi 500810373 NIINNOYI MOLO3NNOO 3HIM INO aaannr 9 jH3dWnr N39
6. NNOO LaNa SWN34 F WN QN49 31 110 1991 NO O3S OL OL INL 102 XNYNO 31049 01 OL IM3ANOO OL 10313S OMY 91 38 OL S3YIM 1ONINOO TV tl 38 OL S3MIM QNO Tv S3MIM TY 031419345 3SIMN3HIO SSIINN 3LON OMY 21 9 9 01 0956 2 5 0 QN E 3Sv8 NO 2 5601 99 o 2 016 ALA M39uvH2 E Ave 01 lt 0002 Live B DOKON YON n Y Go 3088 0 1 009 om 765 ION3 by Be NO 57561 28 B LFanis QNO G 8 0057 D 19 0082 5 SW 00 g ona 0066 E 5 SRI 1915 01 35012 0019 HOLIMS 310W3M 3574 vi
7. L vie i lo 10688 M 5 EET E 0000 086 Nd v 2 N 8 OL a 4311 OL 1 9 H vi 5 13 23 vt vL GND 77 vi GION310S 3AWIS lt 3109193034 PS ano ANIONS vl ir 2 vi 1 5 S3NION3 135310 X04 vi SSH vip 59 5 st alle N vay it lt 8 YOLO3NNOD 501 gt gt 1556 n an F NQ ANO ny eh Ind LAVIS OL MS 553847 oas OL of 4138 A YOLOW 5 Ol is Zn 17 112 T 31049 OL IM3ANOO OL a vi 52 2 GIONTIOS 931815 193135 310N 4 vices 2 lt ae GION310S 1303 Yl vl v3 8 5 MN2415 Figure 6 AE8 Enclosed Wiring Diagram LN I H T WvMHOVIO NOLLO3NNOO 092 021 03501083 83V 45226 1000 91 10 50 95 60 q3SA3d 28 7395 12344002 0530 AJY 01200 LNFTIAINOA YO 80 5 38 01 530010 AINO NO ONY EP
8. 04 ddY 9 500 SWWI23Q A 3 1 10675 IM HSOMHSO 53 NI SNOISN3AIG 79 9 SONIMNLOVANNVAN P P 1 3IV0 48 H2 S3ONVHJIOL 031319395 ASIMYSHLO SSFINN 1813004 lt 90239 0 N3dD NO LON A0078 LAVIS 310W3N NU SWN3l 1198 02 39 20718 NNOO OV CD ILON ajjONVHO ASIJLLVH WA 021 cee 2 clTe et CONISIA 33401802 gs vt Sao os DAY vi CNISIA 1 gt Que lg 9 0 72078 01199 05 MZ TAINS N3ONVHO 1931198 14915 31039 HOV 03 IA N INO NS N A3a s TANVd IND e 3130 907 01 ANOD S7300W N3d0 2 res IS SIsiisiisi EN Aes DA 2 57 MEE FA sg S N SU1V33N35 01 SOLOVINOS 8 9 n S z1 Tm mir 2 50 470 INJ iS LJ Le e E IG E ews 0 A0b2 021 31ONIS 20074 124 2 OV S S E ATEW3SSY AS J J SLAIN TOSI Ce ONISIA 5 4345 91 OLAV 01 A T8N3SSV SIUIVS3N39 AIRW3SSV HOLIAS aASsSNVAL ZOLNAV e 5 9 8 MN2415 B 4 Series AE10 Figure B 5 AE10 Open Frame Wiring Diagram BW0201D N3d0 0139 NOILO3NNDO LW 01020 8 333 61c20000v9d 314 OIILOWIM 818182 YAL
9. uM eva 3005722750 7 80906000000 war NORE OIMLOTId HOTIVH INSNGONVEUY 22530 AG BWO459D Figure C 10 AE11 Connection Diagram MN2415 AZI peloloo pay pau 10 02 ueeJ6 NHO v of av 6ulpuog ON as MIA 630001QM 911118915 EV ds oy aM 1 101290002 lellInq 72 Pry wey Sy mm wey Y pesn 1 jan 41 1eduinf 169100 22 J 120216 8 219 Wy pq 8 ik E E S3TIOSLNOO RE BR gt n
10. 9 1 2 2 t 38 38 41 C SS3NNVH m O3AOW3 X34009 em TaNVd ne Sino mi wal X E Aat E s 2 3NION3 amp pestes ee be be be lo r auvavas aanssaad SOLVHANSS l b gt 25 REEERE 3 O 25 Am sovn NON 1 L h co ELT SS3NNVH REGESS2938q 959 6 RE EBZ 2 Bagg BS E HET LABS P ij 4 TTT 1 1 ou b or 8 B d anis g go 1815 8 3WvH4 555 55 me as ano X 8 avana LA d bo 3 gt 239yYHD son o ur SS3NJVH ot T jme G31Nn0W JONAA OV TINE ALvayd3s SS SS3NJVH avus M TRE avanne SISVHO ams db SEEN 2 4 lt assvoma C 8 Series AE11 Figure C 11 AE11 Customer Wiring Interface Diagram LTO194A00
11. et 5 SEES 0179 0179 0079 0079 S 2 any T oort 5 3unss3ud 10 YATIONLNOO 5 00 9 Logg lOMINOO aionzos g noltog 0917 Ly 0028 5 CA MN2415 B 6 Series AE10 Appendix C Series AE11 Information in this Appendix applies to the AE11 Generator Operator Panel Configuration Figure C 1 AE11 Operator Panel Under Speed Shutdown Alternator Charge Failure Warning Over Speed Shutdown Failure to Start Shutdown High Coolant Temperature Shutdown Aux1 Input Warn Shutdown Low Oil Pressure Shutdown lt Aux2 Input Warn Shutdown Of 2 Stop Manual Auto Hour Meter Run Start fuel solenoid energized Shutdown Warning Indicators Low Oil Pressure High Coolant Temperature Over Speed Engine Under Speed Engine Failure to Start Engine Warning or Shutdown Indicators Alternator Failure to Charge Battery Auxiliary 1 Input Active Auxiliary 2 Input Active Hour Meter Displays total hours of operation based on power applied to Fuel Solenoid Stop Stops the Engine and generator set Manual Run Immediately energizes the crank cycle to start the generator set and produce power Auto Start The engine can only be started by making a connection across the remote start terminals of the control box This allows normal automatic backup operation of the Gene
12. 3NIONS 58 58 Goss 3NYaj 43 018 ANT3H ANTH 3NION3 T WO33 MIA 3NON3 F jana sav A yalavis ysy 31515 xnv xnv 9g 9g HOLMS ive 221 191 55 209 245 185 Lont E 00191 00191 8019 Y wna 315915 id 3065052 oP Sos 0 9 IN 31H03 tos Tor lo sv L dive E 28 Z8 8 Z8 V Vw 3LON 5 S 5 WS 90081 E 5 5 jo lo 1 e z Oly BON 5 B 9200 9 SSs3dd 10 Tni m VE wv NO Q LNOO LYVLS 310W34 3A 091 avis z 20 M3ONVHO ind N3LLYS8 32091 32091 TIST IIN Tans Jans 4 SIAM WAGIAIGNI 803 OL 38NnN 1910 3AoN3 BNA rr 35 8 01 00 38 AV XI44NS Tavis 910 HO INO V W38 90791 NI LNIOd WILNALOd y HOV3 OL Q3Sf SI 38NnN W3N 5097 3NDINN aul ON SI NOILO3NNOO SI 1 472 ON YIWOLSNI E 1904 503 SI FINGOW WYS 72 ma W30 50709 A8 SIYM Nua S3ION oal 11 7 MN2415
13. Regulator Solenoid Fuel Lock Air Cleaner Inlet Connection MN2415 Example Determining Pipe Size for LPG An AE8 has 16Hp engine For LP fuel determine the supply pipe size for 60 feet run 16 x 10 000 160 000 per hour for proper operation 160 000 _ 72516 63 5 cubic feet per hour 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 If it is setup to run on Natural Gas contact your Baldor representative and do not continue with installation The incoming pressure must be as indicated in Table 3 2 Table 3 4 LP Gas Flow Rate Cubic Feet per Hour per Pipe Length Pipe lron Pipe Size NEA 1 5 3 4 1 1 254 lye 1 1 5 2 2 1 5 3 4 6 8 15 48 109 218 475 772 1570 2437 4115 8786 24497 50007 30 33 76 153 339 538 1127 1741 2975 6140 17325 35353 45 27 63 126 275 443 934 1456 2469 5001 14781 28865 60 24 54 110 241 386 817 1266 2184 4304 12236 25004 75 49 98 218 345 709 1108 1899 3798 10957 22345 90 44 89 196 310 633 987 1709 3482 10001 20414 105 41 83 180 285 582 905 1551 3228 9254 18895 120 76 171 266 544 848 1456 3038 8659 17673 150 69 153 241 494 772 1323 2754 7748 15825 180 63 142 222 456 709 1234 2532 7064 14482 210
14. S3LON 9 QI u OS q u ag os OS a u OG os SNOYOL SIANLI VINNY RD Levis 5 N _ ONOI W UaLSWVIC 310H 310W33 Ne hy 3495 9m p QV OMY O1F OF ONT y l1MVIS N39 be 3ZIS_YOLONGNOOD X09078 WSL dWINO 310H 310W33 3 0 dy LYOHS YOLOANNOO A 5 1 3 1 N39 no SYOLONGNOD 5 N 254 95 25 257 254 254 osz dNaL N 3005 01819313 z N N39 2 TYNOUYN 79907 3Z S ALIOV dV 9 9 N N30 N39 Z1 SOV31 1 NOILVOIJILN3QI E N35 i HON 9 2 1 n S VNINH3L dal 0018 5 YINOLSNO 00 61011 Series 11 9 2415 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 X BALDOR GENERATORS WATER E OIL C HIGH TEMPERATURE LOW OIL PRESSURE OVERSPEED BATTERY OVERCRANK Hour Meter sooo of TOR DC CONTROL FUSE AC CONTROL MANUAL AUTO RUN START MASTER NAT GAS L P GAS CONTROL Display Lamps High Temperature Indicates excessive engine coolant temperature Low Oil Pressure Indicates low
15. uonisod AYTAY XILAVIS YOLON 5315915 L MOIVNH3IV yavas 3 IHM MOTI3A 96 d ouibus eon 2 105 Tans SZOL Tang 0007 gt v cW3o 91903 N30 yva OLS ve 994105 YILYVIS T OL Wows 2 01918053077 Se lt SS3NNVH J lt 6509 znao 9 g pauddns o 101015 uo asoy dog Series AE25 D 5 S 1033002 aos UUUUUUU 000 309 3 iun uxo 109 91004328 3 are IpsJeAlun gt 3 yoo 1 488 YA ania e Ws ingo EP eens no ed act 7064 gU Ligg Aojay lt o5Ig 91uM pellddns P404 Peria lt v SUUM MOEA 964 TA indino 965upJ0 xooIg 8 92003 2415 Figure D 6 AE25 Control Box Connection Diagram Bw0041D UW
16. 2002 2 20 99 91 11 3534 WYN 8 3 17 3 LC8016 SVM LVAMWOJ 9S3q A38 aolo3NNoo gt gt SIHL NO AINO 0313977 er zr in er 102 dn 18915 01 7035 01 00 OL INU FROM GENERATOR LND 9NDINVMO MESE 3049 OI LY3ANOO OL TOT 103135 31ON va 280 5 1v041081 N d 0 1081 N d 2 181 o 180 2 9 m S tog IB IS 5 MEC mam Zi iB Og l e le XE iom 55 13 Gnd asva NO SLOVLNOD 1815 1 anis Sones L SOYOLLO8L N d E es eS e S o 1 HOLIMS alors 773 as Ex 010 9 zi S lt 69 E
17. NOLLO3NNDO XD8 JUNINDO 51 lt 239 01700 8 434 996 00007 98 374 76180 NOL lt 002 2 20 21 12 80 035 33 Ad 8 4 MIT A3 01449414 WHOGIVH 181 OL 3NION3 OL Nid 2002 9S3q 3NIO9N3 OL t Z C 9 8 6 OF tt a LLY Y MYY 71 919 3IVW34 HUM q3mddns SSH313W Z zb E s BL 9704 91 eee xessi uo OMV M 1940 IIV rhe lice Lee Leslee e EOD swa E e fe 421492 uolpdAH
18. recedat date dan GWU sms 3 2 Qutdoor Location aa 3 2 Indoor Location ERRAT DARE a Ae 3 2 ace REPETI I7 3 4 Secure the Generator Nose ua sentes abe vedete Mene acp i et wai ubi 3 4 Fuel Gorinections ih Eae eai daga Na gares e CLAU KE 3 5 Electrical GOMMECTIONS 3 8 AES Electrical CONNECTIONS 2 vn eres ocala CR Y ea an 3 9 AE10 Electrical Connections 3 10 Electrical Connections ek eva ace ed RP gc QR dc Rear 3 11 AE25 Electrical Gonrnectlons merren vex ica erepto scit a scatet ree ed RT CERO S ae C A RC era Hd t d 3 12 Engine Oil Level ess adeste ute Dan eee dide rg eed a 3 13 sa i da t ded da A pua P dit dad t du e Con dr editt 3 13 ag RR 3 14 Recommended Engine Oil and Battery 3 15 Post Installation 5 Wald a E ca aa Ec 3 16 Section 4 Operation e RUE EDS ned uas
19. 01 0219 E 01 8 Lal 0072 0012 F x SN 008 c3 0009 10002 S PEL o mu 00 2 53N E z 8 pen LS HOLIMS De Orv Ola 504 Ong NB 0115 BB NOLON MN3IMVIS OL 0018 er o jo 3 ANd O1nv 91 0415 5 182 OA T 0119 0215 Dr A OI3NOVW 3NION3 3 5 ue 0085 o ZI lo lov 0179 0179 0079 0079 Es S ir yap MS 34055384 10 _ oe o xog M3TIOMINO2 XO8 lOMINOO 0059 I GION310S 0095 3nd 0075 dol 8 MN2415 A 6 Series AE8 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 gt RUN OFF REMOTE MANUAL AUTO Controller Fuse 5 Circuit Breaker CONTROLLER FUSE 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 Off off position prevents engine from stating Remote Auto The engine can only be started by making a connection across the remote start terminals of the control box This allows normal automatic backup operation of the
20. 3553 uo p sog 91990 ete beet SSS 37870 3N3NdO3N X3SS3 re p 15 ALON WOad loo e gt m 8 S or F vl 2004 ZIOZ 6104 vi 81 Ln al 791 o 8 R 8L 5009 91 9204 Hi gv e rs os SH HHO as OH 1204 81 ovo 69 vo omy 4 HESHT 0202 22 9 TZOL 6202 22 2 1 Nm 9202 4 19 7473 ECOL w 8102 HS 5 a ean 81 rudis 201 Sv SL SOL SED E zaziv Murs E amv 81 9002 5004 SMY 8l on 1 gt 2 20 S voor nv o m E E amv 8007 O e507 vi 1 gt MV 5007 990 2001 L o E 2 SV Si S009 000 vi JINGOW WaLNOD 135339 TAY FT 105 95 omy ei Mm pss E OMY zm 2000 H lt SL SS 8907 Si E bos 5 01041 1004 Er 2 8 I 8 gt 9 TIO ET e gt 8102 OMY 87 SYNSOIONS 1041405 X M 9107 SMV 8T ONO wine S N e 2000 NV SI omw zz ws es S e 5 NOUS 1107 Si 1005 5 5 5 a TN N 4 IS 39nvo P ssid 10 4 ssl
21. Outputs are solid state rated at 1 2 Amps and switch to battery negative when active Programmable output can be configured to one of the following Pre heat The output is energized for the period of pre heat time prior to cranking and between the cranking attempts Load Transfer The output is active after the safety timer has elapsed Common warning The output is active if there are any warning alarm active Common shutdown The output is active if there are any shutdown alarms active System in auto The output is active when the system is in automatic mode Common Alarm The output is active if there is any alarm condition Energize to stop The output is energized when the engine is required to stop normal or fault conditions and will remain energized for the period of the Energize To Stop Timer to ensure the engine has come to a complete stop 4 8 Operation 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 Description i Notes DC Plant Supply Input ve Connected to plant battery negative DC Plant Supply Input ve i Connected to plant battery positive Recommended Fuse 2A Fuel Solid State Output Used to operate the fuel relay Start Solid State Output Used to operate the cranking relay Auxiliary
22. XICO PHONE 52 477 761 2030 FAX 52 477 761 2010 MIDDLE EAST amp NORTH AFRICA VSE INTERNATIONAL CORP 3233 NORTH ARLINGTON HEIGHTS SUITE 100W ARLINGTON HEIGHTS IL 60004 PHONE 847 590 5547 SINGAPORE 51 KAKI BUKIT ROAD 2 K B WAREHOUSE COMPLEX SINGAPORE 417863 PHONE 65 6 744 2572 FAX 65 6 747 1708 SWITZERLAND POSTFACH 73 SCHUTZENSTRASSE 59 CH 8245 FEUERTHALEN SWITZERLAND PHONE 41 52 6474700 FAX 41 52 6592394 TAIWAN 4F NO 25 SEC 1 TUNHUA S ROAD TAIPEI 10557 TAIWAN R O C PHONE 886 2 2577 4352 FAX 886 2 2577 4157 UNITED KINGDOM 6 BRISTOL DISTRIBUTION PARK HAWKLEY DRIVE BRISTOL BS32 OBF U K PHONE 44 1454 850000 FAX 44 1454 859001 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 BALDOR ELECTRIC COMPANY P O Box 2400 Ft Smith AR 72901 2400 479 646 4711 Fax 479 648 5792 Printed in USA Baldor Electric Company 5 05 MN2415
23. or disconnect box 3 If you mount the battery charger outside you must protect it from the environment 4 not mount the battery charger where flammable liquids or vapors are present MN2415 General Wiring Considerations 1 Control wires and Power wires cannot be located 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 Check with your local building inspector to determine what you must do to comply with the local regulations for grounding of this type of permanent installation AE8 Electrical Connections Applies only to AE8 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 3 Figure 3 3 Single Phase Output Power Connections with Enclosure or Open WT Generator Customer Liton 120VAC Outout gt 6 AC Output Connections L2toN 120VAC M upu YQ 4 24 to Transfer Switch 111012 240VAC 8 es BWO120D Remote Start and Battery Charger Connections Figure 3 4 shows the connections for t
24. trade e Haeo e elata 4 1 Operator Control Panel acts tnr ern oec heuer eee rid eee iere va eb cha 4 1 Operating Procedures SEV 4 3 Manual Start Stop DHT TS 4 3 Automatic Stant Stop 4 3 Automatic Fault Shutdown 4 3 AE11 Operating Procedures 4 4 Warnings and Shutdowns esee hh n 4 4 Editing the Config ration cone eate Rot ure cie mese Rie gebe E mte nate ee 4 5 Electrical Connections oco e 4 9 Garretson Model Fuel Valve Considerations 4 9 Section 5 Troubleshooting and Maintenance 5 1 Maintenance te De AE NSE i er 5 1 Problems and Solutions 3er bra aa ati a aU E Cn ie Fa uc 5 2 Continued on next page MN2415 Table of Contents i Appendix A S ries AEB ante et p tea pea ert eee ee 1 Operator Panel Configuration A 1 Replacement RP MOD Oradea ewes eee cx emi Santas A 2 Wiring DiIagratms o
25. 2213 3752 7600 22462 43867 60 37 83 166 366 587 1241 1924 3319 6542 18595 37999 75 74 149 332 524 1077 1684 2886 5772 16652 33959 90 67 137 298 433 962 1501 2597 5291 15200 31025 105 63 126 274 433 885 1376 2357 4906 14064 28715 120 115 260 404 827 1289 2213 4618 13160 26859 150 105 233 366 750 1174 2011 4185 11775 24050 180 96 216 337 693 1077 1876 3848 10736 21934 210 89 197 308 635 991 1712 3559 9937 20298 240 183 289 596 933 1616 3357 9235 18990 270 171 274 558 875 1520 3127 8658 17903 300 164 260 524 827 1433 2886 8177 16998 Connect the proper size gas pipe at the input to the Natural Gas regulator Connect the Natural Gas pipe line shown in Figure 3 2 using the correct size pipe for the required flow rate and length of pipe Refer to Table 3 3 for pipe size Be certain that all connections are sealed and no leaks are present The installer must ensure that all gas connections comply with all building codes Verify Fuel Supply Pressure Prior to initial operation of generator verify that fuel system pressure is as indicated in Table 3 2 and fuel pipe sizes comply with Table 3 3 Proceed to Electrical Connections Note Regulator shown for Natural Gas only For LPG mount upside down 3 6 Receiving amp Installation Figure 3 2 Gas Line Connections Carburetor Mounting Bracket gt Ie lt Gasket
26. 5 wy gt gt gt l gt 2 to Ee Fo EERE lany s gt YALIN 0355913 m iss E 8g 3 EA 2 99S IN 3mB 5107 59v 8L 81 OMY SL 520 S ES REE BL LE BP OMV GI 6002 31492 5 Tee eases 28 ae a I YOLVYSNID OL Z 90A 7 Tonay 36040A 3NI9N3 OL alrOOME MN2415 D 6 Series AE25 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 CONNECTICUT WALLINGFORD 65 SOUTH TURNPIKE ROAD WALLINGFORD CT 06492 PHONE 203 269 1354 FAX 203 269 5485 FLORIDA TAMPA PUERTO RICO VIRGIN ISLANDS 3906 EAST 11TH AVENUE TAMPA FL 33605 PHONE 813 248 5078 FAX 813 247 2984 GEORGIA ATLANTA 62 TECHNOLOGY DR ALPHARETTA GA 30005 PHONE 770 772 7000 FAX 770 772 7200 ILLINOIS CHICAGO 1601 FRONTENAC ROAD NAPERVILLE IL 60563 PHONE 630 848 5100 FAX 630 848 5110 INDIANA INDIANAPOLIS 5525 W MINNESOTA STREET INDIANAPOLIS IN 46241 PHONE 317 246 5100 FAX 317 246 5110 800 428 4141 IOWA DE
27. 750 31 3HV 5 401029 Q3IJLLN3Q S3HIM SJAM TVNGIAIGNI ASILNSG OL YAEWNN 11910 3578 3HL OL 0300Y 38 AVN Xl4Jns VHdlV 11919 V NI LNIOd VILN3LOd HOW AJILN3GI OL G3SN SI YIAWNN 11910 3NDINN SION Z 90AV rav LION MOLVTn93N 39V110 gnis 4 NOOQ TaNvd 8 2 anis QNO 3000 8 E 50194394434 8 ae anis 13Nvd 7081409 5 5 Olly 3004 SLO 8 vas 9330 SONS NOJd a na OMG N n 6105 ane SISSVHO te 020 gt agsroma r3 a 5 SISVHO HOOOT ps 9 9 M3dwne E n Ap Um ONIGNOS M B znd S 3 ore SU YINOLSNO Pall a 61 6 gt nite ino ov 5 1 3oqBB 1103 eun GE 8 ATBW3SSV W3lLO3N 9NILVLOM V 5778 100 2v 3SYHd gt p 31363 zaps 29 wv y pis 30103 0105 50115 01313 NIVN BYNLVWYY M3LIOX3 qui ZOLL iz P yos az 90115 18N3SSY 9NUYLOY 3JnLY
28. ATLOINIS SI 1 340200 SIHL ara sesrit NUIOVINUO S138V1 Q3ADH3N 66 41 71 8 y 380105 31 0 48 dev 00991 0S6 3 S3IN3S WVNOVIG ININIM MOTIOS OL SNOUYOlID3dS LNIVd m m em SLO BAOH AMSTE NDLLO3NNDO AIWOLSNI ssvio 3389 AF STIONV 10 XX zz z 0 NOILdIMOS3Q 32 015 3NO 803 ddV 9 LF SNOILOYJ4 500 XXX STYNI030 E 4 1 10675 IM HSOMHSO 53 NI SNOISN3AIG 79 9 SONIMNLOVANNVAN P P 1 3IV0 48 H2 S3ONVHJIOL 031319395 ASIMYSHLO SSFINN S 13004 lt 90239 0 N3d0 NO LON A0078 LAVIS 310W3N NU SWN3l 1198 02 39 20718 NNOO OV CD ILON ajjONVHO ASIJLLVH WA 021 cee 2 clTe et CONISIA 33401802 gs vt Sao os DAY vi CNISIA 1 gt Que lg 9 0 72078 01199 05 MZ TAINS N3ONVHO 1931198 14915 31039 HOV 03 IA N INO NS N A3a s TANVd IND e N31N39 1907 01 ANOD S7300W N3d0 res IX i EN Aes DA 2 57 MEE FA sg S N SU1V33N35 01 01991 09 8 9 n S 2 50 470 INJ iS LJ Le e E IG E ews 0 A0b2 021 31ONIS 20074 124 2 OV S S esl S s ATEW3SSY A
29. Generator Set under control of the Transfer Switch Controller Fuse This fuse provides overload protection for the controller circuit board Lamp This Red indicator light will come on when the engine shuts down due to a fault condition Circuit Breaker The 2 pole Circuit Breakers provide overload protection excessive AC current for the generator set output windings MN2415 Series AE10 B 1 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 RM1088A07 lt gt Figure B 3 Frame Assembly Table B 1 Generator Set Parts List Ref No Part No Description pen Enclosed 1 HB6177A01 Adaptor Engine X X 2 62FN4002 Fan X X 3 62RA014A00 Rotor Assembly X X 4 BG6207H03 Rotor Bearing X X 5 62SA0006A00 Stator Assembly X X 6 62EX5001A01 Exciter Assembly X X 7 62EP3202A01 Bearing Bracket X X 8 HA3188A00 Rotor Bolt Rotor to Engine X X Not Shown HB7023A00 Rotor End Plate X 15 RM1088A07 Isolator X X 20 0198 00 X 20 BA5000A00 Base Frame X 21 HB7025A00 Engine Mounting Foot X X 22 HB7002A08 Engine end frame cross member X X 23 HB6068A00 Alternator end frame cross member X X B 2 Series AE10 M
30. SUM 5 vl v ATE OA s viso ZN z 3 5 41 8 gt TER AM 5 298 L8 SSY g qora some wav v 100 Nid ot x n 310v1d3938 0 1 MS 5534 110 A O13NOVW EL ine 4 MOLOW 4314915 OL Re 82 savis 13 53 QION310S 1303 C GL0ZOM8 5 Series AE10 B MN2415 Figure B 6 AE10 Enclosed Wiring Diagram BW0333D 3SVHd DA 0 2 021 035 10 3 01 39 4949910 NDULLO3NNDO UW O 0M8 33N 19 S 0000v9d 3113 OILLOWIM HOGIVg 1 098c YAL lt 002 70 20 82 26 01 Q3SIA3N 11 JO LHS lt 2800016 Od SYM 1VWHO3 0530 34 LNVIIAINDA YO 80vSNI 38 01 530010
31. Solid State Output Configurable output Auxiliary Solid State Output Configurable output Charge Fail Input Excitation Output T Must NOT be connected to plant supply negative if not used Low Oil Pressure Input Switch to negative High Engine Temp Input Switch to negative Auxiliary Input Switch to negative Auxiliary Input i Switch to negative Automatic start Input Switch to negative Not used Not used Functional Earth Connect to a good clean earth point Not used Not used Not used Not used Alternator Input L1 Do not connect if not used 2A Fuse Alternator Input N Do not connect if not used Garretson Model KN Fuel Valve Considerations General The KN is designed for sensitivity and simple operation It is used with low pressure vaporized gaseous fuels where dependable starting is a requirement Because of its extreme sensitivity the KN offers excellent results in most remote starting applications Standby power generators etc With proper installation and maintenance the KN will provide years of trouble free service Operation The KN is an atmospheric zero governor which acts like the float and needle valve in a gasoline carburetor Air flow through a venturi in the carburetor creates a vacuum which acts through the outlet of the KN on the diaphragm Atmospheric pressure then forces the diaphragm toward the vacuum depressing the lever and pulling
32. all pipe thread fittings between the KN and the fuel supply tank being careful not to get any inside the inlet or fittings Excess compound could collect on the seat and orifice and cause hazardous leakage resulting in poor performance After piping is complete turn on the gas and use a soap solution to check all fittings for leaks If an electric solenoid primer is used follow the wiring and adjusting instructions furnished separately kit by connecting into a pressure line at a reduced pressure call us The KN outlet is 3 8 NPT and if an outlet fitting has not been provided select and insert a suitable vapor fitting taking care not to allow any chips or dirt to enter the outlet Use of street ells or conventional pipe fittings in the fuel line between the KN and the carburetor is not recommended as they may restrict the flow of fuel When installation of a properly sized fuel hose between the KN and carburetor is completed if you are installing a complete conversion return to the instructions For field replacement applications the unit is ready for service 4 10 Operation MN2415 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
33. belt etc Rotating parts cause extremely dangerous situations because they can catch loose clothing or extremities and cause serious or fatal injury When operating this generator remain alert at all times Never operate machinery when physically or mentally fatigued or while under the influence of alcohol drugs or medication Never operate the engine when the air cleaner is removed An engine backfire can cause serious burns Never jump start a generator to start the engine If the battery charge is insufficient to start the engine charge or replace the battery and try to restart Jump starting a battery can cause the battery to explode and cause severe injury or death to anyone in the area High voltage is present whenever engine is running Electrical shock can cause serious or fatal injury Never operate electrical equipment while standing in water on wet ground or with wet hands feet or shoes or while barefoot High voltage is present whenever the engine is running Electrical shock can cause serious or fatal injury Always stop engine before connecting or disconnecting power cords or external devices Do not smoke near generator during operation or when close to fuel source LPG and natural gas fuels are flammable and can cause fire explosions injury or death Keep generator at least three feet away from buildings and other structures Keep generator away from flammable or hazardous materials trash rags lubricants explosives
34. included 5 Ground Connection After installation the post installation checks must be performed prior to starting the engine After these checks have been performed and the system operation is verified to be good refer to Section 6 Maintenance for periodic checks that must be performed at scheduled intervals to ensure continued operation with minimal problems Secure the Generator Refer to Table 3 1 for the dimensions and weight of each generator Mounting bolts in the base frame secure the generator to the shipping pallet Remove these bolts lift the generator and remove the shipping pallet Secure the generator to the concrete pad using anchor hardware not provided See Figure 3 1 Anchor bolts must be long enough to extend through the generator mounting frame Table 3 1 Physical Dimensions Generator wu Weight Height Width Length Open Enclosed AE8 E O 36 75 29 00 44 5 255 Ibs 463 Ibs AE10 E O 36 75 29 00 44 5 316 Ibs 509 Ibs AE11 E 30 50 30 375 46 468 Ibs AE25 E NG 34 00 31 5 0 72 1450 16 AE25 E LP 34 00 31 5 0 72 1450 16 3 4 Receiving amp Installation 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 the flow rate required
35. load for an extended period of time at least one hour 4 temperature difference between the two should not exceed 15 degrees Note that opening door window or other opening can upset air flow pattern and result in a significant reduction in the cooling air flow across the generator set This may result in overheating fire or explosion To find out if this is true with your specific application run the Ventilation Test with all doors and windows closed Then repeat this test with different doors and windows open and eventually with all the windows and doors open If any of these tests result in a temperature difference in excess of 15 F you must not run the generator set under those specific conditions Hot Exhaust Gasses Exhaust fumes gases are extremely dangerous and can cause severe illness or death Never breath exhaust fumes produced by a running engine Only run the engine outdoors where ventilation is plentiful Exhaust gases contain carbon monoxide a colorless odorless and extremely dangerous gas that can cause unconsciousness or death Symptoms of carbon monoxide poisoning include dizziness nausea headaches sleepiness vomiting or incoherence If you or anyone else experiences these symptoms get out into fresh air immediately Stop the engine and do not restart the engine until it has been inspected and if necessary repaired or reinstalled in a well ventilated area Hot exhaust gasses must never be directed to
36. output is switched on to operate the load The generator will continue to run until the Stop or Auto Start mode is selected If Auto mode is selected the Remote Stop Delay Timer starts After this delay the Fuel Solenoid is de energized to stop the generator Selecting Stop de energizes the Fuel Solenoid is de energized to stop the generator Warnings and Shutdowns 4 4 Operation Warnings Warnings are used to warn the operator of a problem fault Battery Charge Failure if the module does not detect a voltage from engine mounted alternator the lamp will illuminate Either 8 Volts or 16 Volts depending on the configuration of Nominal DC Voltage Inputs 1 and 2 can be configured as warnings or shutdowns The lamp will be illuminated when the input is active Shutdowns Shutdowns are latching and stop the Generator The alarm must be cleared and the fault removed to reset the module In the event of a shutdown the appropriate lamp is illuminated The alarm condition must be corrected before a reset will take place If the alarm condition remains it is not possible to reset the unit except faults that occur during the Safety On timer period These are delayed alarms like oil pressure is low with the engine at rest Inputs 1 and 2 can be configured as warnings or shutdowns The relevant lamp is illuminated when the input is active MN2415 Shutdowns Continued Fail To Start if the engine does not start after 3 start cycle
37. the engines oil pressure Battery Displays the battery voltage of the starting battery DC Control Fuse Fuse for engine controller AC Control Fuse Fuse for engine controller p Master Control Switch Stop Stops the Engine and generator set Manual Run Immediately energizes the crank cycle to start the generator set and produce power Auto Start The engine can only be started by making a connection across the remote start terminals of the control box This allows normal automatic backup operation of the Generator Set under control of the Transfer Switch whenever utility AC power is lost Natural LP Gas Selector Switch Selects the correct fuel source Natural Gas or L P Gas 4 2 Operation MN2415 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 Should the engine speed exceed the maximum predetermined setpoint the Overspeed shutdown fault circuit will activate terminating the run signal In addition to Overspeed shutdown other engine functions are also monitored and the engine will automatically s
38. to position be careful not to contact overhead wires or other obstacles The generator can weigh as much as 1 500 Ibs Be sure lift or hoist equipment has appropriate tires for the terrain to avoid becoming stuck or tipping over If the shipping pallet is intact use a fork lift to move the generator If the shipping pallet has been removed use two steel pipes through the Lift Point holes to lift the generator See Figure 3 1 Figure 3 1 Generator Lifting amp Mounting amp AE10 Not To Scale 5 263 Four mounting A holes 0 38 dia 8 88 A d Electrical 8 88 Stub Up E 7 75 in Fuel Inlet on Horizontal Surface CBS _ 44 50 i 5 p Lift Point 9 Alternator End 5 Lift Point gt lt Width rt 29 00 Thru Base 5 zs Stub Up Area All dimensions are in inches 1 50 AE11 AE25 2 Six mounting k Stub U holes 0 410 dia ns m m 30 00 7 Fuel amp Electrical A 1 50 gt s 42 00 3 19 m yt Fuel Inlet Zone 46 00 OT 72 00 gt 3 19 812 b x Electrical 26 14 Four mounting Y n StbUP 2094 holes 0 38 dia 29 29 Alternator End 1 Alternator End LTO143A30 lt 30 29 gt rt 31 25 MN2415 Receiving amp Installation 3 1 Physical Location The mounting locatio
39. 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 Installation The KN should be mounted as close to the carburetor as possible with the arrow on the cover pointing up and the diaphragm in a vertical position This helps to minimize the effects of gravity on diaphragm travel This unit should also be placed for easy access to the primer if provided There are two sets of mounting holes provided either set of mounts will adequately support the KN The bottom set of holes has a 1 3 4 bolt spacing for use with all Garretson universal mounting brackets The mounting bosses on the cover are spaced 5 3 4 for 5 16 bolts Before installing the fuel supply line be sure that the gas pressure is no more than the maximum inlet pressure shown on the front of the KN If the pressure is greater leakage could result in a fire hazard and or hard starting The piping to the inlet should be of sufficient size to allow full flow to the KN This is very important in natural gas installations as any restrictions can affect engine performance If a solenoid is used ahead of the KN in the low pressure line it should have an orifice at least as big as the orifice in the KN Flexible piping to the inlet should be used to prevent cracking from vibration if the KN is mounted on the engine or other vibrating surface Note Thread sealing compound should be used on
40. when in the area around the battery WARNING The battery electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive and corrosive If electrolyte contacts the skin flush the area immediately with water and wash it off using soap and water If electrolyte contacts the eyes immediately flush the eye thoroughly with water and seek medical attention quickly WARNING Before cleaning inspecting repairing or performing any maintenance to the generator set always be sure the engine has stopped and that all rotating parts have also stopped After stopping certain components are still extremely hot so be careful not to get burned Before servicing the generator set be sure to disconnect the spark plug wires and the battery terminals to prevent accidental engine rotation or starting WARNING Engine coolant is under pressure and is near the boiling point of water when engine is hot Do not open the coolant system until the engine has completely cooled Hot coolant can cause severe burns and other injuries When engine is cool coolant level can be checked WARNING Before servicing the generator set be sure to disconnect the spark plug wires and the battery terminals to prevent accidental engine rotation or starting WARNING Inspect all wiring frequently and replace any damaged broken or frayed wiring or wires with damaged insulation immediately Electrical shock can cause serious or fatal injury WARNIN
41. wiring Check engine oil pressure Check oil pressure switch and wiring Check switch polarity i e Normally Open or Normally Closed High Engine Temperature fault Excessive Temperature Defect in sender or wiring Check engine temperature Check switch and wiring Check switch polarity i e Normally Open or Normally Closed Shutdown fault Fault Trip Failed switch or wiring Clear trip condition and reset controller Check switch and wiring of fault indicated by the LED Check configuration of input Fail to Start is activated after pre set number of attempts to start No fuel No starting current to starter motor Engine fault Check fuel solenoid is on and battery supply is present at solenoid Check fuel Check battery supply Refer to engine manual Continuous starting of generator in AUTO Remote Start circuit fault Check that there is no signal present on the Automatic start input Generator fails to start at remote start command No Remote Start Signal Wrong generator mode Check the Remote Start input signal Check that the Auto Start mode is selected Pre heat inoperative Check wiring to engine heater plugs Check battery supply is present at the Pre heat output of module Check pre heat has been selected in your configuration NB all the outputs are negative switching Starter motor inoperative Check wiring to starter solenoid Check battery suppl
42. 09A22 Hinge Nylon Not Shown HW2410A02 Gas Spring 30 Ib Not Shown EH0309A02 Control Box Not Shown EM0046A00 Engine Controller 4110 Auto Start Not Shown RE5031A01 Relay Not Shown 0027 01 Voltage Regulator AVC63 20 Not Shown CK0070A29 Circuit Breaker 50Amp Not Shown FU066A02 Fuse AGC1 Not Shown FU066A00 Fuse MTH 5 Not Shown SE0057A02 Solenoid Engine Starting 12V Not Shown EA5038A00 Muffler Not Shown HB6116A00 Battery Tie Down Not Shown HA3187A12 Battery Tie Down Bolt Not Shown EA0010A04 Battery Charger 12V 2AMP Not Shown EA0000A00 Regulator K N Manual Prime Not Shown SE0071A00 Solenoid Automatic Gas Valve Conversion from LPG to Natural Gas Optional Procedure If this is a new installation begin with step 5 If the generator has been installed ensure that the following steps are performed 1 Place the controller in the OFF position 2 Place the circuit breaker in the OPEN position 3 Turn off the LPG supply Disconnect and remove the LPG equipment and hoses 4 Disconnect the negative terminal from the starting battery Figure C 4 Maxx 90 Elbow Regulator 5 Open the lid and remove the front panel by removing the two 7 16 bolts along the top edge of the front panel 6 Remove the hose that connects to the 90 elbow at the top of the demand K N regulator Figure C 4 MN2415 Series AE11 C 3 7 Remove the insert from the 90 elbow Figure C 5 8 Connect the hose and
43. 58 130 202 418 652 1127 2342 6439 13356 240 120 190 393 614 1063 2209 6077 12405 270 113 180 367 576 1000 2057 5697 11780 300 108 171 345 544 943 1899 5381 11179 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 1 Connect the proper size gas pipe at the input to the LP Gas regulator Connect the LPG pipe line shown in Figure 3 2 using the correct size pipe for the required flow rate and length of pipe Refer to Table 3 4 for pipe size Be certain that all connections are sealed and no leaks are present The installer must ensure that all gas connections comply with all building codes 2 Verify Fuel Supply Pressure Prior to initial operation of generator verify that fuel system pressure is as indicated in Table 3 2 and fuel pipe sizes comply with Table 3 4 3 Proceed to Electrical Connections MN2415 Receiving amp Installation 3 7 Electrical Connections Class 1 wiring methods must be used for field wiring connections to terminals of a class 2 Warning Warning WARNING 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 Natio
44. 7A00 Carburetor Adapter X X Not Shown EA0000A00 Regulator K N Manual Prime X X Not Shown SE0052A00 Solenoid Low Pressure X X Wiring Diagrams Wiring diagrams for these generators are contained on the following pages of this appendix MN2415 Series AE8 A 3 Figure A 4 AE8 Customer Connection Diagram 1 gt 5 9 8 8 30 L ara 86 82 21 SNOISIA3y 3215 lMVd 133HS NG 3lvG wos Alva 35 313 4 PPL 40 NOISSIAM3d LNOHLIM 18 0530 ava 827516 ON AVM NI 0321101 38 LON s138v1 667 571 v _ a IVILN3GIJNOO
45. AJY MHOLVH3N39 MN2415 C 6 Series AE11 Figure C 9 AE11 Engine Connection Diagram BW0458D LW LL 3v NOLLO3NNOO 3NION3 49 N31HO3 Sate n AB vOOZ ZZ vO 60 25 11 0353 689 N60000NV9QN 3114 6090 000000 wal 10 NOISN3A A3y 09 ORILOWIM YOCTVA 2 29 VOISL 303 NOLLO3NNOO 35 34 0530 TYnNYN 8 8 Old OMG 338 AVT3H MBISVIS E qION hos 1303 7313 1odLNOO 3NION3 SL3NOdNOO NNY LYVLS 3NI9N3 OI 38 3311938 uy 2 301918 T3444 53 SIYM ON 0800049 944 qezoow9 NOLLINOI WI dal avds dS ov AYTAY 331315 us imi NOISJ3A 9 aWvad Sy 1310 8 NOISS3A ov SNIN SV9 TYanLYN e 8 31000N hivds NYS E 37057 02091 2057 SOLON S4 gt
46. BALDOR Automatic Emergency Generator AE8 AE10 AE11 and AE25 Installation amp 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 1 1 Safety UM CREER IQ E br 1 1 RESPONSIDIINY ioi po perk e pb EUMD Rae RE 1 1 IMPORTANT SAFETY INSTRUCTIONS 1 2 Caution Statements eret VA REA ce dpa a rac ah Soc 1 6 Section 2 General Information ee Lee Eie red ere s UE e 2 1 Limited Warranty ecu t e e teu c o e t i ott e t S Ue s e e tette 2 1 Section 3 Receiving amp Installation eoe rue CURRO 3 1 Receiving amp Inspection aes Ree Dee E e CO eh oe ne eee ates 3 1 Lifting the Generator i aeu be CARE bee bea Seige kee dk Bee ede 3 1 PhysiCalvLOcCation
47. Down Period is initiated After the Cool Down Period has elapsed the Fuel Solenoid is de energized bringing the generator to a stop Manual Operation There is no Start Delay in Manual Run This mode is activated by pressing the Manual Run pushbutton see Figure 4 2 If the pre heat output option is selected the pre heat timer is starts and the corresponding auxiliary output if configured will energize After this delay the Fuel Solenoid is energized then one second later the Starter Motor is engaged The engine is cranked for 10 second period If the engine fails to start the starter motor is disengaged for a 10 second rest period Should this sequence continue beyond the 3 starting attempts the start sequence will be terminated and Fail to Start fault will be illuminated When the engine starts the starter motor is disengaged and locked out at 20 Hz measured at the Alternator output Rising oil pressure can also be used to disconnect the starter motor however it cannot be used for under speed or over speed detection When the starter motor has disengaged the Safety On timer starts This timer is preset to 12 seconds and allows engine speed Oil Pressure High Engine Temperature Under speed Charge Fail and Auxiliary fault inputs to stabilize without triggering a fault Once the engine is running the Warm Up timer starts if selected This allows the engine to stabilize before the load is switched on After the Warm Up delay the AC
48. FAX 204 956 4251 AUSTRALIA UNIT 3 6 STANTON ROAD SEVEN HILLS NSW 2147 AUSTRALIA PHONE 61 2 9674 5455 FAX 61 2 9674 2495 UNIT 8 5 KELLETTS ROAD ROWVILLE VICTORIA 3178 AUSTRALIA PHONE 61 3 9753 4355 FAX 61 3 9753 4366 BALDOR CENTROAMERICA RESIDENCIAL PINARES DE SUIZA POL 15 44 NVA SAN SALVADOR EL SALVADOR CENTRO AMERICA PHONE 503 288 1519 FAX 503 288 1518 BALDOR SUDAMERICA CALLE F EL CANGREJO CONDOMINIO CONDADO PLAZA APT 11D BELLA VISTA PANAMA CITY DE PANAMA PHONE 507 265 6041 CHINA SHANGHAI JIAHUA BUSINESS CENTER ROOM NO A 8421 808 HONG QIAO ROAD SHANGHAI 200030 PHONE 86 21 64473060 FAX 86 21 64078620 GERMANY DIESELSTRASSE 22 D 85551 KIRCHHEIM MUNICH GERMANY PHONE 49 89 90508 0 FAX 49 89 90508 492 INDIA 14 COMMERCE AVENUE MAHAGANESH COLONY PAUD ROAD PUNE 411 038 MAHARASHTRA INDIA PHONE 91 20 25 45 95 31 32 FAX 91 20 24 55 95 30 ITALY BALDOR ASR AG SUCCURSALE DI MENDRISIO VIA BORROMINI 20A CH 6850 MENDRISIO SWITZERLAND PHONE 41 91 640 9952 FAX 41 91 630 2633 JAPAN DIA BLDG 802 2 21 1 TSURUYA CHO KANAGAWA KU YOKOHAMA 221 0835 JAPAN PHONE 81 45 412 4506 FAX 81 45 412 4507 KOREA ROOM 210 BUPYEONG INDUSTRIAL COMMERCIAL COOPERATIVE 396 16 CHEONGCHEON 2 DONG BUPYEONG GU INCHEON KOREA 403 858 PHONE 82 32 508 3252 FAX 82 32 508 3253 M XICO 2 0 BLVD AL AEROPUERTO LE N 37545 GUANAJUATO M
49. 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 the generator set and produce power Master Control Stop Stops the Engine and generator set Switch Remote Auto The engine can only be started by making a connection across the remote start terminals of the control box RUN STOP REMOTE MANUAL AUTO Allows normal automatic backup operation of the Generator Set under control of the Transfer Switch whenever utility AC Controller gt power is lost Fuse 69 Controller Fuse i CONTROLLER Fuse for engine controller Dr Lamp This Red indicator light will come on when the engine shuts down due to Lamp a fault condition Circuit Breaker Circuit Protection for AC power output Circuit Breaker 2 pole Circuit Protection for the generator set out put windings Circuit Breaker Figure 4 2 Operator Control Panel AE11 Under Speed Shutdown Alternator Charge Failure Warning Over Speed Shutdown Failure to Start Shutdown High Coolant Temperature Shutdown e m Aux1 Input Warn Shutdown Low Oil Pressure Shutdown lt Aux2 Input Warn Shutdown sk S or on z Stop Manual Auto Hour Meter Run Start fuel solenoid energized Shutdown Warning Indicators Low Oil Pressure High Coolant Temperature Over Speed Engine Under Speed Engine Failure to Start Engine Warning or
50. G Disconnect all electrical wires and load devices from generator power outlets before servicing the generator Electrical shock can cause serious or fatal injury Always treat electrical circuits as if they are energized WARNING Check all fuel supply piping and their connections monthly for fuel leaks LPG and natural gas fuels are flammable and can cause fire explosions injury or death If a leak is found replace only with approved pipe or components Continued on next page MN2415 Product Safety Information 1 5 Caution Statements Caution Caution Caution Caution Caution Caution Caution 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 Do not apply high voltage to windings do not start the generator in 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 Use only original equipment or authorized replacement parts Using the correct parts will assure continued safe operation as designed Do not support the generator from the top of the frame or enclosure Do not tamper with or change the engine speed Engine spee
51. High resistance connections connections will be warm or hot Internal failure of Alternator Low power factor Verify engine RPM Check engine for malfunction or system for overload Reduce load Verify all connections and terminal tighness Return to factory for repair Reduce inductive motor load Some AC motors use about the same current regardless of load Do not use motors of greater horsepower rating than is necessary to move the mechanical load High output voltage Excessive speed fixed speed mode Check engine for malfunction Verify engine RPM Electrical shock when frame is touched Static charge Grounded armature or field coil Ground generator frame at local reference ground see Section 3 Return to factory for repair Mechanical noise Internal failure of Alternator Loose or misaligned coupling 5 2 Troubleshooting and Maintenance Return to factory for repair Tighten align coupling and alternator shaft to engine shaft MN2415 Problem Controller does not power up even with correct DC power applied Possible Cause Wiring Mistake Loss of DC Supply Table 5 2 Troubleshooting Guide Digital Controller Only 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
52. IE 7 RM1088A11 TS25 Green 5 RM1088A12 TS45 Red RM1088A13 TS80 White RM1088A25 TS45 Green Table D 1 Generator Set Parts List HB6072A04 HB6072A05 21 22 Ref No Part No Description 1 HB6179A00 Adaptor Engine 2 62FN2000A02 Fan 3 62RA0025A00 Rotor Assembly 4 BG6207H03 Rotor Bearing 5 62SA0017A00 Stator Assembly 6 62EX5002A04 Exciter Assembly 7 62EP3200A02 Bearing Bracket 8 HB7023A00 Rotor End Plate 9 HA2444A02 Rotor Bolt Rotor to Engine Not Shown 0027 01 Voltage Regulator AVC63 2 0 15 RM1088A11 Isolator 20 BA0232A03 Base Frame 21 HB6072A04 Engine Mounting Foot Right 22 HB6072A05 Engine Mounting Foot Left D 2 Series AE25 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 Radiator Cooling Not Shown EA0005A08 Upper Radiator Hose Not Shown EA0005A38 Lower Radiator Hose Not Shown TA0000A07 Coolant Recovery Tank Not Shown TA0002A07 Cap Coolant Recovery Tank
53. N2415 Table B 1 Generator Set Parts List Continued Ref No Part No Description pen 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 Left Side X Not Shown HB2400A00 Enclosure Latch X Not Shown BE0364A17 Control Box X Not Shown EH0296A02 Control Box X Not Shown 5 9094 Toggle Switch Master Control X X Not Shown DI0181A00 Glo Light X X Not Shown 010176 00 X Not Shown CK0070A05 Circuit Breaker 50Amp X Not Shown CK0070A29 Circuit Breaker 50Amp X Not Shown EB1243A00 Control Circuit Board X X Not Shown FU066A02 Fuse AGC1 X X Not Shown FU066A00 Fuse MTH 5 X Not Shown EA5009A00 Muffler X Not Shown EA0008A08 Muffler Silencer X Not Shown HB6116A00 Battery Tie Down X X Not Shown HA3187A12 Battery Tie Down Bolt X X Not Shown EA0010A04 Battery Charger 12V 2AMP X X Not Shown HB6146A00 Fuel Load Block K N X X Not Shown HB6147A00 Carburetor Adapter X X Not Shown EA0000A00 Regulator K N Manual Prime X X Not Shown SE0052A00 Solenoid Low Pressure X X Wiring Diagrams Wiring diagrams for these generators are contained on the following pages of this appendix MN2415 Series AE10 B 3 Figure B 4 AE10 Customer Connection Diagram
54. ND 20393 SW AVERY COURT TUALATIN OR 97062 PHONE 503 691 9010 FAX 503 691 9012 PENNSYLVANIA PHILADELPHIA 1035 THOMAS BUSCH MEMORIAL HIGHWAY PENNSAUKEN NJ 08110 PHONE 856 661 1442 FAX 856 663 6363 PITTSBURGH 616H BEATTY ROAD MONROEVILLE PA 15146 PHONE 412 380 7244 FAX 412 380 7250 TENNESSEE MEMPHIS 4000 WINCHESTER ROAD MEMPHIS TN 38118 PHONE 901 365 2020 FAX 901 365 3914 TEXAS HOUSTON 4647 PINE TIMBERS SUITE 135 HOUSTON TX 77041 PHONE 713 895 7062 FAX 713 690 4540 DALLAS 3040 QUEBEC DALLAS TX 75247 PHONE 214 634 7271 FAX 214 634 8874 UTAH SALT LAKE CITY 2230 SOUTH MAIN STREET SALT LAKE CITY UT 84115 PHONE 801 832 0127 FAX 801 832 8911 WISCONSIN MILWAUKEE 2725 SOUTH 163RD STREET NEW BERLIN WI 53151 PHONE 262 784 5940 FAX 262 784 1215 INTERNATIONAL SALES FORT SMITH AR P O BOX 2400 FORT SMITH AR 72902 PHONE 479 646 4711 FAX 479 648 5895 CANADA EDMONTON ALBERTA 4053 92 STREET EDMONTON ALBERTA T6E 6R8 PHONE 780 434 4900 FAX 780 438 2600 OAKVILLE ONTARIO 2750 COVENTRY ROAD OAKVILLE ONTARIO L6H 6R1 PHONE 905 829 3301 FAX 905 829 3302 MONTREAL QUEBEC 1844 WILLIAM STREET MONTREAL QUEBEC H3J 1R5 PHONE 514 933 2711 FAX 514 933 8639 VANCOUVER BRITISH COLUMBIA 1538 KEBET WAY PORT COQUITLAM BC V3C 5M5 PHONE 604 421 2822 FAX 604 421 3113 WINNIPEG MANITOBA 54 PRINCESS STREET WINNIPEG MANITOBA 1 2 PHONE 204 942 5205
55. Not Shown EA0044A07 Valve Fumoto F 107 N Not Shown EA0044A00 Valve Fumoto T 202N Not Shown EA0001A01 Sender Water Temperature Not Shown EA0001A02 Sender Oil Pressure Not Shown EA0007A05 Magnetic Pickup Assembly Not Shown EA0029A02 Fuel Actuator Ford 2 5L Not Shown SE0052A00 Fuel Lock Solenoid Not Shown EA0000A02 Fuel Regulator Not Shown EA0015A08 Air Filter Not Shown EA0029A03 Fuel Mixer Ford 2 5L Not Shown EA0030A02 Diaphragm Natural Gas Not Shown GS0091A00 Gasket Throttle Not Shown GS0091A01 Gasket Actuator to Mixer Not Shown BE0412A00 Control Box Not Shown 0045 01 Engine Controller Memory 09 132 Tooth Not Shown EM0039A02 Controller LRG423 for Ford 2 5L Not Shown CK0070A59 Circuit Breaker w o shunt trip Not Shown RE5031A09 Relay VF7 41F 11 Not Shown EA5034A02 Diode Kit with 10 amp 1 4 Ring Terminals Not Shown HB6116A00 Battery Tie Down Not Shown HA3187A12 Battery Tie Down Bolt Not Shown EA0010A02 Battery Charger 12VDC Not Shown SP9094 Switch DPDT Not Shown SP9113 Switch Nat Gas L P Gas Not Shown WD3203A00 Oil Pressure Gauge Not Shown WD3204A00 Water Temperature Gauge Not Shown WD3201A11 Volt Meter Not Shown WD3201A00 Elapsed Time Meter Not Shown FU066A07 Fuse AGC15 Not Shown FU066A00 Fuse MTH 5 Not Shown LB0094B19 Decal Control Panel AE25 Not Shown LB0100A22 Decal Baldor Auto Emergency 20 Not Shown LB0100A02 Decal Baldor Auto Emergency 12 Not Shown LB0100A03 Decal Baldor Auto Emergency 39 sp
56. RM1088A07 Isolator Engine end X X 20 BA0191A00 Base Frame X 20 BA5000A00 Base Frame X 21 HB7025A00 Engine Mounting Foot X X 22 HB7002A07 Engine end frame cross member X 22 HB7002A08 Engine end frame cross member X 23 HB6150A00 Alternator end frame cross member X 23 HB6150A01 Alternator end frame cross member X A 2 Series 8 MN2415 Table A 1 Generator Set Parts List Continued Ref No Part No Description pen 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 Left Side X Not Shown HB2400A00 Enclosure Latch X Not Shown EH0308A00 Control Box X Not Shown EB1243A00 Circuit Board ARSS 3 X Not Shown EH0296A00 Control Box X Not Shown SP9094 Toggle Switch Master Control X X Not Shown DI0181A00 Glo Light X X Not Shown 010176 00 Diode X X Not Shown OC6030F11 Capacitor 30MFD 370V 90 degree X X Not Shown CK0070A04 Circuit Breaker 40Amp X Not Shown CK0070A27 Circuit Breaker 35Amp X Not Shown FU066A02 Fuse AGC1 X X Not Shown EA5009A00 Muffler X Not Shown EA0008A08 Muffler X Not Shown EA0008A08 Muffler Silencer X Not Shown HB6116A00 Battery Tie Down X X Not Shown HA3187A12 Battery Tie Down Bolt X X Not Shown EA0010A04 Battery Charger 12V 2AMP X X Not Shown HB6146A00 Fuel Load Block K N X X Not Shown HB614
57. RNING WARNING WARNING Burn WARNING WARNING WARNING MN2415 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 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 Always wear safety glasses with side shields and hearing protection when working near the generator Improper operation may cause violent motion of connected equipment Be certain that unexpected movement will not cause injury to personnel or damage to equipment Never operate the generator set indoors or in a poorly ventilated area such as a tunnel or cave Exhaust fumes are extremely dangerous to all personnel that are in or in contact with that area Never permit anyone to operate the generator without proper instructions Be sure to keep a copy of this manual with the generator so that all users can be properly informed of its safe operation Never allow children or pets to be in the area where the generator is running The generator and the equipment being powered by the generator may cause injury or death Never operate the generator unless all guards covers shields and other safety items are properly installed Do not put hands feet tools clothing or other objects near rotating parts such as drive shaft pulley
58. S J J Attn Cog tt N3HDLSQ2 4345 91 OLAV 01 A T8N3SSV SIUIVS3N39 AlRW3SSV HOLIAS aASsSNVAL ZOLNAV e 5 9 8 MN2415 A 4 Series AE8 Figure A 5 AE8 Open Frame Wiring Diagram 340 83V 8949910 1123 02 43H 69120000v9d 374 709 81 lt 1 lt 2 YAL 2002 22 20 25 96 71 q3SIA3d Hl A3H d A3y I L 016 SYM LVWHOd NOGTVS 2530 A38 01830 30193339 9 52 m zao ov 69 189 MOLIOYdVO S TWNINYAL ONIN 47 1 NNOO N3l4V S3HONI 119 gt MOlvino3H 30 330 35 8 5 ___ ___ 5 Ors 5 Sof VR SQ li 4314915 OL i 9 SLOVINOD 1491 io 01 aul 1934 5 110 NOTI3A 55598 0000 085 51011875
59. S MOINES 1800 DIXON STREET SUITE C DES MOINES IA 50316 PHONE 515 263 6929 FAX 515 263 6515 MARYLAND BALTIMORE 6660 SANTA BARBARA RD SUITE 22 24 ELKRIDGE MD 21075 PHONE 410 579 2135 FAX 410 579 2677 MASSACHUSETTS BOSTON 6 PULLMAN STREET WORCESTER MA 01606 PHONE 508 854 0708 FAX 508 854 0291 MICHIGAN DETROIT 33782 STERLING PONDS BLVD STERLING HEIGHTS MI 48312 PHONE 586 978 9800 Baldor District Offices FAX 586 978 9969 MICHIGAN Continued GAND RAPIDS 668 3 MILE ROAD NW GRAND RAPIDS MI 49504 PHONE 616 785 1784 FAX 616 785 1788 MINNESOTA MINNEAPOLIS 21080 134TH AVE NORTH ROGERS MN 55374 PHONE 763 428 3633 FAX 763 428 4551 MISSOURI ST LOUIS 422 INDUSTRIAL DRIVE MARYLAND HEIGHTS MO 63043 PHONE 314 298 1800 FAX 314 298 7660 KANSAS CITY 915 W PLATTE VALLEY DR RIVERSIDE MO 64150 PHONE 816 587 0272 FAX 816 587 3735 NEW YORK AUBURN ONE ELLIS DRIVE AUBURN NY 13021 PHONE 315 255 3403 FAX 315 253 9923 NORTH CAROLINA GREENSBORO 1220 ROTHERWOOD ROAD GREENSBORO NC 27406 P O BOX 16500 GREENSBORO NC 27416 PHONE 336 272 6104 FAX 336 273 6628 OHIO CINCINNATI 2929 CRESCENTVILLE ROAD WEST CHESTER OH 45069 PHONE 513 771 2600 FAX 513 772 2219 CLEVELAND 8929 FREEWAY DRIVE MACEDONIA OH 44056 PHONE 330 468 4777 FAX 330 468 4778 OKLAHOMA TULSA 2 EAST DAWES BIXBY OK 74008 PHONE 918 366 9320 FAX 918 366 9338 OREGON PORTLA
60. Shutdown Indicators Alternator Failure to Charge Battery Auxiliary 1 Input Active Auxiliary 2 Input Active Hour Meter Displays total hours of operation based on power applied to Fuel Solenoid Stop Stops the Engine and generator set Manual Run Immediately energizes the crank cycle to start the generator set and produce power Auto Start The engine can only be started by making a connection across the remote start terminals of the control box This allows normal automatic backup operation of the Generator Set under control of the Transfer Switch whenever utility AC power is lost MN2415 Operation 4 1 Figure 4 3 Operator Control Panel AE25 BALDOR eee GENERATORS E WATER OIL C 9 HIGH TEMPERATURE LOW OIL PRESSURE OVERSPEED BATTERY OVERCRANK Hour Meter STOP MANUAL AUTO DC CONTROL FUSE AC CONTROL FUSEC RUN START MASTER NAT Gas L P GAS CONTROL Display Lamps High Temperature Indicates excessive engine coolant temperature Low Oil Pressure Indicates low engine oil pressure Overspeed Indicates engine speed is greater than preset limit Overcrank Failure of the engine to start by the end of the crank period results in overcrank shutdown and alarm indication Hour Meter Displays total hours of operation based on power applied to Fuel Solenoid Meters Water Displays the temperature of the engine coolant Oil Displays
61. Timer O O O O O O 0 Seconds 5 Seconds 10 Seconds 15 Seconds 20 Seconds 30 Seconds 60 Seconds 180 Seconds eeooeeo prior to 10 Seconds 15 Seconds 20 Seconds 30 Seconds 60 Seconds 180 Seconds top Delay 5 Seconds 10 Seconds 15 Seconds 20 Seconds 30 Seconds 60 Seconds 180 Seconds Provides a delay between deactivating the remote start input and actually stopping the engine 5 Seconds 10 Seconds 15 Seconds 20 Seconds 30 Seconds 60 Seconds 180 Seconds ontrols of the engine stop solenoid When the engine is to be stopped the Energize To Stop output becomes active closing the stop solenoid fuel valve When the engine comes to rest the stop solenoid will remain energized for the period of the Energize To Stop Timer to ensure the engine has come to a complete stop Warm up Timer 0 Seconds 5 Seconds 10 Seconds 15 Seconds 20 Seconds 30 Seconds 60 Seconds 180 Seconds Delay between the engine being available for use and the closure of the generator load switching device to allow time for the engine to warm before being eoeoe o loaded This occurs after the 12 second safety on timer 4 6 Operation MN2415 Table 4 1 Progra
62. a building it is essential to provide 1 Adequate control and exhausting of the heated air 2 Anadequate and constant supply of incoming cooling air 3 Adequate control and discharge of the engine s hot exhaust gases 4 Adequate ventilation of the building when the engine shuts down Several other factors should be carefully evaluated when selecting a location for installation 1 For effective cooling and maintenance the system should be mounted on flat smooth non flammable level surface A concrete pad is ideal and provides a secure installation 2 Installation should prevent water levels from reaching the generator Drainage must be adequate to keep concrete pad free from standing water 3 Installation should prevent obstructions by buildup of leaves grass sand snow etc If these items pose a problem consider building a small fence or other break to protect the unit from accumulation of debris 4 Installation should place the generator as close as possible to the fuel supply and transfer switch 5 Atleast forty eight 48 inches clearance must be provided on all sides for air flow 6 Maximum Ambient temperature is 122 F 50 C Engine Cooling A sufficient flow of clean cool air is required for combustion and to dissipate the heat produced by the engine Approximately 6096 of the heat value of the fuel used is given off as heat cooling air and exhaust The air that will cool the engine must be brought in from outs
63. able of batteries and the required precautions Keep unauthorized personnel away from batteries 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 The risk of such shock is reduced when the ground lead is removed during installation and maintenance An open bottom stationary engine generator set must be installed over noncombustible materials and shall be located such that it prevents combustible materials from accumulating under the generator set Installation and repair procedures requires specialized skills with electrical generating equipment and small engine systems Any person that installs or performs repairs must have these specialized skills to ensure that the generator set is safe to operate Contact Baldor for installation or repairs Be sure all wiring complies with the National Electrical Code NEC and all regional and local codes or CE Compliance Improper wiring may cause a hazardous condition and exposure to electrical hazards can cause serious injury or death 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
64. aking a connection across the remote start terminals of the control box This allows normal automatic backup operation of the Generator Set under control of the Transfer Switch Controller Fuse This fuse provides overload protection for the controller circuit board Lamp This Red indicator light will come on when the engine shuts down due to a fault condition Circuit Breaker The 2 pole Circuit Breakers provide overload protection excessive AC current for the generator set output windings MN2415 Series AE8 1 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 20 Figure A 2 Alternator Assembly Figure A 3 Frame Assembly RM1088A01 RM1088A06 RM1088A07 Table A 1 Generator Set Parts List Ref No Part No Description pen Enclosed 1 HA9139A01 Adaptor Engine X X 2 61FN3000 Fan X X 3 61RA0016A00 Rotor Assembly X X 4 BG6204H03 Rotor Bearing X X 5 61SA0015A03 Stator Assembly 5 61SA0015A04 Stator Assembly X 6 61EP3204A01 Bearing Bracket X 6 61EP3204A07 Bearing Bracket X 7 EH0321A00 Cover X 8 HA1037A00 Washer X X 15 RM1088A01 Isolator Control Box X 16 RM1088A06 Isolator Generator end X 16
65. all times Keep non qualified personnel at a safe distance from this equipment Only qualified personnel familiar with the safe installation operation and maintenance of this device should attempt start up or operating procedures A Always stop engine before making or removing any connections A Always stop engine and allow it to cool before refueling When your generator is delivered it becomes the responsibility of the owner operator of the generator set to prevent unsafe conditions and operation of the equipment Some responsibilities include but are not limited to the following 1 It is the responsibility of the owner operator of this generator to ensure that this equipment is correctly and safely installed 2 It is the responsibility of the owner operator of this generator to ensure that this equipment when installed fully complies with all federal state and local codes It is the responsibility of the owner operator of this generator to ensure that any person operating this equipment has been properly trained 4 It is the responsibility of the owner operator of this generator to ensure that any person operating this equipment has access to all manuals and information required for the safe use and operation of this equipment 5 It is the responsibility of the owner operator of this generator to ensure that it is properly maintained and safety inspected at regular scheduled intervals 6 Itis the responsibility of t
66. allation or operation IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important instructions for the generator that should be followed during installation operation and maintenance of the generator For ease of reading the Warning statements are divided into four categories Operation Burn Installation and Maintenance Operation WARNING WARNING WARNING WARNING WARNING WARNING WARNING Never operate this generator in a manner other than as described in this manual Operation in any manner not described in this manual should be considered unsafe and should not be attempted Never start the engine unless you have first verified that the installation and operation of the generator are as described in this manual 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 Exhaust fumes gases are extremely dangerous and can cause severe illness or death Never breath exhaust fumes produced by a running engine Only run the engine outdoors where ventilation is plentiful Exhaust gases contain carbon monoxide a colorless odorless and extremely dangerous gas that can cause unconsciousness or death Symptoms of carbon monoxide poisoning include dizziness nausea headaches sleepiness vomiting or inc
67. any of the following general recommendations General 1 Inspect the fuel system for leaks Replace all defective components immediately Inspect and replace any fuel line that shows signs of deterioration Inspect all the fuel clamps to ensure they are tight Inspect and clean the battery posts and the associated battery cable terminals Inspect the external wire cables and connectors used with the generator set for cuts fraying or loose connections Repair or replace any problems prior to using the unit Engine 1 Clean and or replace fuel oil and or air filters per the engine manufacturers guidelines 2 Check oil level regularly at least every 5 to 8 operating hours Maintain the proper oil level 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 5 Clean the cooling fins on the engine to keep the engine s heat dissipation potential at its maximum 6 Inspect and clean all governor and carburetor linkages so they operate properly Alternator also called Generator End This generator set must be run at its proper speed to obtain the correct electrical power at its output All engines have a tendency to slow down when a load is applied to it The engine governor is designed to hold the operating speed as nearly constant as possible When the electrical load is increased the engine is more heavily loaded and engine speed drops sl
68. at are much more corrosive than others Prevention of a failure is better than being forced to make a repair 1 13 14 15 16 17 18 19 3 16 Receiving amp Installation Generators that have been in transit or storage for long periods may be subjected to extreme temperature and moisture changes This can cause excessive condensation and the generator windings should be thoroughly dried before bringing the generator up to full nameplate voltage If this precaution is not taken serious damage to the generator can result Verify that the transfer switch is in Utility Power mode No power must be present at the generator or transfer switch connections Verify with a voltmeter Verify that the engine starting battery negative lead is disconnected so accidental starting is not possible Verify that the generator is securely mounted and anchored to its cement pad Verify that proper clearance exists on all sides and top of enclosure Verify that generator power is properly connected to the transfer switch Verify that generator and transfer switch are properly grounded Verify that the remote start wires are properly connected and tight between the generator and transfer switch terminals Assure that generator is a safe distance from any flammable or combustible material Verify that the generator and transfer switch load are voltage compatible Verify that no load is connected to the circuit breaker and or transfer swi
69. at tuel valves are ON Check fuel level in tuel tank Low Oil Level Low Oil Pressure Sutdown activated Replensih oil to full Restricted air flow Check replace air filter No spark Check replace spark plug s No engine speed during crank Check that engine switch is in Start position The magnetic pickup must be correctly adjusted and operating Engine will not crank electric start Dead battery Emergency Stop LED is ON Remove battery and trickle charge or replace with new battery Never Jump Start Reset controller after an Emergency Stop Engine starts but will not run smoothly Fuel or ignition problem Refer to engine manual Engine overheats Excessive load Debris or dirt buildup on engine Remove one or more electrical loads Remove debris Clean engine surfaces to allow cooling No output voltage Ciruit Breaker tripped or failed Internal failure of Alternator Reset circuit breaker or replace if required Return to factory for repair Output voltage varies Irregular speed fixed speed mode Fluctuating speed fixed speed mode Loose terminal or load connections Check engine for malfunction or load for fluctuation Stabilize load The addition of a lamp load resistance load may compensate partially for load changes caused by intermittent motor operation Do not overload Verify all connections and terminal tighness Low output voltage Low engine speed Excessive load
70. cal ground reference may require a driven earth ground conductor at the generator installation site Make the ground connection as shown in Figure 3 11 Use the appropriate size wire as required by NEC and local codes Figure 3 11 Frame Ground Connection Nut Washer Ground Wire Lug Washer Earth Ground Stud 4 Frame 1 Open the enclosure access panel door 2 Figure 3 1 2 Connect the ground wire to the earth ground terminal shown in Figure 3 11 This ground is the local reference ground to ground the generator frame only Engine Oil Level AE8 AE10 AE11 25 These generators are shipped dry which means there is no oil in the engine and no battery installed 1 Check the engine oil level it should be empty 2 See Table 3 5 and add the appropriate amount of oil to the engine crankcase 3 Add alittle at a time and check the oil level to ensure that you do not overfill the crankcase Stop adding oil when the oil level reaches the full line Coolant Level AE25 only 1 Check the coolant level while the engine is cold it should be full 2 Ifthe coolant level is low add some coolant as recommended in the engine manual usually a 50 50 mixture of antifreeze and water MN2415 Receiving amp Installation 3 13 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 remo
71. codes may also require proper grounding of generator systems Never allow the exhaust outlet to be positioned so that the exhaust gases are directed towards any openings or air entry routes doors windows vents etc of an occupied building When discharging the hot exhaust gases out of the building do not direct them towards anything that could catch fire or explode Place protective covers over all rotating parts such as drive shaft pulley belt etc Rotating parts cause extremely dangerous situations because they can catch loose clothing or extremities and cause serious or fatal injury Unauthorized modification of a generator set may make the unit unsafe for operation or may impair the operation of the unit Never start a generator set that has been modified or tampered with Be sure that all covers and guards are properly installed and that the unit is safe before starting the engine If you are unsure contact Baldor before starting the engine When moving the generator use reasonable caution Be careful where you place fingers and toes to prevent injury Pinch Points Never try to lift a generator without a hoist or lift means because they are heavy and bodily injury may result Never connect this generator to the electrical system of any building unless a licensed electrician has installed an approved transfer switch The national electrical code NEC requires that connection of a generator to any electrical circuit normally powered by mean
72. culate into the engine s cooling air intake 2 The exhaust system is subject to the engine s vibration and it must therefore be solidly secured to reduce mechanical stress and the potential for breakage 3 The engine s exhaust system is the hottest component of the installation and extreme care and considerations must be given to it Receiving amp Installation 3 3 Indoor Location Continued Installation 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 Acarbon 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 The generator is completely assembled tested and adjusted at the factory before it is shipped to you The procedures presented in this manual are suggestions and it is the responsibility of the Owner Operator to arrange for these procedures to be performed by licensed contractors according to all applicable codes including local codes for your Municipality City County and State Installation generally includes the following Secure Generator to concrete pad Connect Fuel Supply Electrical Connections power wiring optional transfer switch and control wiring Battery not
73. d corrosive The following precautions are to be followed when working on batteries 1 Wear full eye protection safety glasses or goggles and protective clothing 2 Where electrolyte contacts the skin flush the area immediately with water and wash it off using soap and water 3 Where electrolyte contacts the eyes immediately flush the eye thoroughly with water and seek medical attention quickly 4 Spilled electrolyte is to be washed down with an acid neutralizing agent A common practice is to use a solution of one pound 500 grams bicarbonate of soda to one gallon four liters of water The bicarbonate solution is to be added until evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried A battery presents a risk of fire because they generate hydrogen gas Hydrogen gas is extremely explosive Never jump start a battery smoke in the area around the battery or cause any spark to occur in the area around the battery The following precautions are to be followed when working on batteries 1 Do not smoke when near batteries 2 Do not cause flame or spark in battery area 3 Discharge static electricity from body before touching batteries by first touching a grounded metal surface 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 posit
74. d is factory set to produce the correct voltage and output frequency Never operate the engine without a muffler The engine is designed to have the correct exhaust components installed and operating without these components can present a fire hazard cause excessive exhaust gases and cause damage to engine Inspect muffler periodically and replace if necessary The Programmable Output Contacts selection must agree with the external control wiring prior to energizing the controller Failure to do so may cause severe equipment damage 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 1 6 Product Safety Information MN2415 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 Please refer to the engine manual for information relative to engine operation maintenance recommendations and additional safety warnings Copyright Baldor 2004 All rights reserved This manual is copyrighted a
75. ddress and telephone number of the party requiring warranty service must be included Baldor is not responsible for removal and shipment of the Baldor product to the service center or for the reinstallation of the Baldor product upon its return to the party requiring warranty service Problems with Baldor products can be due to improper maintenance faulty installation non Baldor additions or modifications or other problems not due to defects in Baldor workmanship or materials If a Baldor Generator repair facility determines that the problem with a Baldor product is not due to defects in Baldor workmanship or materials then the party requesting warranty service will be responsible for the cost of any necessary repairs EXCEPT FOR THE EXPRESSED WARRANTY SET FORTH ABOVE BALDOR GENERATORS DISCLAIMS ALL OTHER EXPRESSED AND IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE AND MERCHANTABILITY NO OTHER WARRANTY EXPRESSED OR IMPLIED WHETHER OR NOT SIMILAR IN NATURE TO ANY OTHER WARRANTY PROVIDED HEREIN SHALL EXIST WITH RESPECT TO THE GOODS SOLD UNDER THE PROVISIONS OF THESE TERMS AND CONDITIONS ALL OTHER SUCH WARRANTIES ARE HEREBY EXPRESSLY WAIVED BY THE BUYER UNDER NO CIRCUMSTANCES SHALL BALDOR GENERATORS BE LIABLE OR RESPONSIBLE IN ANY MANNER WHATSOEVER FOR ANY INCIDENTAL CONSEQUENTIAL OR PUNITIVE DAMAGES OR ANTICIPATED PROFITS RESULTING FROM THE DEFECT REMOVAL REINSTALLATION SHIPMENT OR OTHERWISE This is the sol
76. dn Ov3l v 9 leeuMA 4 i GL X JolplsV lleds GND 2 PS 179 7109 9 7109 99 jeduunp a puno49 0 0 9109 10 0 06 HY per de S 6 NN o 6 5 8 ja aoe N N 2 T ud E deis 23 ge R B N N CN N EX N D 9MV 91 VV VV LOON H SMV 9 6 8 L 9 86 C ZOON H 9 6109 OMV 9 TOOL SMV 9 ISNVd ION LNOO OL ZOOL 91 1002 OMV 9 2004 91 2002 91 dX xsss3 uo M 9909 3 3 uo pesog 21992 31972 3N3MdO3N X3SS3 pasog 21900 31ON MN2415 D 4 Series AE25 UW Wv3OVIO NOILO3NNOO LNSNLYVdWOD 3NION3 S1SC3V 492003 33 482 00007 98 3113 05 jJhLLONTM diva OBLELE HAL lt 002 62 60 2111 5 3 MIT 3078 0935 SVM SvOZ 870L QAW3H 0530 A34 WEO026D
77. e warranty of Baldor Generators and no other affirmations or promises made by Baldor Generators shall be deemed to create an expressed or implied warranty Baldor Generators has not authorized anyone to make any representations or warranties other than the warranty contained herein Warranty Period enerator Series Labor Parts Portable Products Premier Powerchief DG Series K Series 1 Year 3 Years Towable Products TS 1 Year or 3 000 Hours Whichever comes first 3 Years or 3 000 Hours Whichever comes first POW R LITE Light Towers 1 Year or 3 000 Hours Whichever comes first 3 Years or 3 000 Hours Whichever comes first Excluded from any warranty coverage regardless of time period Light Fixture Lamps and Ballasts 3600 RPM Standby Systems Some AE Models 1 Year or 1 000 Hours Whichever comes first 3 Years or 1 000 Hours Whichever comes first 1800 RPM Standby Systems Some AE Models DLC GLC 1 Year or 3 000 Hours Whichever comes first 3 Years or 3 000 Hours Whichever comes first Industrial Standby Systems 1 Year or 1 000 Hours Whichever comes first 2 Years or 1 000 Hours Whichever comes first Industrial Prime Power Systems 1 Year or 1 000 Hours Whichever comes first 1 Year or 1 000 Hours Whichever comes first International 1 Year or 1 000 Hours Whichever comes first 1 Year or 1 000 Hours Whichever comes first For products cover
78. e 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 Any person that installs or repairs this generator must have these specialized skills to ensure that this generating unit is safe to operate Contact Baldor for repairs or any questions you may have about the safe installation and operation of this system The precaution statements are general guidelines for the safe use and operation of this generator It is not practical to list all unsafe conditions Therefore if you use a procedure that is not recommended in this manual you must determine if it is safe for the operator and all personnel in the proximity to the generator and connected loads If there is any question of the safety of a procedure please contact Baldor before starting or stopping the generator This equipment contains high voltages Electrical shock can cause serious or fatal injury Only qualified personnel should attempt the start up procedure or troubleshoot this equipment This equipment may be connected to other machines that have rotating parts or parts that are driven by this equipment Improper use can cause serious or fatal injury Only qualified personnel should attempt the start up procedure or troubleshoot this equipment System documentation must be available to anyone that operates this equipment at
79. ed under labor coverage travel expenses will be allowed up to 7 hours straight labor or 300 miles whichever occurs first and only applies to permanently wired and mounted products AE DLC GLC IDLC No warranty registration card is necessary to obtain warranty on Baldor Generators You must save the purchase receipt Proof of purchase date serial number and model number will be required for all portable and Towable products to qualify for any warranty consideration For all other products a start up inspection form warranty registration must be completed in its entirety and submitted to Baldor Generators within 30 days of start up to qualify for any warranty consideration MN2415 General Information 2 1 2 2 General Information MN2415 Section 3 Receiving amp Installation Receiving amp Inspection When you receive your generator there are several things you should do immediately Observe the condition of the shipping container and report any damage immediately to 1 2 3 the commercial c arrier that delivered your system Verify that the part number of the system you received is the same as the part number listed on your purchase order If the system is to be stored for several weeks before use be sure that it is stored ina location that conforms to published storage temperature and humidity specifications Lifting the Generator When lift or hoist equipment is used to lift the generator and move it
80. engine oil pressure Overspeed Indicates engine speed is greater than preset limit Overcrank Failure of the engine to start by the end of the crank period results in overcrank shutdown and alarm indication Hour Meter Displays total hours of operation based on power applied to Fuel Solenoid Meters Water Displays the temperature of the engine coolant Oil Displays the engines oil pressure Battery Displays the battery voltage of the starting battery DC Control Fuse Fuse for engine controller AC Control Fuse Fuse for engine controller 0000 edd Master Control Switch Stop Stops the Engine and generator set Manual Run Immediately energizes the crank cycle to start the generator set and produce power Auto Start The engine can only be started by making a connection across the remote start terminals of the control box This allows normal automatic backup operation of the Generator Set under control of the Transfer Switch whenever utility AC power is lost Natural LP Gas Selector Switch Selects the correct fuel source Natural Gas or L P Gas MN2415 Series AE25 D 1 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 Figure D 3 Frame Assembly T
81. ent Ri Twisted Pair Remote Start Switch Twisted Pair Remote Start Switch R2 Close to Start Close to Start e 1 S OF Batt S Battery _ Battery TSS Charger mt Charger BWO201D 52 55 To 120VAC 120 0 0 Shore Power Shore Power Connect DK1 and DK of the battery charger go to the D1 and D2 terminals of the terminal block if a Master Control Systems Inc 3 10 Receiving amp Installation Battery charger is installed DK1 and DK2 are not polarity sensitive 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 Output Power Connections AE11 with Enclosure rd 8 98 Customer 12 12 86 Output Connections Generator to Transfer Switch Output Jumpered Jumpered 9 N L1 to N 120VAC L2 to N 120VAC L1 to L2 240VAC BWO0459D Remote Start and Battery Charger Connections Figure 3 8 shows the connections for the battery charger and the remote start contacts of the transfer switch When the Remote Start Switch is closed the generator will start The unit will remain running until this connection is opened When the Remote Sta
82. er Speed Detection O Disabled Enabled U S 20 If this is enabled the unit will shut down the generator if the frequency falls below 20 of the nominal frequency Auxiliary Input 1 O O Immediate Warning Immediate Warning Open on Fault Immediate Shutdown Close on Fault Immediate Shutdown Open on Fault Delayed Warning Close on Fault Delayed Warning Open on Fault Delayed Shutdown Close on Fault Delayed Shutdown Open on Fault JE JE JE OLOO eeooeeo ee Note 1 Auxiliary Input 2 Immediate Warning Close on Fault e Immediate Warning Open on Fault O Immediate Shutdown Close on Fault Immediate Shutdown Open on Fault Delayed Warning Close on Fault Delayed Warning Open on Fault f Delayed Shutdown Close on Fault Delayed Shutdown Open on Fault Note 1 2415 Operation 4 7 Note 1 Programmable input can be configured to on of the following ee Note 2 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 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 Immediate shutdown close on fault If the input is activated at any time the generator will be shutdown and energize the common warning a
83. et 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 The risk of such shock is reduced when the ground lead is removed during installation and maintenance 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 A battery presents a risk of fire and explosion because they generate hydrogen gas Hydrogen gas is extremely explosive Never jump start a battery smoke in the area around the battery or cause any spark to occur in the area around the battery WARNING Do not mutilate the battery or dispose of a battery in a fire The battery is capable of exploding If the battery explodes electrolyte solution will be released in all directions Battery electrolyte solution is caustic and can cause severe burns and blindness If electrolyte contacts skin or eyes immediately flush the area with water and seek medical attention quickly WARNING A battery presents a risk of electrical shock hazard and high short circuit current Electrical shock can cause serious or fatal injury Never wear jewelry watch or any metal objects
84. for each fuel type Note The AE25 must be ordered for use with Natural gas or LPG Table 3 2 Fuel Consumption Natural and LPG equirec ressure Natural Gas oz inches water column 160 6 oz 11 200 6 oz 11 200 4 02 7 400 6 oz 11 General Considerations 1 Agenerator set needs the engine to deliver 2 hp of energy to the alternator for every 1000 watts of electric output power example an 8000 watt generator needs the engine to deliver 16 hp of energy to the generator end 2 Anengine needs 10 000 BTU s of fuel energy per horsepower of engine power to provide a sufficient supply of fuel example a 16 Hp engine needs 160 000 BTU s of fuel energy for it to work properly This fuel must be supplied to the regulator on the generator set at a pressure indicated in Table 3 2 To achieve this pressure in an L P System you will normally have to reduce the tank pressure by means of a primary regulator or a regulator system of 2 or more regulators 3 There are 2 516 BTU s in one cubic foot of Propane LP Fuel There are 1 096 BTU s in one cubic foot of Natural Gas 4 There are 36 39 cubic feet in one gallon of Propane There are 57 75 cubic feet in one gallon of Natural Gas 5 There are 8 58 cubic feet per pound of Propane There are 23 56 cubic feet per pound of Natural Gas 6 When installing the piping for the gaseous fuel supply please refer to the pipe chart in Tables 3 3 and 3 4 to be s
85. h on the rear bottom edge of the printed circuit board This is partially hidden to prevent accidental operation When Configuration Mode is selected the Auto LED will flash rapidly and all normal operations are suspended Figure 4 4 Configuration Editor Access Switch in Normal Mode Switch in Configuration Mode Editing The Configuration MN2415 The Stop pushbutton is pressed to select the LED that corresponds to the function The first is the Pre Heat Timer Pressing Stop again displays Start Delay etc The 5 LED s on the left display the code for each function See Table 4 1 The Manual pushbutton is pressed to change the value The 3 LED s on the right display the present value See Table 4 1 When the correct parameter value is displayed press the Auto Start button to save the new setting Repeat the process for each function value you want to change When configuration is complete return the Configuration Mode Selector Switch to the Normal Mode position Note When configuration is complete return the Configuration Mode Selector Switch to the Normal Mode position to resume normal operation Table 4 1 shows the programmable functions and values for this engine controller Operation 4 5 Table 4 1 Programmable Functions and Values 12 Value Preset in Bold Pre Heat
86. he battery charger and the remote start contacts of the transfer switch When the Remote Start Switch is closed the generator will start The unit will remain running until this connection is opened When the Remote Start Switch is opened the control circuits allow the engine to run for approximately 60 90 seconds before it shuts off This time delay allows the engine to run unloaded to cool down before stopping Figure 3 4 Remote Start amp Battery Connections AE8 AE8 with Enclosure 16AWG Customer Provided Optional Equipment 16AWG _ Customer Provided ided Optional Eq Equipment pisted Pair Remote Start Switch Twisted Pair Remote Start Switch R2 76752 Close to Start Close to Start Batty O OF Batt C5 Out Battery Out Battery TSS n Charger 1551 To 120VAC Bwo183D ps To 120VAC 0 0 SE Shore Power Shore Power BW0120D Note Connect DK1 and DK2 of the battery charger go to the D1 and D2 terminals of the terminal block if a Master Control Systems Inc Battery charger is installed DK1 and DK2 are not polarity sensitive MN2415 Receiving amp Installation 3 9 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 bo
87. he owner operator of this generator to ensure that any person who has not been trained on the safe use of this equipment does not have access to this equipment Read This Manual Thoroughly MN2415 If you do not understand any concept any procedure any safety warning statement any safety caution statement or any portion of this manual contact Baldor or your nearest authorized Baldor representative We are happy to make sure you understand the information in this manual so that you can safely enjoy the full use of this generator Product Safety Information 1 1 Symbols al This symbol is shown throughout the manual to indicate a connection to ground reference point A 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 WARNING Caution Note There are three classifications of precautionary statements used in this manual The most critical is a WARNING statement then the Caution statement and the least critical is the Note statement The usage of each statement is as follows 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 damage to property Additional information that is not critical to the inst
88. hose clamp to the 90 elbow Figure C 5 90 Elbow with LPG Hose fuel line and Insert removed 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 Install the control box cover and the front panel The unit has now been converted to operate on Natural Gas Figure C 6 Lt GEN L1 BAT Charger L2 GEN N BAT Charger C 13 GEN G BAT Charger dumper akachen NGEN Remote Start to K N Regulator c LCS 59 Remote Start Gen Groundin electrode Fuel Jumper Terminal Wiring Diagrams Wiring diagrams for these generators are contained the following pages of this appendix C 4 Series AE11 MN2415 P NOUDaNNOO BWO341D Figure C 7 AE11 Customer Connection Diagram Series AE11 C 5 we
89. house transfer switch distribution box battery charger etc be properly installed Circuit Protection Circuit protection is not provided with the generator When connecting the generator output to an electrical load a UL listed circuit breaker with the appropriate ratings shall be provided within 25 feet of the genset Use only copper wires Generator Rating Kilowatt kW Input Breaker 1 Phase 3 Phase 1 Phase VAC Catalog No Rating Amps AE8 8 120 240 120 240 480 AE10 10 120 240 120 240 480 AE11 11 120 240 120 240 480 AE25 25 120 240 120 240 480 Transfer Switch Considerations The following are general considerations for the safe use of a transfer switch 1 The transfer switch should be located inside the building near the main breaker box or the disconnect box 2 transfer switch must be kept away from any location that might allow water to get on it 3 If the transfer switch is mounted outside it must be protected from the environment 4 not mount the transfer switch on the generator set 5 Do not mount the transfer switch where flammable liquids or vapors are present Battery Charger Considerations 3 8 Receiving amp Installation 1 Mount the battery charger on the generator or as close to the generator as possible 2 f you mount the battery charger inside the building mount it near the main breaker box
90. ide the building A sufficient air flow of rate Cubic Feet per Minute CFM will allow the incoming fresh air to cool the engine This requires a power ventilation system of sufficient CFM to be located at the highest possible point of the building to exhaust hot air and draw in cool fresh air For 8 12KW we recommend an exhaust fan of at least 2000 CFM Note The exhaust fan must not be located where it could easily become blocked by leaves snow water debris etc 3 2 Receiving amp Installation MN2415 Indoor Location Continued WARNING WARNING WARNING WARNING MN2415 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 Ventilation Test To test the ventilation system do the following 1 Place a thermometer as close as you can to the cool air intake of the engine s blower housing but do not let the thermometer touch any material surface 2 Place another thermometer outside the building or compartment in the open air Keep the thermometer out of direct sunlight or any other heat sources 3 Run the engine under maximum
91. ightly 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 1 Clean the generator set and remove any and all dust dirt or other foreign material 2 Inspect and clean the cooling air intake and exhaust louvers of the generator end Make sure they are clean Remove dirt or any buildup that may restrict the cooling air flow 3 Clean the generator set and its components with a damp cloth or sponge Never use a water hose or pressure washer as this may damage electrical components 4 Inspect and replace any control panel components that are broken or not working properly receptacles circuit breakers switches etc o RON Troubleshooting and Maintenance 5 1 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 1 General Troubleshooting Guide Problem Possible Cause Remedy Engine cranks but will not start No Tuel Check th
92. ive battery terminal or wire The risk of such shock is reduced when the ground lead is removed during installation and maintenance The correct type battery must be installed in the battery compartment provided see Table 3 5 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 1 Open access doors and locate battery tray 2 Place the correct battery see Table 3 5 on the tray 3 Install the Battery Hold Down Bar and Rods as shown in Figure 3 12 a Place the bent end of the Battery Hold Down Rod through the hole in the Battery Tray b Place the threaded end of the Battery Hold Down Rod through the hole in the Battery Hold Down Bar and secure with flat washer lock washer and nut c Repeat steps 3a and 3b for the other Battery Hold Down Rod 3 14 Receiving amp Installation MN2415 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 amp Nut a Battery Hold Down Bar Battery Install away from terminals Battery Hold Down Rod Battery Tray 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 Connect cha
93. lit Not Shown LB0094A11 Decal Danger High Voltage Not Shown LB0094A30 Decal Warning Auto Start Not Shown LB0095A07 Placard Line Not Shown LB0095A08 Placard Load Not Shown LB0095A15 Placard Neutral Not Shown LB0095A16 Placard L1 Not Shown LB0095A17 Placard L2 Not Shown LB0095A42 Placard Remote Start Not Shown LB0095A51 Placard A C Connection Not Shown LB0094A36 Decal Danger Hot Not Shown LB0095A37 Placard Ground Wiring Diagrams Wiring diagrams for these generators are contained on the following pages of this appendix MN2415 Series AE25 D 3 Figure D 4 AE25 Receptacle Connection Diagram BW0049D WVSOVIC NDLLO3NNDO 3799193938 S Se3Y LN 06 00 8 333 8 910000 94 314 705 OPRILOWIM 5 17 8 2002 52 60 97 27 11 93535 Aid 8 3 OL LASN 5530 9 1001 OMY 9 100 Em 91 1004 ral 9 2004 iw 9 1004 ig 2 9 ZOON EBEN B olo 2 yog Jed
94. ly ited aed oka tod pb P ek iy Gaile e es A 3 Appendix B Series 10 ected B 1 Operator Panel Configuration B 1 Replacement vost AGE eG de B 2 Wining Diagrams be a cies bb eb das eo ob e o e op e B 3 Appendix C SOMOS AEM IE C 1 Operator Panel Configuration C 1 Replacement Parts eU e E ad Eds C 2 Conversion from LPG to Natural Gas C 3 Wiring Diagrams RI Que D ec ESL ER EMEN ER C 4 Appendix D Series AE25 uec P EISE D 1 Operator Panel D 1 Replacement Parts iu Bares Vana a e de aa D 2 Wiring Diagrams cee iss a Raain Paula ote D 3 ii Table of Contents MN2415 Section 1 Product Safety Information Safety Notice Responsibility 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 caus
95. mmable Functions and Values Continued ooling Timer O 0 Seconds 5 Seconds 10 Seconds 15 Seconds 20 Seconds 30 Seconds 60 Seconds e 180 Seconds 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 15 particularly useful when used in conjunction with turbo charged engines Nominal Frequency O O O O O O 50Hz O S 14 Overshoot 24 60Hz 0 5 14 Overshoot 24 e nominal line frequency Either 50 Hz or 60 Hz Nominal DC Voltage O O 12VDC CF 8VDC 24VDC 16VDC The generator battery voltage Either 12 Volts or 24 Volts It is used for the charge alternator failure level OP ose on Fault Open on Fault onfiguration for the oil pressure switch Either to close to battery negative on a fault or open on a fault H Q ose on Fault Open on Fault onfiguration for the coolant temperature switch Either to close to battery negative on a fault or open on a fault rank Disconnect O Disabled Pressure Enabled 2 second delay this is enabled the starter motor will disconnect 2 seconds after the oil pressure switch detects oil pressure NOTE Not suitable for all generators due to the different monitoring points on lubrication systems Und
96. n 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 WARNING An open bottom stationary engine generator set must be installed over noncombustible materials and shall be located such that it prevents combustible materials from accumulating under the generator set Outdoor Location with Baldor Supplied Enclosure If the generator is installed outdoors there should not be a cooling problem The factory installed enclosure is designed to keep out undesirable weather elements while providing cooling and ventilation It should be installated on a concrete pad with at least thirty six 36 inches clearance on all sides for air flow 1 For effective cooling and maintenance the system should be installated on a concrete pad with at least thirty six 36 inches clearance on all sides for air flow and service access 2 Installation should prevent water levels from reaching the generator Drainage must be adequate to keep concrete pad free from standing water 3 Installation should prevent obstructions by buildup of leaves grass sand snow etc If these items pose a problem consider building a small fence or other break to protect the unit from accumulation of debris Indoor Location Open Frame Configuration When the Generator is installed in
97. nal Electrical Code and local codes Never connect this generator to the electrical system of any building unless a licensed electrician has installed an approved transfer switch The national electrical code NEC requires that connection of a generator to any electrical circuit normally powered by means of an electric utility must be connected by means of approved transfer switch equipment to isolate the electrical circuit from the utility distribution system when the generator is operating Failure to isolate the electrical circuits by such means may result in injury or death to utility power workers due to backfeed of electrical energy onto the utility lines Incorrect installation of this generator set could result in property damage injury or death Connection of the generator to its fuel source must be done by a qualified professional technician or contractor 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 Intended Use The intended purpose of this generator set is to provide emergency power when the main utility power supply is interrupted Therefore it is important that all the wiring that connects the generator set with your
98. nd all rights are reserved This document may not in whole or in part be copied or reproduced in any form without the prior written consent of Baldor Electric Company Inc Baldor Generators have earned the reputation of being high quality and dependable We take pride in this fact and continue to keep our quality standards high on our 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 Baldor makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied warranties of fitness for any particular purpose The information in this document is subject to change without notice Baldor assumes no responsibility for any errors that may appear in this document Limited Warranty Baldor Generators will replace or repair free of charge any part or parts of the generator of their manufacture that are defective in workmanship and materials for a period of time as set forth in the Warranty Period chart below All Baldor products requiring warranty service shall be transported or shipped freight pre paid at the risk of the party requiring warranty service to a Baldor Generator repair facility or to Baldor Generators Customer Service Department in Oshkosh Wisconsin Written notification of the alleged defect in addition to a description of the manner in which the Baldor generator is used and the name a
99. nd common shutdown output The generator can not be started Immediate shutdown open on fault If the input is deactivated at any time the generator will be shutdown and energize the common warning and common shutdown output The generator can not be started Delayed warning close on fault If the input is activated and the safety time has elapsed the unit will alarm and energize the common warning and common alarm output Delayed warning open on fault If the input is deactivated and the safety time has elapsed the unit will alarm and energize the common warning and common alarm output Delayed shutdown close on fault If the input is activated and the safety time has elapsed the generator will be shutdown and energize the common warning and common shutdown output Delayed shutdown open on fault If the input is deactivated and the safety time has elapsed the generator will be shutdown and energize the common warning and common shutdown output Table 4 1 Programmable Functions and Values Continued Not Used Pre heat Load Transfer Common Warning Common Shutdown System in Auto Common Alarm Energize to Stop O O O Auxiliary Output 2 Not Used Pre heat Load Transfer Common Warning Common Shutdown System in Auto Common Alarm Energize to Stop O eeooeeo ee Note 2 Note 2
100. oherence If you or anyone else experiences these symptoms get out into fresh air immediately Stop the engine and do not restart the engine until it has been inspected and if necessary repaired or reinstalled in a well ventilated area Hot exhaust gasses must never be directed toward anything that may catch fire or explode This generator 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 arrestor The spark arrestor must be maintained in effective working order by the operator Some parts of this generator rotate during operation Rotating parts can present extreme danger if clothing or body extremities are caught by the rotating part and can cause serious or fatal injury Never touch a part of the generator until the engine has been stopped and all rotating parts are completely stopped Also disconnect the spark plug wires and battery connection to prevent accidental engine rotation during servicing Never move a generator set that is running Loads should be connected and position secure before starting the engine Hazards are caused by moving a generator set that is running Continued on next page 1 2 Product Safety Information MN2415 Operation Warning Statements Continued WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WA
101. om Verify the adjustments Replace controller if failed speed Magnetic pickup is incorrect Service Service for your generator can be obtained from Baldor Generators Please have the following information available prior to contacting the factory The model number and serial number of the generator set A complete and accurate description of the problem Parts Parts for your generator can be obtained from Baldor Generators Please have the following information available prior to contacting the factory The model number and serial number of the generator set complete and accurate description of the part part number if known Note Engine parts can usually be obtained from a local distributor by using the information in the engine manufacturer s owner s manual 5 4 Troubleshooting and Maintenance MN2415 Appendix A Series AE8 Information in this Appendix applies to the AE8 Generator Operator Panel Configuration Figure A 1 8 Operator Panel Master Control Switch gt RUN OFF REMOTE MANUAL AUTO Controller Fuse 5 Circuit Breaker CONTROLLER FUSE 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 Off off position prevents engine from stating Remote Auto The engine can only be started by m
102. p the engine move the Master Control Switch to the Stop position immediately and repair the leak before proceeding Verify that operation is smooth If belt squeals vibrations or other sources of noise exist stop the engine move the Master Control Switch to the Stop position immediately and repair before proceeding Verify that the correct voltage exists line to line and line to neutral at the generator and at the transfer switch WARNING Engine coolant is under pressure and is near the boiling point of water when engine is hot Do not open the coolant system until the engine has completely cooled Hot coolant can cause severe burns and other injuries When engine is cool coolant level can be checked 24 After the operation checks are made stop the engine move the Master Control Switch to the Stop position and wait at least 2 hours for the engine to cool When the engine is cool check engine oil and coolant levels as instructed in the engine operation manual 25 Close all enclosure covers The post installation checks are now complete MN2415 Receiving amp Installation 3 17 3 18 Receiving amp 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
103. paints etc and grass or leaf build up Keep a fire extinguisher near the generator while generator is in use An extinguisher rated ABC by the National Fire Protection Association is appropriate Parts of this generator are extremely hot during and after operation To prevent severe burns do not touch any part of the generator until you have first determined if the part is hot Wear protective clothing and after use allow sufficient time for parts to cool before touching any part of the generator Do not touch the hot exhaust parts or the high voltage spark plug or coil terminals of the engine Although spark plug voltages are not normally lethal a sudden involuntary jerk of the hand or body part caused by contact with high voltage or a hot surface can result in injury to yourself or others Engine coolant is under pressure and is near the boiling point of water when engine is hot Do not open the coolant system until the engine has completely cooled Hot coolant can cause severe burns and other injuries When engine is cool coolant level can be checked Continued on next page Product Safety Information 1 3 Warning Statements Continued Installation WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING Warning WARNING WARNING WARNING WARNING WARNING Installation and servicing of batteries is to be performed or supervised by personnel knowledge
104. pically 5 minutes the controllers RUN output will be immediately terminated which will initiate the engine to stop Manually Stop the Generator Set at anytime by simply pushing the Stop button The controllers RUN output will be immediately terminated which will initiate the engine stop sequence BON Automatic Fault Shutdown AE11 and AE25 MN2415 When a fault circuit is programmed as a Shutdown the engine will immediately stop when the fault is activated A specific shutdown fault can be programmed with a definite time transient delay period that must expire before the shutdown is activated The stop sequence will cause the controllers RUN output to be immediately terminated which will cause the engine to stop A Warning lamp does not terminate generator set operation It only warns that a condition exists alternator charge failure etc but allows generator operation to continue Operation 4 3 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 If the Remote Start signal is removed during the Sta
105. rator Set under control of the Transfer Switch whenever utility AC power is lost MN2415 Series AE11 C 1 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 RM1088A15 Figure C 3 Frame Assembly Table C 1 Generator Set Parts List Part No Description HB6177A02 Adaptor Engine 62FN4002 Fan 62RA0016A00 Rotor Assembly BG6207H03 Rotor Bearing 62SA0025A00 Stator Assembly 62EX5001A01 Exciter Assembly 62EP3202A01 Bearing Bracket 8 HA3188A00 Rotor Bolt Rotor to Engine Not Shown HB7023A00 Rotor End Plate 15 RM1088A15 Isolator 20 EH0491A09 Base Frame 21 HB6068A02 Engine Mount Kohler CP23 22 HB6068A16 Engine Alternator Mount 23 HB6068A03 Alternator Mount C 2 Series AE11 MN2415 Table C 1 Generator Set Parts List Continued Ref No Part No Description Not Shown EH0491A02 Enclosure Top Not Shown 0491 11 Enclosure Access Panel Not Shown EH0491A01 Enclosure Front Not Shown EH0491A10 Enclosure Right Side Hinge amp Rear Not Shown EH0491A13 Enclosure Left Side Latch amp Front Not Shown HB2414A05 Latch Not Shown HW2409A21 Hinge Nylon Not Shown HW24
106. rging source to the battery terminals 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 The risk of such shock is reduced when the ground lead is removed during installation and maintenance 9 ovg Recommended Engine Oil and Battery Type When replacing batteries use only the recommended battery for your generator see Table 3 5 Table 3 5 Recommended Engine Oil and Battery Type OIL RECOMMENDED AMPS COLD CAPACITY BATTERY CRANKING 2 2 PIS Interstate SP 40 340 2 2 PIS Interstate SP 40 340 2 0 QTS Interstate SP 40 340 4 5 QTS BCI Group 24 750 MN2415 Receiving amp Installation 3 15 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 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 Note These precautions are especially necessary in locations such as seaboard installations and other high humidity areas Some installations will be in atmospheres th
107. rt Delay timer the unit returns to stand by After the Start Delay if the pre heat output option is selected the pre heat timer is starts and the corresponding auxiliary output if configured will energize After these delays the Fuel Solenoid is energized then one second later the Starter Motor is engaged The engine is cranked for a 10 second period If the engine fails to start the starter motor is disengaged for a 10 second rest period Should this sequence continue beyond the starting attempts the start sequence will be terminated and Fail to Start fault will be illuminated When the engine starts the starter motor is disengaged and locked out at 20 Hz measured at the Alternator output Rising oil pressure can also be used to disconnect the starter motor however it cannot be used for under speed or over speed detection When the starter motor has disengaged the Safety On timer starts This timer is preset to 12 seconds and allows engine speed Oil Pressure High Engine Temperature Under speed Charge Fail and Auxiliary fault inputs to stabilize without triggering a fault Once the engine is running the Warm Up timer starts if selected This allows the engine to stabilize before the load is switched on After the Warm Up delay the AC output is switched on to operate the load When the Remote Start signal is removed the Stop Delay timer is initiated After which the Load Transfer output if configured is deactivated and the Cool
108. rt Switch is opened the control circuits allow the engine to run for approximately 60 90 seconds before it shuts off This time delay allows the engine to run unloaded to cool down before stopping Figure 3 8 Remote Start amp Battery Connections AE11 with Enclosure TBP Li S S NISS T GTS ST 16AWG _ Customer Provided ided Optional Eq Equipment Remote Start Twisted Pair Remote Start Switch Remote Start Close to Start uoi unger 212 8 Fuel J 1 ut uel Jumper ou Battery Fuel Jumper IN Natural Gas 1 Battery To120VAC ambu Shore Power pwossgp Note Remove Fuel Jumper _ if LP Gas is used MN2415 Receiving amp Installation 3 11 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 Output Power Connections AE25 with Enclosure Natural Gas or LPG 42 5 Line Gen 0 ano n UE G Load N L1 to N 120VAC L2 to N 120VAC Customer 111012 240VAC AC Output Connections to Transfer Switch Remote Start and Battery Charger Connections Figure 3 10 shows the connec
109. s 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 High Engine Temperature if engine coolant temperature exceeds the high engine temperature limit after the Safety On timer a shutdown will occur and the High Engine Temperature Shutdown lamp is On Overspeed if engine speed exceeds the pre set limit 1496 above the nominal frequency a shutdown will occur and the Overspeed Shutdown lamp is On The Overspeed shutdown is not delayed shutdown is immediate Note During start up the Overspeed trip level is extended to 24 above the normal frequency for the duration of the safety timer to allow an extra trip level margin This prevents nuisance tripping during start up Underspeed if engine speed goes below the pre set trip 2096 of the nominal frequency after the Safety On timer delay a shutdown will occur and the Underspeed Shutdown lamp is On Inputs 1 and 2 can be configured as warnings or shutdowns The relevant lamp is illuminated when the input is active Editing the Configuration The 4110 engine controller is fully configurable from the front panel There is no requirement for a computer or software Access Configuration Editor Figure 4 4 With the unit is in Stop mode Configuration Mode is selected by a small switc
110. s of an electric utility must be connected by means of approved transfer switch equipment to isolate the electrical circuit from the utility distribution system when the generator is operating Failure to isolate the electrical circuits by such means may result in injury or death to utility power workers due to backfeed of electrical energy onto the utility lines Circuit overload protection must be provided in accordance with the National Electrical Code and local regulations Check Ground Fault Circuit Interrupt GFCI receptacles monthly by using the Test and Reset buttons Only a professional experienced technician should install a fuel supply system LPG and natural gas fuels are flammable and can cause fire explosions injury or death Fuel supply lines should be kept away from sharp objects to prevent rupture Comply with all NFPA regulations and local codes for shut off valves regulators fuel line type connectors etc Have electrical circuits and wiring installed and checked by licensed electrician or qualified technician Electrical shock can cause serious or fatal injury Incorrect installation of this generator set could result in property damage injury or death Connection of the generator to its fuel source must be done by a qualified professional technician or contractor Continued on next page 1 4 Product Safety Information MN2415 Warning Statements Continued Maintenance WARNING Before servicing the generator s
111. tch Inspect the engine and generator and verify that there are no loose wires or components Tighten if necessary Verify that the ground conductor is of correct wire size and properly connected Verify engine oil level is full Refer to engine manual if necessary Verify engine coolant level is full Refer to engine manual if necessary Verify exhaust system to assure it is in properly connected and pointing away from combustible materials Verify that the Master Control Switch is still in the Stop position Connect the engine starting battery negative lead Verify the fuel source is ON and the pressure and flow rate are correct Remove all tools rags etc from inside the generator enclosure Close all enclosure doors and be sure no hands are inside the generator enclosure when it starts 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 fails to start refer to Section 5 Troubleshooting 23 With the engine running several checks must be made a d Verify there are no fuel leaks If a fuel leak is detected stop the engine move the Master Control Switch to the Stop position immediately and repair the leak before proceeding Verify there are no coolant or oil leaks If a leak is detected sto
112. the valve seat away from the orifice which allows fuel to flow as long as the demand persists When the vacuum ceases a spring force pushes on the lever and forces the valve seat against the orifice shutting off the fuel flow It is important to remember that fuel should not flow through the KN when the engine is not running A properly adjusted KN requires a vacuum of only 0 25 to 0 35 of water column to start the opening sequence Due to this sensitivity most installations do not need priming to start unless low cranking speeds or restricted and lengthy piping are required If priming is necessary and a manual primer is installed use only 1 or 2 second bursts of fuel and immediately try to start the engine If there is a choke on the carburetor do not use it as this will probably cause flooding and hard starting As you can see the operation of this unit is simple and basic If you are having trouble operating the engine in most cases the fuel controller is not malfunctioning There is generally a problem with the engine or fuel supply so do not make adjustments or attempt to service the KN until you are sure it is needed MN2415 Operation 4 9 Figure 4 5 Garretson KN Fuel Valve Outlet Primer Optional Lock Off Adjustment Inlet A 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
113. tions for the battery charger and the remote start contacts of the transfer switch When the Remote Start Switch is closed the generator will start The unit will remain running until this connection is opened When the Remote Start Switch is opened the control circuits allow the engine to run for approximately 60 90 seconds before it shuts off This time delay allows the engine to run unloaded to cool down before stopping Figure 3 10 Remote Start amp Battery Connections AE25 with Enclosure Natural Gas or LPG R2 R1 1 16AWG Twisted Pair Wire Customer Provided Optional Equipment Battery n n Charger Remote Start Switch Close to Start 120 Shore Power 8 8 3 12 Receiving amp Installation MN2415 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 It is important for safety reasons that the Generator set transfer switch and battery charger share a common Ground and neutral The NEC requires that the frame and exposed metal surfaces be at local ground reference potential to avoid electrical shock hazard A lo
114. top for any shutdown fault The engine will also stop or when the remote start signal is removed or local Stop is pressed The engine controller operation includes time delay circuits for normal operating conditions such as start delays cool down and cranking periods Manual Start Stop All models Push the Manual Run button to immediately initiate the engine crank cycle to start the engine and generate AC power This mode does not require a start command from a remote device but operates immediately when the button is pushed When pushed the following happens 1 Engine Crank cycle begins 2 When the engine starts and accelerates to nominal speed the controllers speed sensor will terminate the Engine Crank cycle Manually Stop the Generator Set at anytime by simply pushing the Stop button The controllers RUN output will be immediately terminated which will initiate the engine stop sequence Automatic Start Stop All models Push the Auto Start push button The following happens 1 Theengine will automatically start upon activation of the remote start contact input The remote device transfer switch initiates a start sequence when utility power fails When the remote start signal is activated the engine will start The automatic stop sequence will be initiated by removal of the remote start signal When the start signal is removed a cool down delay function will be initiated When the cool down time delay period expires ty
115. ure you are using piping of significantly large size to deliver the necessary amount of fuel 7 df copper tubing is used it should be having a minimum wall thickness of 0 032 inches Black Iron Pipe is recommended but follow building codes for your area The following pamphlets are available from National Fire Protection Association NFPA P O Box 9101 Quincy MA 02269 No 37 Combustion Engines 54 Gaseous Appliances and piping No 58 Storage and handling LPG Example Determining Pipe Size for Natural Gas An AE8 has a 16Hp engine For Natural Gas fuel determine the supply pipe size for 60 feet run 16 x 10 000 160 000 per hour for proper operation 160 000 _ E 71 096 146 cubic feet per hour From Table 3 4 a 60 foot run requires a minimum 1 pipe at full engine load MN2415 Receiving amp Installation 3 5 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 Iron Pipe Size Length Feet 1 5 3 4 1 1 1 1 5 2 2 1 5 3 4 6 8 15 73 165 332 722 1174 2386 3704 6253 13352 37229 30 50 115 232 515 818 1712 2646 4521 9331 26330 53728 45 41 95 191 418 673 1419
116. ved 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 WARNING WARNING WARNING WARNING WARNING WARNING Procedure 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 Do not dispose of battery or batteries in a fire The battery is capable of exploding If the battery explodes electrolyte solution will be released in all directions Battery electrolyte solution is caustic and can cause severe burns and blindness If electrolyte contacts skin or eyes immediately flush the area with water and seek medical attention quickly Do not mutilate the battery The battery contains electrolyte solution which is caustic and can cause severe burns and blindness If electrolyte contacts skin or eyes immediately flush the area with water and seek medical attention quickly A battery presents a risk of electrical shock hazard and high short circuit current The following precautions are to be followed when working on batteries 1 Remove watches rings necklaces and all other metal objects 2 Use tools with insulated handles 3 Wear rubber gloves and boots The battery electrolyte is a dilute sulfuric acid that is harmful to the skin and eyes It is electrically conductive an
117. ward anything that may catch fire or explode Never allow the exhaust outlet to be positioned so that the exhaust gases are directed towards any openings or air entry routes doors windows vents etc of an occupied building When discharging the hot exhaust gases out of the building do not direct them towards anything that could catch fire or explode Exhaust fumes gases are extremely dangerous and can cause severe illness or death Never breath exhaust fumes produced by a running engine Only run the engine outdoors where ventilation is plentiful Exhaust gases contain carbon monoxide a colorless odorless and extremely dangerous gas that can cause unconsciousness or death Symptoms of carbon monoxide poisoning include dizziness nausea headaches sleepiness vomiting or incoherence If you or anyone else experiences these symptoms get out into fresh air immediately Stop the engine and do not restart the engine until it has been inspected and if necessary repaired or reinstalled in a well ventilated area It is extremely important to discharge engine exhaust gasses away from the engine and out of the building The direction of the discharged hot air and hot exhaust gases is important as they have the potential to create brown spots on the lawn In extreme cases this extremely hot air could cause dried grass or other debris to ignite Guidelines for Exhaust System 1 It is extremely important that you do not allow the hot exhaust gases to re cir
118. x shown in Figure 3 5 Figure 3 5 Single Phase Output Power Connections AE10 with Enclosure AE10 Open BWO201D a 2 3 Generator E oe Customer Generator SI Customer Output S N N E AC Output Connections Output AC Output Connections X p 12 0 Transfer Switch 4 L2 Transfer Switch To F G We prx 120VAC Se 120VAC L2 to N 120VAC L2 to N 120VAC LitoL2 240VAC Note G and N are internally 240VAC BW0333D tied to Frame Ground Remote Start and Battery Charger Connections Figure 3 6 shows the connections for the battery charger and the remote start contacts of the transfer switch When the Remote Start Switch is closed the generator will start The unit will remain running until this connection is opened When the Remote Start Switch is opened the control circuits allow the engine to run for approximately 60 90 seconds before it shuts off This time delay allows the engine to run unloaded to cool down before stopping Figure 3 6 Remote Start amp Battery Connections AE10 AE10 with Enclosure S6 16AWG _ Customer Provided Optional Equipment 16AWG _ Customer Provided ided Optional Eq Equipm
119. y Check battery supply is present on the Starter output of module NB all the outputs are negativeswitching Fuel solenoid inoperative MN2415 Note Note Check wiring to fuel solenoid Check battery supply Check battery supply is present on the fuel output of module NB all the outputs are negativeswitching Table 5 2 is provided as a guide check list only It is possible for the module to be configured to provide a wide range of different features always refer to the source of your module configuration if in doubt All the outputs are solid state rated at 1 2 Amps and switch to battery negative when active Troubleshooting and Maintenance 5 3 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 stopped Verify the engine is at a complete stop before trying to reset Controller not in OFF mode Set the controller to the OFF mode before trying to reset Engine alarms are ON for high engine Sending unit is disconnected open Verify the sending units wiring to controller terminals is not open or temperature or low oil pressure when circuit shorted engine is operating properly Defective sending unit Verify the engine mounted senders have correct resistance values for corresponding input temperature or pressure Overspeed shutdown occurs at normal Controller has failed or input fr

Baldor AE11 Portable Generator User Manual

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