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Baja Marine 242 Boat User Manual

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3. 01 3N3HA WOXI 1 0 i 6 S lI 9 0 BATTERY REQUIREMENTS FOR BALDOR GENERATORS SERIES GENERATOR MODEL RECOMMENDED BATTERY COLD CRANKING AMPS MINIMUM OHV Models Interstate SP 30 Exide PV30H 300 Robin Models BCI 16 B 300 PCM60RE 16 300 PREMIER K SERIES SERIES K300 K6500 Interstate SP 30 Excide PV 30H PREMIER PC Models Interstate SP 30 Excide PV 30H Interstate SP 30 Exidee PV 30H Interstate SP 30 Exidee PV 30H Lu Q ui 5 zo n AE8 10 12 Interstate SP 30 Excide PV 30H AE20LS AE20DLS BCI Group 24 AE25LS AE45LS BCI Group 24 AUTOMATIC EMERGENCY STANDBY TS25 BCI Group 24 TS40 TS80 DLC75 DLC100 BCI Group Com 31 5130 15175 31 DLC130 DLC175 BCI Group Com 31 NOTE IDLC and GLC Units of comparable size would require the same size battery as those listed above SWITCHABLES DLC IDLC GENERATORS Or Equivalent INSTALLATION NOTES When securing battery to rack place tie down over edge of battery e and away from terminals Form S SAL 101 Revised July 5 2002 Effective May 1 2001 39 GENERATOR END COMPONENTRY MQ MMA Page 40 FOR AE12 UNITS WI THOUT ENCLOSURE OLD PART NEW PART DESCRIPTION Voltage Regulator Basler VR63 4 FOR AE12 UNITS WITH ENCLOSURE OLD PART NEW PART DESCRI PTI ON Circuit Bre
4. 14994 8 DECIMALS 1 005 FRACTIONS 31 64 CHNGD WIRE LABELS TO NEW 4 DIGIT CODE EN XX 01 ANGLES 317 CONNECTION DIAGRAM CONN OF 1 0 RECP DIODES amp LABELS PAINT SPECIFICATIONS TO FOLLOW DRAWING AE 12 ENCLOSED ELECTRIC PRODUCTS DELETED AUTO CHOKE F 930 16600 ADDED USED AT AUTO PRIME THIS DOCUMENT IS STRICTLY CONFIDENTIAL ANO MAY 2 2 95 ADDED FOR AUTO CHOKE PRIME NOT BE REPRODUCED OR UTILIZED IN ANY WAY OLOR MATERIAL DWG NO 910 830 pm ovt _ ___________ sv WITHOUT PRIOR WRITTEN PERMISSION OF DATE BY SHEET PART REMSIONS MANUFACTURING INC 12 2 94 HJ 1 OF 3 7 M E US 22 2 gU Ee AVM 032 30 03200008238 38 LON 27 f 3WI4d23x0H29 OLAV 303 34010 03409 6567272 v ON se z za ON Luvd 1 0 31 25 Bsy f l 30 NOISSINY3d as 50 avo un 06 ON TVILN3OI3NOO 15 10 SI 14300900 SIKL ane PE 00991066 EBEB T oa BUR TN eren a y necs wear p T
5. OW C 4 2 5909 5 th D I 0 Page 20 of 45 NATURAL GAS FLOW CHART Pipe Capacity in Cubic Feet IRON PIPE SIZE 12 34 1 114 1 12 2 242 o3 8 7 se sm 722 1124 2386 6253 13352 37220 50 115 232 55 1712 2646 4521 9331 26330 53728 os wie 2212 se 7600 22462 mor sez 1023 3310 6562 1505 37000 ___ 32 wr te 5 72 16862 33050 zm 48 082 ts 2597 15200 es tm 126 4906 287 ssr 1077 ws 3018 10736 21034 as wr sos sss vor 172 369 202 8 ws me we 558 5 n I l An Engine needs 10 000 BTU s HP For Natural Gas there are 1 000 BTU s Cubic Ft Page 21 of 45 OPERATI ON PRIOR TO STARTI NG THE UNI T 1 Locate and set up the generator set in an open dry well ventilated and reasonably level location OPERATING THIS UNIT I N AN AREA NOT SUI TABLE FOR IT S PROPER USE N WARNING MAY CAUSE DAMAGE TO THE UNIT SEVERE I NJ URY OR DEATH SEE LOCATI ON I NFORMATI ON SECTI ON LOCATED ELSEWHERE IN THIS MANUAL 2 If grounding is required for your application check to make sure your unit is grounded properly 3
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7. 6 oz Minimum v Condensation in line check for flow potential water traps and lines that run in and out of buildings Improper Fuel Mixture v Check main adjustment see adjustment section below v Check auto prime adjustment see adjustment section below Fuel Valve v Check function by connecting leads to generator battery If click is heard valve is working Engine Out of Tune v Check condition AND function of spark plugs generators running on gaseous fuel leave the plugs very clean It is important not to go by looks alone If in doubt change NOTE Some Multi cylinder engines will appear to run well without load NOTE but stumble with load a bad plug is most often the problem v Check condition of air filter replace if dirty if pre cleaner is saturated with oil the fuel system will be thrown out of balance and not operate properly V Oil Level All Pow R Gard engines have Low Oil Shutdown of varying types To be sure check the oil level and if no spark the oil pressure switch function ADJ USTMENTS Auto Prime Pow R Gard models from 5 to 12KW can come equipped with an electric solenoid operator Auto Prime device The device is electrically connected to the starter system on the generator and supplies an initial feed of fuel for quicker engine starting Once started the engine s vacuum keeps the fuel flowing On generators not so equipped the engine vacuum is used exclusively
8. Check the engine s oil level and add whatever amount of oil is necessary to bring it up to the level that is recommended by the engine manufacturer 4 Check the fuel system for fuel leaks 5 Make sure all circuit breakers are set pushed In CONTROLS AND THEI R FUNCTI ONS Master Control Switch RUH REMOTE MAHUAL OFF AUTO This switch is a three position toggle switch which allows the user to choose the automatic or manual mode of operation The center position is the off position By putting this switch in the OFF position the generator set will not start under any conditions To reset the control logic after a fault has occurred this switch must be put into the Off position for a minimum of 10 seconds Run Manual Mode When the Master Control Switch is put into this position it immediately energizes the crank cycle to start the generator set The generator set will continue to produce power until the Master Control Switch is put into the OFF position or until a fault condition develops Page 22 of 45 Remote Auto Mode This is the position you need to have the Master Control Switch set in when you wish to operate the Generator Set automatically in conjunction with a Transfer Switch This way the generator set can only be started by making a connection across the remote start connection points on the terminal block located in the control box Should this remote start connection be opened up while the engine is running t
9. N damage injury or death I nstallation of this generator set must be performed by qualified professional technicians or contractors This information is for general reference only I t must not be used as NOTICE the single source of information for installing the generator set For more specific detailed information read the installation manual that accompanied the generator set as well as the transfer switch manual There are two main wiring circuits that must be installed by a licensed electrician to properly interface your Baldor Pow R Gard generator set with your transfer switch and the building facility it will be providing power to The connection on the generator set consists of two terminal blocks which are located on the generator set On units with the factory installed enclosure the connection box is located in the engine enclosure bulkhead Access to the customer connection box is achieved by removing the appropriate louvered enclosure end panel See Drawing on following page On units without the factory installed enclosure the customer connection box is located either above the generator windings or it is mounted on the generator frame next to the unit REMOTE START CONNECTIONS These terminal block connecting points See figure 1 are where you connect the two wires from the remote start contacts of the transfer switch Once a connection is made across these connecting points via the transfer switch or some other swit
10. Loc sv WITHOUT PRIOR WRITTEN PERMISSION OF LEASE DATE SCALE DATE 08 D SHEET 2 MANUFACTURING INC 5 24 93 1 OF 1 910 828 pene ue EE 55 IW 6 SENIORI EQ SEDENT 3 CONTROLLER BOX CONTROL BOX LEGEND MALE FEHALE SPADE CONN es 0 BULLET 1110 3 SHE 1 REMOTE REMOTE oo Es 4 SWITCH 51 2 1 spiren D CLOSE TO START ALARM LITE 2 Mw 2317509 13 gt 2 500 5 g ORS ON BASI 1 0 RECEPTACLE ENGINE OUT Battery C 7010 CHARGER 579042 CE 3 G 2 7010 C FUSE 182 NOTE t UNLESS OTHERWISE SPECIFIEO 1 ALL WIRES BLACK 2 ALL GND WIRES TO BE 14 AWG 3 ALL CONTROL WIRES TO BE 16 AWG CRANKING SELECT TO CONVERT TO CYCLE CRANK CUT 1 2 DELAY ADD 10 SEC ON START UP CUT J3 ae J1 J2 LABELED ON DIAGRAM ONLY DIODES TO 1N5408 OR EQUIVILANT T amp J MANUFACTURING INC REGULATOR Fl F2 54 UNLESS OTHERWISE SPECIFIED TOLERANCES 11 11 ALL DIMENSIONS IN INCHES OSHKOSH Wl 54901 CHNGD 5520 6010 7200 TO GND POS amp
11. THE GENERATOR AS YOU WILL BE WORKING AROUND FAST ROTATING COMPONENTS ALONG WITH LIVE WIRES AND BARE CONNECTIONS LOW VOLTAGE OUTPUT Possible Problems 1 Generator speed too slow f the generator is turning too slow the generator set will produce low or no output voltage Make sure the generator is turning at the speed specified on the nameplate 2 Broken wires or loose connections Broken wires or loose connections can cause the generator set to have low or no output voltage Check all wiring for broken wires and bad loose connections HIGH VOLTAGE OUTPUT Possible Problems 1 Generator speed too fast f the generator is turning too fast the generator set will produce high output voltage Make sure the generator is turning at the speed specified on the nameplate Page 25 of 45 TROUBLESHOOTI NG FOR GASEOUS FUEL SYSTEM N WARNING N GASEOUS FUELS ARE HI GHLY COMBUSTI BLE AND CAN CAUSE EXPLOSI ONS FIRE NJ URY OR DEATH THE FUEL SUPPLY SYSTEM MUST ONLY BE I NSTALLED AND ADJ USTED BY AN EXPERI ENCED PROFESSI ONAL TECHNICIAN USING APPROVED PI PING AND COMPONENTRY PRIOR TO MAKI NG ANY ADJ USTMENTS THAT WI LL TAKE THE GENERATOR SET OUT OF IT S FACTORY PRESET CONDITION PLEASE NOTE THE CONDI TI ON SETTING OF THE ADJ USTI DEVICE THI S WI LL ALLOW YOU TO RETURN TO THE FACTORY PRESET CONDI TI ONS IF IN THE EVENT OF MAKI NG AN ADJ USTMENT THE GENERATOR SET S PERFORMANCE GETS WORSE Prior to troubleshooting
12. engines have a tendency to slow down when a load is applied to it The governor on the engine is designed to hold the operating speed as nearly constant as possible When the load connected to the generator set is increased the engine is more heavily loaded and as a result the engine speed drops slightly This slight decrease in engine speed results in a slight decrease in generator voltage and frequency output This voltage and frequency variation has no appreciable effect in the operation of motors lights and most appliances and tools However timing devices and clocks will not keep perfect time when used on this generator Page 6 of 45 MAI NTENANCE MAI NTENANCE SHOULD ONLY BE PERFORMED ON THE GENERATOR SET N WARNING N AFTER THE ENGI NE HAS STOPPED AND THE GENERATOR SET HAS COOLED DOWN THE BATTERY AND SPARK PLUG SHOULD ALSO BE DI SCONNECTED PRI OR TO PERFORMI NG MAI NTENANCE GENERATOR END MAI NTENANCE Generator end maintenance consists of cleaning the generator set inspecting the wiring and fuel system and making any necessary adjustments Generator end maintenance should be performed on a monthly basis or sooner if needed CLEANI NG Clean the generator set and remove any and all dust dirt or other foreign material v Inspect and clean the cooling air intake and exhaust louvers of the generator end Make sure they are free of caked on dirt or any other material that may restrict the cooling air flow through the genera
13. etc Any potential problems should be corrected by a qualified technician as soon as possible Baldor Generators does NOT recommend and strongly discourages the operation of their generators inside residential or other N WARNING N occupied buildings due to the hazards associated with toxic fumes hot operating conditions and combustible fuel Prior to installing the generator set an adequate operating site should be selected for it When selecting a site for your generator set take into account factors such as safety noise cooling and other miscellaneous considerations Only generator sets with the factory installed enclosure should be NOTICE placed outdoors in constant direct exposure to the elements These enclosure equipped units should be mounted outside in a fashion similar to home central air conditioners SAFETY CONSI DERATI ONS 1 The generator set must not be located near any combustible material due to the substantial amount of heat generated by the unit while it is operating 2 When the installation is in a confined area the exhaust must be plumbed to the outside air Care must be taken so that no re circulation of exhaust fumes exists 3 Adequate ventillation must be present whenever the generator set is running not only to evacuate the heated cooling air and exhaust fumes but also to prevent the potential of an LP fume concentration 4 The generator set should not be located in a spot that is prone to s
14. significant amount of time 3 months or longer you should store the generator to prevent any problems that could arise from sitting idle Please fully read the following guidelines prior to storing the unit 1 Drain the used oil from the engine s crankcase and refill it with fresh clean oil if your engine is diesel proceed to step 4 NA Remove the spark plug and 1 oz of clean engine oil into the cylinder Put a rag over the spark plug port and turn the engine over approximately 5 times to distribute the oil in the cylinder Replace the spark plug but do not reconnect it This will help prevent accidental or unauthorized starting 4 Provide maintenance to the engine and generator set as described in the engine and generator maintenance sections of this manual 5 Cover any bare metal spots with paint or another type of rust preventative 6 Disconnect and remove the battery if your generator set is so equipped Page 9 of 45 ORDERI NG PARTS When Generator repair parts are needed they may be obtained by calling the Customer Service Department at Baldor Generators or the nearest local office of Baldor Electric Motors Drives and Generators Accurate information such as the following will assure that you receive accurate parts for your particular generator 1 Provide the model of the generator set 2 Provide the serial number of the generator set 3 Acomplete and accurate description of the part along with a part numbe
15. to begin and maintain the flow of fuel In almost all hard starting or intermittent starting situations the auto prime is adjusted to rich Please note this while making this adjustment You would need to adjust it to be less rich Page 27 of 45 Begin by locating the auto prime adjustment wheel It protrudes from the secondary regulator mounted on the generator and is often covered by a red vinyl cap The adjustment knob is orange and just below the knob is a gold colored washer To adjust hold the washer and rotate the orange knob counterclockwise to lean the adjustment Try this adjustment hot and cold In all multi cylinder engines the device may be disabled in lieu of adjustment Main Mixture The main mixture is located on the secondary regulator and is a very large brass screw and lock nut Begin by loosening the lock nut and counting the turns until the screw just seats Record this number so that you may return to it later REMEMBER the generator DID run previously either at the factory or at the site Proceed by disconnecting the generator set s Auto Prime if so equipped by unplugging the terminal on the orange wire Check that all fuel supply lines are turned on where applicable Check that he generator s main line output breaker is turned OFF where applicable The next step is to start the generator Voltage will be available at WARNING the output terminals and anywhere the generator is connected Thin
16. which it has to operate Some applications are very often used in dusty or dirty conditions which can cause what appears to be excessive wear Such wear when caused by dirt dust grit or other abrasive material which has entered the generator because of improper maintenance is not covered by Warranty For all product lines the engine manufacturer warrants engine systems Contact Baldor Generators for current engine warranties Owner s Responsibilities The owner is obligated to operate and maintain the generator in accordance with the recommendations published by Baldor Generators in the Operator The owner is responsible for the costs associated with maintenance and any adjustments that may be required The owner is responsible for payment of any of the following expenses that might be incurred as a result of a failure under the terms of this warranty 1 Rental equipment used to replace the equipment being repaired 2 Telephone or other communication expenses 3 Living and travel expenses of persons performing service except as specifically included within the terms of specific warranty 4 The premium costs for overtime labor requested by the owner 5 All parts transportation costs Limitations Baldor Generators is not responsible for the repair of generators required because of normal wear accident misuse abuse improper installation lack of maintenance unauthorized modifications or improper storage
17. with NFPA regulations and your local codes in regard to shut off valves regulators etc and any other recommendations or requirements they may have This Generator Set Creates A Significant Amount Of WARNING N Heat And If Not Handled Properly Can Become Substantial Fire Hazard Keep the generator set at least three feet away from buildings or other structures Keep the generator set away from flammable and other hazardous materials trash rags lubricants explosives paints etc Keep the generator set free of grass leaves and excessive grease and oils Allow the generator set to cool before transporting it or storing it indoors Have fire extinguisher accessible and nearby while operating the generator set This generator set must not be used on or near any forest covered brush covered or grass covered land unless the engine s exhaust system is equipped with a spark arrester and it must be maintained in effective working order by the operator Operation inside an enclosed compartment or building is a potential fire hazard and should not be done unless approval is obtained from Baldor Generators Engine Generator overheating can cause severe damage due to restricted obstructed or improper air flow that is necessary for the proper cooling of the unit Hot exhaust gases being discharged by the engine must never be directed toward anything that could catch fire or explode TABLE OF CONTENTS SECTI ON P
18. 1 3H9M SNOISHINIQ 75 iari 10 3240 1 6 XN 210 rn 2 1688 33340902 2600 49 43908VH 4331198 32078 NOI123NNO2 83089 2 4831198 18915 310H38 2 2 2990 20 Jj 2 2 9 50 wun 9 n wwe to 15150 093 gt 0 23 8 9 0 18 USE INE SP T fest a WIN 211016 4 4 New 2p 2fv 9078 01123 02 ES B 5 vati 4783559 501953430 1 nua 4 A CL Ze ec 5 5 81 067 HSOXHSO Q31YUOgUOONI ON OR 213 LINN 03501283 3 8 Wisuryn a 667 9 40 NOWONGOYd LY 39NVHO 01 10370805 3LON SlH 6 2 1 peste Cv 01108 3578 T 0 222 _ 1803 _ 5 5 52 LZ WOLLOS 35 8 Xddv NOHOSNNOO 191610313 ey 6 5 e amp 3 2 1 14 FLYWHEEL ALTERNATOR LEGEND 14 BLUE P 2 STARTER 14 MT P SOLENOID T lt war
19. 3 of 45 SI MPLE TROUBLESHOOTI NG Listed below are the more simple solutions to some of the more common problems that are reported to the Customer Service Department at Baldor Generators These troubleshooting solutions are meant to be an aid for a person who has minimal electrical knowledge and experience More in depth detailed troubleshooting information for a person more knowledgeable and experienced in electricity can be obtained by contacting the Technical Service Department at Baldor Generators by calling 920 236 4200 BEFORE BEGI NNI NG TO TROUBLESHOOT THE GENERATOR SET WARNING N DISCONNECT THE SPARK PLUG IF APPLICABLE AND THE BATTERY APPLICABLE AND ALLOW THE UNIT TO COOL DOWN EYE PROTECTION SHOULD BE WORN WHI LE TROUBLESHOOTING WARNING 7 THIS GENERATOR SET NO OUTPUT Possible Problems 1 The generator speed is too slow f the generator is turning too slow the generator set will produce low or no output voltage Make sure the generator is turning at the speed on the nameplate 2 Broken wires or loose connections Broken wires or loose connections can cause the generator set to have low or no output voltage Check all wiring for broken wires and bad loose connections 3 Badcircuit breaker f a circuit breaker opens up and will not reset or the reset button is not free floating your generator will not produce power out of all the receptacles Check for continuity across each circuit breaker wit
20. AGE Safety Warnings Prefix Forward 1 Generator Specifications 2 Location Information Ee Yea 3 Connection Information 4 Engine Information 2 222 rr em 6 Basic Generator Maintenance 7 Basic Engine Maintenance 8 Storage or Long Term Non Use Instructions 9 Parts amp Service Information 10 General Installation amp Site Selection Guidelines 11 Electric Installation 5 13 AE8 Enclosed Assembly Diagram 16 Connection Box for AE8 10 Units with Enclosure 17 AE8 and AE10 Installation Diagram 16 Basic Gaseous Fuel Information 17 Propane Gas Flow 20 Natural Gas Flow Chart ore scite 21 Operation 22 Simple Electrical Troubleshooting 24 Gaseous Fuel System Troubleshooting 26 Electrical System Troubleshooting 29 AE Series Interconnection 31 Customer Connection Wiring Diagram AE12 Base Outline Drawing AE12 OPEN Connection Diagram AE12 Enclosed Wiring Diagram 12 Enclosed Connection Diagram Gen End Componentry Diagram Parts Break Down for AE12 Warranty Inform
21. ATI ON READ THE INSTALLATION MANUAL THAT ACCOMPANIED THE GENERATOR SET Before undertaking installation of gaseous fuel supply piping from a remote fuel source to the generator set a check should be made concerning local and state regulations governing the use application and installation of gaseous fuel These regulations along with the standards set forth by the NFPA National Fire Protection Agency should be followed for safe dependable and proper installation The applicable NFPA regulations are covered in the following NFPA Publications No 37 Combustion Engines No 54 Gaseous Appliances and piping No 58 Storage and handling LPG These publications are available at a nominal price from The National Fire Protection Agency P O Box 9101 Quincy MA 02269 GASEOUS FUEL SUPPLY PI PI NG N WARNING N GASEOUS FUELS ARE HI GHLY COMBUSTI BLE AND CAN CAUSE EXPLOSI ONS FI RE I NJ URY OR DEATH THE FUEL SUPPLY SYSTEM MUST ONLY BE I NSTALLED AND ADJ USTED BY AN EXPERI ENCE PROFESSI ONAL TECHNI CI AN USI NG APPROVED PI PI NG AND COMPONENTRY For the purpose of calculating piping size the fuel consumption of an engine is figured at approximately 10 000 BTU s needed per horsepower per hour For example a 10 horsepower engine will require 100 000 BTU s of gaseous fuel per hour Operating on natural gas which contains 1 000 BTU s per cubic foot this engine would require 100 cubic feet of natural gas an hour to operate properly In
22. BOX FOR AE12 UNITS WITHOUT ENCLOSURE To Remote Start Terminal in the Transfer Switch EC amp NO E1in the Transfer Switch NEU Neutral the Transfer Switch To E2 in Transfer Switch GRD To Ground in the Transfer Switch Page 15 of 45 CUSTOMER CONNECTION BOX FOR AE12 UNITS WITH ENCLOSURE To E1 in Transfer Switch To Neutral in Transfer Switch Mtr E2 in Transfer Switch To Remote Start Terminals in Transfer Switch CUSTOMER CONNECTION BOX To B Positive in Battery Charger gue B Negative in Battery Charger To 1 in Battery Charger DK2 in Battery Charger um BATTERY CHARGER OPTIONAL Baldor Generators strongly recommends that all electrical devices share a common ground i e Generator Set Transfer Switch Battery Charger Load Devices etc The grounding stud for the generator set is located under customer connection box Page 16 of 45 GASEOUS FUEL I NFORMATI ON N WARNING N INCORRECT I NSTALLATI ON OF THI S GENERATOR SET COULD RESULT IN PROPERTY DAMAGE I NJ URY OR DEATH INSTALLATION OF THIS GENERATOR SET MUST BE PERFORMED BY A QUALI FI ED PROFESSI ONAL TECHNI CI AN OR CONTRACTOR THI S INFORMATI ON 15 FOR GENERAL REFERENCE ONLY IT MUST NOT NOTICE BE USED AS THE SI NGLE SOURCE OF I NFORMATI ON FOR I NSTALLI NG THE GENERATOR SET FOR MORE SPECI FI C DETAI LED I NFORM
23. ENANCE REPAI RS AND OR ANY ADJ USTMENTS MADE TO THE GENERATOR SET N WARNING N SHOULD ONLY BE PERFORMED BY A COMPETENT MECHANI C FAMI LI AR WI TH THE OPERATI ON SERVICING AND SAFETY PRECAUTIONS RELEVENT TO THE ENGI NE BEI NG WORKED ON This manual contains only very minimal engine maintenance instructions You should refer to the engine manufacturer s owner s manual for specific maintenance instructions for the engine on your generator set Any maintenance instructions or recommendations in the engine owner s manual take precedence over any of the following general recommendations 1 Clean and or replace any fuel oil and or air filters per the engine manufacturers guidelines 2 Check oil level regularly at least every 5 to 8 hours of operation Be sure the proper oil level is maintained 3 Change the oil as is recommended in the engine manufacturer s owner s manual 4 Replace the spark plug s as is recommended by the engine manufacturer if applicable to the engine 5 Clean the cooling fins on the engine to keep the engine s heat dissipation potential at it s maximum 6 Inspect and clean all governor and carburetor linkages and make sure they operate properly 7 Inspect the recoil rope for any damage and replace it if necessary if applicable 8 Clean the trash screen around the recoil or other cooling air intake Page 8 of 45 STORAGE OR LONG TERM NON USAGE If you will not be using the generator set for a
24. However these pressures are usually under 50 PSI For this reason the primary regulator used with natural gas systems does not have to regulate the high pressures normally associated with LP gas systems SECONDARY REGULATOR supplied This regulator provides the final control of the gaseous fuel prior to it entering the carburetor This regulator is frequently referred to as the Low Pressure Demand Regulator This regulator receives gas at a pressure of 4 to 6 ounces from the primary regulator then reduces the pressure and delivers it to the engine s carburetor as the engine demands LP Tanks The fuel vessel is usually the responsibility of the fuel supplier The fuel supply must be adequate in order to meet the customer s needs The fuel tanks cylinders must meet all requirements set forth by local and state regulations LP Cylinder Tanks This type of tank is commonly used on the smaller portable generator sets and is usually only equipped with a manual shut off valve Although this type of tank is of adequate strength to withstand the high fuel pressures it has one drawback in that the tank is normally of such a small size that you can only achieve minimal run times off of the tank of fuel before it has to be refilled 4 to 7 hours LPG bulk tanks The American Society of Mechanical Engineers has established certain requirements for the construction of LPG bulk tanks These tanks range in size from 20 gallon capacity all the way u
25. ICULAR 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 CIR CUMSTANCES SHALL BALDOR GENERATORS BE LIABLE OR RESPONSIBLE IN ANY MAN NER WHATSOEVER FOR ANY INCIDENTAL CONSEQUENTIAL OR PUNITIVE DAMAGES OR ANTICIPATED PROFITS RESULTING FROM THE DEFECT REMOVAL REINSTALLATION SHIP MENT OR OTHERWISE This is the sole 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 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 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
26. Normal Wear This warranty will not cover repair where normal use has exhausted the life of a part or generator It should be remembered that the service life of any generator is dependent on the care it receives and the conditions under which it has to operate Some applications are very often used in dusty or dirty conditions which can cause what appears to be excessive wear Such wear when caused by dirt dust grit or other abrasive material which has entered the generator because of improper maintenance is not covered by Warranty No person is authorized to give any other warranties or to assume any other liabilities on Baldor Generators behalf unless made or assumed in writing by an officer of Baldor Generators and no person is authorized to give any warranties or assume any other liability on behalf of the seller unless made or assumed in writing by the seller Major components such as engines used in Baldor Generators generator sets that are not manufactured by Baldor Generators are specifically excluded from Baldor Generators coverage and are covered separately by their respective manufacturers Warranty terms and policies of excluded products are included with their owners information package supplied with each product 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 PROPO
27. OPERATOR S MANUAL FOR YOUR BALDOR GENERATORS AUTOMATIC EMERGENCY POW R PRODUCTS BALDOR GENERATORS 3815 Oregon Street Oshkosh WI 54902 Telephone 236 4200 Fax 920 236 4219 S PSG 002 13 EFFECTI VE DATE 4 2 97 12 COVER 0 REVISION DATE 8 13 02 Safety Warnings Improper Maintenance or Repair Can Result in WARNING J Property Damage Mechanical Failure Severe Injury or Death Place protective covers and guards over the rotating parts if rotating parts such as the drive shaft pulley belt etc are left exposed they are potentially hazardous When cleaning repairing or inspecting make sure all moving parts have stopped Prior to working on the generator set disconnect the spark plug and battery to prevent accidental starting Use only original equipment or authorized replacement parts Use of correct parts will assure the operator of the safety integrity that was designed into the unit Unauthorized modifications to the generator set may impair the function and or safety of the unit Do not operate the generator set without a muffler Inspect periodically and replace if necessary Do not touch the hot exhaust components or the high voltage spark plug and coil terminals While Spark Plug Voltages are not normally lethal an involuntary jerk of the hand caused by a hot surface or by an electrical shock can result in injury Repair of electrical generating equipment re
28. R GUI DELI NES OR RECOMMENDATI ONS Page 5 of 45 ENGI NE I NFORMATI ON This operator s manual only covers basic day to day engine operating instructions However the engine manufacturer s manual is included with your generator set and should be referred to for any additional information you may need Become familiar with and follow all the engine manufacturer s operation safety and maintenance guidelines OIL Use a high quality oil of the type specified in the engine owner s manual for your specific operating conditions Check the oil regularly or at minimum every 5 8 hours of operation TO HELP PREVENT ENGI NE DAMAGE CHECK THE OI L LEVEL OF THE N WARNING N ENGI NE REGULARLY AND MAKE SURE IT 1 S MAINTAINED AT THE PROPER LEVEL FUEL LP or Natural Gas Make sure the gaseous fuel being supplied to the unit is in vapor form and that it is being delivered to the engine s gaseous fuel regulator at the pressure specified on it An engine needs 10 000 BTU s of fuel per each engine horsepower to operate properly GASEOUS FUEL I S EXTREMELY FLAMMABLE AND CAN CAUSE PROPERTY WARNING N DAMAGE SEVERE I NJ URY OR DEATH CHECK THE GASEOUS FUEL SUPPLY SYSTEM ON A MONTHLY BASI S FOR LEAKS HAVE ANY LEAKS REPAI RED BY AN EXPERI ENCED PROFESSI ONAL PRI OR TO STARTI NG YOUR GENERATOR SET OPERATI NG SPEED This generator set must be run at it s proper designed speed in order to obtain the electrical power it was built to produce All
29. SITION 65 WARNING Diesel engine exhaust and some constituents are 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
30. Set Produces Electricity 4nd With That WARMING 15 The Potential Danger For Electrocution Know how to stop the engine quickly and understand the operation of all controls Do not operate electrical equipment while standing in water on wet ground or with wet hands or shoes Use extreme caution when working on electrical components Potentially dangerous voltage is present when the engine is running Always treat the electrical circuits as if they were energized Disconnect all leads plugged into the unit Prior to working on it Have the electrical circuits serviced only by qualified technicians Inspect wiring frequently and replace frayed broken or poor leads Do not connect this unit to any building s electrical system unless you utilize an approved transfer switch or the main service entrance switch has been disconnected and locked open Circuit overload protection must be provided in accordance with national electrical codes and local regulations Check GFCI Receptacles monthly by using the Test and Reset buttons designed into them Depending on your application it may be mandatory to ground or not ground this unit to earth ground Comply with local electrical codes 2222 FOR GASOLINE OR DIESEL POWERED GENERATOR SETS 72222 Gasoline And Diesel Fuel Are Flammable And Can ARNING A nn A Cause Explosions Fire Injury Or Death Operate the generator set on a level surface If the gener
31. addition to fuel consumption the following factors must be considered when installing the gaseous fuel supply piping l Pressure loss due to the number of fittings elbows reducers etc 2 Specific gravity of the gaseous fuel 3 Pressure loss due to the length of the fuel supply piping The accompanying gas flow pipe capacity charts list the capacity of various sizes and pipe run lengths The capacity which is given in cubic feet per hour is calculated for both propane and Page 17 of 45 natural gas A pressure drop of 0 3 water column is used to account for nominal number of fittings and metering equipment Referring to the fuel consumption figures we can use this chart to calculate proper sizing For example if the engine is located 30 feet from the main fuel source s primary regulator and the engine needs 100 cubic feet of natural gas per hour you can easily determine that the pipe size must be at least 3 4 inch in order to deliver the volume of fuel necessary for the engine to operate properly PRI MARY REGULATOR not supplied The function of the primary regulator is to provide initial control of the fuel under pressure as it comes off a transmission line or in the case of LP gas from a storage tank The primary regulator distributes line pressures to more workable pressures ranging from 4 to 6 ounces approximately 11 of water column A natural gas supplier may boost pressure somewhat to achieve even distribution
32. aker Box empty Contrl Box Bus system may only recognize as a production component rather than a spare part Page 41 of 45 Limited Warranty Unless otherwise provided Baldor generators are warranted against defects in Baldor workmanship and materials for a period of time as set forth in the Warranty Period chart below If a Baldor product is defective due to Baldor workmanship or materials and the defect occurs during the warranty period then Baldor will either repair the product or replace it with a new one whichever Baldor believes to be appropriate under the circumstances Service for warranty issues regarding any Baldor Generators Products Warranty is available by contacting Baldor Generators Customer Service Department in Oshkosh Wisconsin A list of Baldor s generator repair facilities may be obtained by contacting Bal dor Generators at Customer Service Baldor Generators 3815 Oregon Street Oshkosh Wisconsin 54902 920 236 4200 telephone 920 236 4219 facsimile Baldor products requiring war ranty service shall be transported or shipped freight pre paid at the risk of the party requiring warran ty service to a Baldor Generator repair facility or to Baldor Generators Customer Service Depart ment 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 address and telephone number of the party requi
33. and continue to keep our quality standards high on the list of priorities We are also constantly researching new technological ideas to determine if they could be used to make our generator sets even better Thank you for purchasing your Baldor generator set Effective February 26 1998 Revised August 12 2002 S PSG 001 25 Page 1 of 45 SPECI FI CATIONS FOR YOUR AE12 bBALDOR GENERATOR SET RATI NGS 12 KW ENGI NE CHARACTERI STI CS FUEL TYPE LP Natural Gas Make ONAN ELECTRI CAL CHARACTERI STI CS Model P224 Voltage 120 240 Cooling Air Phase 1 Power Factor 1 Amps 100 50 Hertz 60 Voltage Regulation Frequency Regulation Total Harmonic Distortion Motor Starting HP No Cylinders 2 H P 24 0 R P M 3600 1 FUEL CONSUMPTI ON Full Load 596 LP Gas 96 C F H 896 Natural Gas 260 C F H 6 Dimensions w enclosure IN LxWxH 44 1 2 x29 4 Weight 585 Lbs Dimensions w o enclosure IN LxWxH 33x27x30 Weight 389 Lbs NOTE The enclosed information covers basic installation operating and maintenance for this specific generator Installation of this generator is the sole responsibility of the owner Baldor Generators provides an AE Installation manual with the shipment of your generator which contains more specific information regarding the installation of your AE Unit Any questions regarding this information may be directed to the Customer Service departmen
34. ation 33 34 35 36 37 40 41 43 FORWARD This manual contains the information you need to safely and efficiently operate your generator set During the preparation of this manual every effort was made to ensure the accuracy of its contents Never operate this generator set without first carefully reading this manual and observing all the safety warnings it presents While safety is built into every Baldor Pow R Gard generator set careless or improper operation could possibly result in mechanical failure property damage severe injury or even death Note that this manual covers only very basic information in regards to the engine A separate owner s manual for the engine is supplied with this unit for your use Please refer to this manual for information relative to engine operation maintenance recommendations and additional safety warnings As soon as you receive your generator set inspect it closely for shipping damage If you find some damage notify the transportation company immediately and file a freight damage claim Think of this manual as a tool to help you get the most out of your generator set We strongly suggest that you keep this manual with your generator set and refer to it when questions arise in regards to its operation Baldor Generators has been in business since 1965 The generator sets we manufacture have earned the reputation of being of high quality and dependability We take pride in this fact
35. ations Manual Fuel Valves In addition to the electrical fuel shut off valve a LPG system should include a manually operated safety shut off valve located close to the fuel source This valve may well be a valve located on the tank itself or it may be a valve installed in the fuel transmission line A manual shut off valve is often required by existing regulations in many localities ZN CAUTION N For indoor installations by NFPA definition an automatic positive shut off valve must be installed to assure that the flow of fuel will be stopped should the engine fail while it is unattended Page 19 of 45 PROPANE GAS FLOW CHART Pipe Capacity in Cubic Feet IRON PIPE SIZE 12 34 1 114 412 2 wwe zm ss 772 5570 2437 vis 2407 sum 33 153 339 538 1127 1741 2975 6140 17325 35353 275 s nase 2009 soot 10701 8865 ss no 2n so wes 2104 1236 su 3228 9254 18895 3038 8659 17673 e msan ma tss wr ze 7 2532 me tme ae ese we so ew wes 0077 tous sm ser Lope m pe pm pm m An engine needs 10 000 BTU s HP For Propane there are 91 547 BTU s Gal For Propane there are 2 516 BTU s Cubic Ft
36. ator set is tilted fuel spillage may result Handle fuel with care It is highly flammable Use only clean properly marked and approved safety containers for refueling and storing fuel Stop the engine and allow it to cool before refueling Do not overfill the fuel tank Only fill the tank to within 1 2 of the top of the tank to allow space for fuel expansion If fuel is spilled wipe it up carefully and wait until the fuel has dried before starting the engine Make sure the fuel cap is properly closed after refueling Never operate the generator set while smoking Never operate the generator set near an open flame Never store the generator set with fuel in the tank indoors or in an enclosed poorly ventilated enclosure where fuel fumes may reach an open flame electrical spark or pilot light as on a furnace water heater clothes dryer etc When transporting over long distances or rough roads drain the fuel tank to prevent leakage and spillage AN WARNING N Gaseous Fuels are Highly Combustible and can Cause Explosions Fire Injury or Death 2222 FOR GASOLINE OR DIESEL POWERED GENERATOR SETS 22722 Check fuel supply piping and their connections on a monthly basis for fuel leaks Use only approved piping and componentry in your fuel supply system A professional experienced technician should only install the fuel supply system Do not run the fuel line up against any sharp objects Comply
37. battery charger go to the D1 and D2 terminal connection points on the terminal block pictured in figure 3 The wires from the terminals labeled and B on the battery charger go to the POS and NEG terminal connection points on the terminal block pictured in figure 3 jo POS in Battery Charger NEG o o To B in Battery Charger pilo o To DK1 in Battery Charger D2 o o To DK2 in Battery Charger Connection Terminal Block on Enclosed Generator Sets FIGURE 3 Page 14 of 45 UNI TS WITHOUT ENCLOSURE The wires from the terminals labeled DK1 and DK2 on the battery charger must be connected across the starter motor One lead must go to ground and the other must go to the starter motor or the switched on the Starter Solenoid DK1 and DK2 are not polarity sensitive and are therefore interchangeable with one another Wires from the terminals labeled and B on the Battery Charger go to the battery on the generator set goes to the positive post of the battery and B goes to the negative post on the battery It is important not only functionally but also for safety reasons NOTICE that the Generator set transfer switch and battery charger share a common Ground and neutral To determine the proper type and gauge of wire to use for NOTICE connecting the generator set transfer switch and battery charger together you should consult a local licensed electrician CUSTOMER CONNECTION
38. can start generator as programmed Public Service power drops ATS closes R terminals generator starts Ground fault problems in the conduit lead to the majority of continued run problems l Disconnect both the R wires at the generator Put generator control switch into AUTO A Generator should start B Generator should only run for 90 seconds If so GO TO STEP 3 C If the generator continues to run allow 15 minutes If the generator shuts down but not at 90 seconds record time and contact factory 2 Jump momentarily the R terminals A Generator should start B Generator should only run for 90 seconds If so GO TO STEP 3 C If the generator continues to run allow 15 minutes If the generator shuts down but not at 90 seconds record time and contact factory 3 Place generator control switch to OFF A Reconnect the R terminals at generator Now remove the ATS connections B Place generator into AUTO setting C With the R wires apart the generator should not start If generator starts but did not in step 1 bad wiring exists in conduit Momentarily hold the R wires together Generator should start Open connection from step D Generator should only run for 90 seconds If so GO TO STEP 4 If the generator continues to run allow 15 minutes If the generator shuts down but not at 90 seconds record time and contact factory mo 4 Check ATS R terminals If red light or other indicator i
39. ch device a circuit is completed to the control logic of the generator set causing the unit to start The unit will remain running until this connection is opened Once the remote start connection is opened the logic circuitry allows the engine to run for approximately 60 90 seconds before it shuts off This time delay is to allow the engine to run unloaded for a period of time to cool down Pos o REMOTE START CONTACTS RR1 Connection points on Connection points on units with an enclosure units without an enclosure FIGURE 1 Page 13 of 45 POWER CONNECTI ONS These terminal block connections are used to interface the wires cables from the emergency power supply input terminals located inside the transfer switch 1 1 o o 120 120 NEU o _ 24086 o neu 4 120 120VAC o o 4 units without units with an enclosure an enclosure FIGURE 2 BATTERY CHARGER CONNECTI ONS OPTI ONAL If you purchased a Master Control Systems Inc Battery charger with your generator set you must run two sets of wires from the battery charger to the generator set UNI TS WI TH FACTORY INSTALLED ENCLOSURE The terminal block that contains the connection points for the remote start on the enclosed units also contains the connection points for interfacing the battery charger to the generator set The wires from the terminals labeled DK1 and DK2 on the
40. 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 Limited Warranty Continued Notes for Warranty Period 1 Labor coverage for warrantable repairs is provided for the applicable period not to exceed published rates as contained in the Baldor Generators Warranty Policy Mileage is allowed only for permanent installations not to exceed published rates as contained in the Baldor Generators Warranty Policy 2 Proof of purchase date is required for all Portable and Towable products to qualify for any warranty consideration Serial number and model number will be required for all warranty work 3 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 Owner s Responsibilities Limitations The owner is obligated to operate and maintain the generator in accordance with the recommendations published by Baldor Generators in the Operator s Manual for the generator The owner is responsible for the costs associated with maintenance and any adjustments that may be required The owner is responsible for payment of any of the followin
41. e Lock connector D TO STARTER MOTOR LOW GNON 14 WHITE T SENSOR F g u TO FUEL 1 0 RECEPTACLE 13 ALARM LITE TI SOLENOID 14 8 gt e 165 Lis wert gt 9 5 pos 5 4 14 ORANGE P TO Lx FRAME BATTERY So TO REMOTE START CONTACTS AS SEEN VR63 4 REGULATOR 22 HZ 34 CRANKING SELECT TO CONVERT TO CYCLE CRANKING CUT JI amp 2 TIME DELAY TO ADO 10 SEC TO START UP CUT J3 Ji J2 amp LABELED F1F2 UNLESS OTHERWISE SPECIFIED TOLERANCES ALL DIMENSIONS IN INCHES DECIMALS i 005 FRACTIONS 1 64 1 ANGLES it PAINT SPECIFICATIONS TO FOLLOW DRAWING T amp J MANUFACTURING INC OSHKOSH WI 54901 ONLY ON THIS DIAGRAM APP FOR SURFACE DESCRIPTION 1 PIECE QTY DATE GLASS CONNECTION DIAGRAM AE 12 OPEN ONLY ELECTRIC POWR PRODUCTS oen 586993 un verre 6 23 98 REMOVED AUTO PRIME f ___ 950 16600 COLOR MATERIAL _ 11721797 DELETED AUTO CHOKE ADDED USED DOCUMENT 15 STRICTLY CONFIDENTIAL AND MAY DWG 910 828 2 1071797 Rs REPRODUCED OR UTILIZED IN ANY WAY DESCRIPTION
42. environment HEAT All engines give off considerable heat when running Since the engine and your generator set uses air to keep it cool it is important that the temperature of the area in which it is located does not exceed 100 degrees F Even while it is running Where natural ventilation is inadequate a fan to boost circulation should be utilized EXHAUST Exhaust gases from internal combustion engines are extremely poisonous We recommend that this unit not be placed in an indoor environment However if this is the application you choose the engine exhaust fumes must be vented to the outside EXHAUST FUMES CAN CAUSE SEVERE I NJ URY OR DEATH ALWAYS N WARNING N OPERATE IN A WELL VENTILATED AREA CONFI NED SPACE This unit must not be operated in a confined space or an enclosed compartment area Running the generator set in this environment is a potential fire hazard and is not authorized Engine and generator overheating damage could also occur due to restricted cooling air flow to and from the unit OPERATI NG THI S UNIT IN AN AREA WI THOUT ADEQUATE N WARNING VENTI LATI ON CREATES A POTENTI AL FI RE HAZARD ALWAYS OPERATE THIS UNIT IN WELL VENTILATED AREA Page 3 of 45 CONNECTI ON I NFORMATI ON Your new Baldor Pow R Gard Generator has all interconnecting wiring which is terminated at a junction box All wiring will be clearly labeled as being load remote start contacts and input terminals and are to be c
43. g expenses that might be incurred as a result of a failure under the terms of this warranty 1 Rental equipment used to replace the equipment being repaired 2 Telephone or other communication expenses 3 Living and travel expenses of persons performing service except as specifically included within the terms of specific warranty 4 The premium costs for overtime labor requested by the owner 5 All parts transportation costs All warranty claims must be submitted to a Baldor Generator repair facility prior to the expiration of the warranty period Baldor Generators shall have no responsibility or liability for any defect latent or otherwise discovered after the expiration of the warranty period provided herein Extended warranties are available for certain Baldor products These warranties are described in Baldor s catalog and other sales literature Extended warranties are subject to the terms and conditions of this Limited Warranty as modified by the additional terms of the extended warranty Baldor Generators is not responsible for the repair of generators required because of normal wear accident misuse abuse improper installation lack of maintenance unauthorized modifications or improper storage Normal Wear This warranty will not cover repair where normal use has exhausted the life of a part or generator It should be remembered that the service life of any generator is dependent on the care it receives and the conditions under
44. h a continuity tester or ohmmeter The wires must be removed from the circuit breaker prior to checking it 4 Loss of residual magnetism Loss of residual magnetism will not allow the generator s excitation system to build up and thus the generator set will not produce any power To Flash the generator set restore residual magnetism follow these steps Preferred Method A With the generator set stopped remove the generator s end cover and locate the set of three posts on the rotor plate at the tail end of the rotor there will be a wire wrapped around the center post and the left hand post B Using a 12 VDC battery touch the positive battery lead to the center post while touching the negative battery lead to the right hand post Allow the battery to remain across these posts for 2 seconds C Replace the end cover and start the unit Page 24 of 45 Alternate Method With the generator running and the end cover removed momentarily connect a 12 VDC battery across the capacitor s terminals for a fraction of a second Having the battery across the capacitor longer than a fraction of a second may damage the windings of the generator This is called flashing the generator Stop the unit after doing this and replace the end cover If you still have no output look for other reasons or call Baldor Generators for Technical Support at 920 236 4200 BE EXTREMELY CAREFUL WHEN USI NG THE ALTERNATE Z N WARNING 1 METHOD FOR FLASHING
45. he engine will shut down after a 60 90 second Cool Down time delay The engine can be shut down immediately from this position by putting the Master Control Switch into the OFF position A fault condition will also shut the engine down immediately Fault I ndicator Light This circular Red indicator light will come on in conjunction with the engine shutting down whenever a fault condition develops One Fault Condition that will cause a shut down is if the engine s starter motor cranks for more than 30 seconds without the engine starting This fault shutdown is to prevent damage to the starter motor Another Fault Condition will develop if the generator set stops producing power while the engine is running This fault shutdown is to prevent further potential damage to the generator end itself Another Fault Condition will develop if the engine s Low Oil Pressure Protection System shuts the engine down To reset the Control Logic once a Fault Condition has occurred you must put the Master Control Switch onto the OFF position for a minimum of 10 seconds Fuse for the Control Logic Board This fuse is rated at 1 Amp It s purpose is to prevent excessive and potentially damaging current from getting to the circuit board Circuit Breaker The Circuit Breakers on the generator set provide overload protection for the generator set These Breakers protect the generator set against potential damage from excessive AC current Page 2
46. ing or home where the building is also supplied electricity by a local utility shall be connected only by a competent electrician and only after the main service entrance switch has been disconnected and locked open This will isolate the building s electrical system from the local utility s electrical transmission wires and prevent the hazard of electrical back feed to utility service workers Any generator set that is permanently connected to a building or home where the building is also supplied electricity by a local utility shall be connected only by means of a double throw transfer switch This will isolate the building s electrical system from the local utility s electrical transmission wires and prevent the hazard of electrical back feed to utility service workers DO NOT CONNECT THI S GENERATOR SET TO ANY BUILDI NG S ELECTRI CAL AN WARNING N SYSTEM UNLESS YOU USE AN APPROVED TRANSFER SWITCH OR THE MAIN SERVI CE ENTRANCE SWI TCH HAS BEEN DI SCONNECTED AND LOCKED OPEN ANY TEMPORARY OR PERMANENT WI RI CONNECTIONS MADE BETWEEN N WARNING GENERATOR SET AND AN EXISTI NG ELECTRI CAL SYSTEM MUST ONLY BE DONE BY A QUALIFI ED COMPETENT ELECTRI CI AN 1 MPROPER WI RI NG CONNECTI ONS COULD CAUSE EQUI PMENT DAMAGE PROPERTY DAMAGE INJURY OR DEATH CHECK ALL NATI ONAL ELECTRI C CODES AND ALL LOCAL CODES I N REGARDS TO YOUR SPECI FI C APPLI CATI ON ANY NATI ONAL ELECTRI C CODE OR LOCAL CODE WILL TAKE PRECEDENCE OVER ANY OF OU
47. k ahead and warn others of your intentions Operate the generator with the operation switch in the Manual Run mode The engine should begin cranking While the engine is cranking turn the main adjustment screw counterclockwise until the engine starts Continue to rotate back and forth until smooth operation is obtained Adjustments that are too rich too far counterclockwise or too lean too far clockwise will result in the same rough sound Use slow rotating motion to find the smoothest spot Once set energize the AC breaker and apply available load Readjust main mixture screw until generator with or without applied load is smooth This will most likely be a slight rotation richer than initial setting at no load Shut off engine by placing the Operation Switch into the OFF position If operation problems persist contact your dealer or call Baldor Generators for Technical Support at 920 236 4200 Page 28 of 45 ELECTRICAL SYSTEM GENERATOR FAILS TO START Test each of the following and record actual findings If your findings do not match the values listed contact Baldor Generators for Technical Support at 920 236 4200 1 With generator in OFF position place meter on battery terminals in control box Red to B Black to B Should have 12 VDC Record Actual 2 Repeat when generator operation switch is in the RUN position Should have 8 12 VDC Record Actual A bad battery will gi
48. nnects to the Emergency Load Center When Public Service power fails the ATS closes a contact causing GEN to start Once AC power from generator is observed at the ATS the ATS will switch the Emergency Load Center over to the GEN When Public Service power returns the ATS will switch the Emergency Load Center back to Public Service power and open engine start to contact telling GEN to shut off CAUTIONS Emergency load center loads must not exceed GEN s capacity TheATS shall be protected by a circuit breaker appropriate for the ATS rating in the Customer Primary Load Center If you have any questions contact Baldor Generators for technical support at 920 236 4200 Page 32 of 45 CUSTOMER CONNECTION WIRING DIAGRAM AE SERIES ea m 8 5 C 8 INI a e D eee 5 As 40 NOISSINYIE INORA EST 133010 ON AYM ANY Mi 032711 YO 0321005433 38 LON 1 5611771 9104 12448 09943 667 Y t ONY MINKNOD 419415 15381300 SHL SE EEr 3087 313411 500013 OJAN WZTUTT T v 3010 COLD LUI Us 0455 TONIVWO MONOJ OL 080609 73 E 3 NO1123NN03 3380150 3234 DD 103 0 5 12522742 55241202 a 1 21412530 puo
49. onnected as described below LOAD These connections are rated and sized according to the KW of the generator Proper lead wire from these points to the automatic transfer switch or load switching device is mandatory See enclosed transfer switch information for corresponding generator input terminals WIRING Use sufficiently large insulated wire to connect the generator set to the load The gauge of wire will depend largely on the distance the permissible voltage drop and the size and type of load If you are not sure of the gauge wire needed for your application consult a competent electrician FRAYED CUT BROKEN LOOSELY CONNECTED OR I MPROPERLY WARNING SIZED POWER CORDS OR WIRES CAN CAUSE EQUIPMENT DAMAGE FIRE SEVERE I NJ URY OR DEATH INSPECT AND MAINTAIN ALL POWER CORDS ON A REGULAR BASIS REMOTE START CONTACTS This two wire connection once connected to an appropriate switch will start the generator and perform as described in the remote start stop literature These contacts are connected to the Engine Start Contacts of the automatic transfer switch A Two Pole normally open closed to operate switch may also be used to start the generator INPUT These connections are for units with float type battery chargers or engine block heater combinations A constant supply of 120 volts AC or as specified is needed at these terminals to power these devices NOTE Power is not required when the unit is in
50. operation Internal battery charging and radiant heat during operation eliminate the need for these devices NOTE It is recommended that units utilizing an automatic transfer switch with adjustable time delay have the initial adjustments made prior to startup Factory recommendations are to allow a 2 second delay on startup and a 15 second delay on emergency to normal so if your public service power is interrupted the automatic transfer switch will tell your generator to start after two seconds of power loss Then once Public Service Power is restored the generator will continue to operate for an additional fifteen minutes just in case there is yet another outage of power GROUNDING If grounding is necessary in your application according to National Electric Code and or local codes drive a 3 4 or 1 pipe into the ground as close to the Generator Set as is possible This pipe must penetrate moist earth minimum of 8 feet Connect a ground clamp to this pipe and run a No 10 wire or larger from it to the ground stud on the generator set Page 4 of 45 Do not connect the ground wire from the generator set to a water pipe a ground used by a radio system I MPROPER GROUNDI NG CAN CAUSE EQUI PMENT DAMAGE SEVERE WARNING IN URY OR DEATH INSPECT AND MAI THE GROUNDING SYSTEM IN ACCORDANCE WITH ALL APPLI CABLE CODES CONNECTI ONS TO HOUSE WIRI NG Any electrical generator that is temporarily connected to a build
51. p to 90 000 gallons in increments of 20 gallons Although some of the smaller tank sizes are used in mobile applications the ASME approved tank is generally used in stationary applications Page 18 of 45 Because tank pressures range from 0 to 200 PSI in LPG tanks these tanks cannot be filled to capacity ASME tanks are filled to 9096 capacity to allow for expansion of gases during increases in temperature The recommendation of the local certified professional fuel supplier should be followed when installing storage vessels and fuel piping Fuel valves While the secondary demand regulator supplied with this generator set is designed to close and stop fuel when the engine is not running it should not be relied upon to completely seal off the fuel system when the engine is stopped A ruptured diaphragm or a piece of dirt in the regulator could prevent the regulator s valves from seating with a result that gas would continue flowing through the carburetor into the engine and out into the surrounding air Since gaseous fuels are heavier than air they tend to settle in low areas which could present a serious hazard Electric fuel shut off valves This type of fuel valve interfaces with the electronic control circuitry of the generator set and is automatically activated to seal off the fuel the instant the engine s ignition system is shut down This type of fuel valve is mandated by federal and state regulations in most generator set applic
52. quires specialized skills Repair personnel must have a thorough understanding of generator and small engine repair procedures JN WARNING N Exhaust Fumes Gases re Extremely Dangerous Can Cause Illness Or Death Never inhale exhaust gases They contain carbon monoxide a colorless odorless and extremely dangerous gas that can cause unconsciousness or death Symptoms of carbon monoxide poisoning can include dizziness nausea headaches sleepiness vomiting or incoherency If you or anyone else experiences any of these symptoms get out into the fresh air immediately Shut the unit down and do not operate it until it has been inspected and if necessary repaired Never Operate the generator set indoors or in a poorly ventilated area such as a tunnel or cave CALIFORNIA PROPOSITION 65 WARNING engine exhaust from this product contains chemicals known to the state of California to cause cancer birth defects or other reproductive harm Improper Operation Can Result In Property Dam age ARNING A an A Mechanical Failure Severe Injury Or Death Know how to stop the engine quickly and understand the operation of all controls Never permit anyone to operate the generator set without proper instructions Never allow children to operate the generator set Children and pets must be kept away from the area of operation due to the possibility of burns from hot engine components or injury from any equipment the genera
53. r if known 4 Quantity of parts NOTE Engine parts can usually be obtained from a local representative of your engine manufacturer via the information in the engine manufacturer s owner s manual Baldor Generators can obtain engine parts for most models if necessary However we do not stock engine parts nor are we a dealer in engine parts SERVI CE Service for your generator set can be obtained from the service department at Baldor Generators by calling 800 872 7697 Please have the following information available prior to contacting the factory 1 The model of the generator set 2 The serial number of the generator set 3 Acomplete and accurate description of the problem Page 10 of 45 GENERAL I NSTALLATI ON amp SI TE SELECTI ON GUI DELI NES This information is for general reference only It must not be used as NOTICE the single source of information for installing the generator set For more specific detailed information read the installation manual that accompanied the generator set Incorrect installation of the generator set could result in property N WARNING damage injury or death Installation of this generator set must be performed by qualified professional technicians or contractors CAUTION N The generator set installation along with it s fuel supply piping should be inspected on a regular basis for potentially dangerous situations i e fuel leaks exhaust leaks loose or broken wiring
54. ring warranty service must be included Baldor is not responsible for removal and ship ment 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 Customers who are unable to take or ship the Baldor product to a Baldor Generator repair facility or who desire a repair to be made by other than a Baldor Generator repair facility should contact Baldor Generators Customer Service Department at 920 236 4200 Baldor in advance of such service must approve a repair by anyone other than a Baldor Generator repair facility in writing 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 Parties requir ing warranty service not satisfied with a determination that a problem is outside of warranty coverage should contact Baldor Generators Customer Service Department at 920 236 4200 for further con sideration EXCEPT FOR THE EXPRESSED WARRANTY SET FORTH ABOVE BALDOR GEN ERATORS DISCLAIMS ALL OTHER EXPRESSED AND IMPLIED WARRANTIES INCLUDING THE IMPLIED WARRANTIES OF FITNESS FOR A PART
55. s on at ATS public service power is on Terminals should be open B Check manual controls of ATS generator test exerciser C Replace control logic of ATS Page 30 of 45 SERI ES INTERCONNECTI ON THE FOLLOWING ARE PRINCIPLES OF INSTALLATION PLEASE NOTE LOCAL FEDERAL OR NEC CODES PREVAIL OVER THESE SUGGESTIONS Abbreviations GEN Generator Assembly ATS Automatic Transfer Switch Customer s Normal Panel Those circuits in a separate load box that will be powered by the generator Normal Power Supplier Load Center Emergency Load Center Public Service GEN to ATS Wiring wires for AC load 4 if three phase sized for the generator s load amperage A Ground wire is to connect all circuits GEN ATS Load Centers to the building s ground system 2 wires 14 gauge twisted pair for GEN remote start signal GEN to ATS Optional 120 volt feed for GEN mounted battery charger 12 volt wires 4 for building mounted battery charger Load center to ATS wires for AC feed four for three phase sized for ATS rating A ground wire is connected to all circuits GEN ATS Load Centers to the building s ground system ATS to emergency Load Center 3 wires for AC feed four for three phase sized for ATS rating Aground wire is to connect all circuits GEN ATS Load Centers to the building s ground system Page 31 of 45 Normal Operation Public Service power feeds the ATS which co
56. t at Baldor Generators This information is designed to be a guide for an experienced electrician Those not qualified should not attempt installation Page 2 of 45 LOCATI ON The following information is provided to assure that you get the best service from your Automatic Emergency Generator Several factors should be taken into consideration in choosing the best location in which to permanently mount this unit SURFACE Baldor Generators strongly recommends that your AE Unit be installed on a concrete or cement slab of appropriate size relative to the generator s base which is at least five 5 feet from any building structure shrubbery or any other obstruction that could possibly catch fire due to the extreme heat output of this generator set MOI STURE electrical equipment should be protected from excessive moisture Failure to do so will result in deterioration of the wiring insulation and may result in short circuits and a possible electrocution hazard OPERATI NG ELECTRI CAL EQUI PMENT I N WET ENVI RONMENTAL JN WARNING CONDITIONS CREATES A POTENTI AL ELECTROCUTION HAZARD DO NOT OPERATE ELECTRI CAL EQUI PMENT WHI LE STANDI WATER ON WET GROUND OR WI TH WET HANDS OR SHOES DIRT Foreign materials such as dust sand and other abrasive materials have a tendency to cause excessive wear to both engine and generator parts It is important that the unit be permanently located and operated in a reasonable clean
57. tanding water Baldor Generators strongly recommends that your AE Unit be installed on a concrete or cement slab of appropriate size relative to the generator s base which is at least five 5 feet from any building structure shrubbery or any other obstruction that could possibly catch fire due to the extreme heat output of this generator set Page 11 of 45 COOLI NG CONSI DERATI ONS when installing the generator set it should be mounted no closer than 5 feet away from any wall or object that would inhibit the cooling air flow that is necessary to operate the unit properly When installing the generator set inside a non occupied building an adequate supply of cooling air must be directed ducted to the cooling air intake of the engine The heated cooling air blowing off the back of the engine must be directed away from the unit so as not to be re circulated with the cool intake air It is extremely important that the generator set be kept clear of snow leaves grass and other debris NOI SE CONSI DERATI ONS This generator set will develop noise levels similar to that of common lawn and garden equipment Units supplied with enclosures will have their noise level significantly reduced MISCELLANEOUS CONSI DERATI ONS There should be adequate access to the generator set for maintenance repair Page 12 of 45 ELECTRI CAL I NSTALLATI ON GUI DELI NES Incorrect installation of the generator set could result in property WARNING
58. the gaseous fuel systems in regards to an engine not starting make sure that that the engine has ignition If the engine does not have a spark the problem is not due to a faulty fuel supply but rather is due to a problem in the engine control circuitry or the engine itself BASI C DESCRI PTI ON The gaseous fuel system on your generator operates on 6 ounces of pressure If the fuel is liquid propane LP it must be first vaporized before being delivered to the generator Once at the generator and electric valve keeps fuel from flowing unless the engine is running Inside the generator is a regulator called the secondary regulator that delivers fuel based on engine vacuum Proper maintenance is key to reliable performance We recommend only those skilled and licensed for repair of gaseous fuel powered generating systems be enlisted to service this product This basic guide is to assist those knowledgeable with generators in correction of fuel related operation and starting problems INITIAL CHECKS v Fuel supply is on and available at the fuel valve v Engine has spark and rotates at normal speed if not consult the engine operating guide for assistance in your area v Battery is charged and connected properly v Assume nothing If you have not checked it consider it not checked Page 26 of 45 PROBLEMS AND POSSIBLE SOLUTIONS In Order of Occurrence Inadequate Fuel Supply v Undersized piping check pressure at secondary regulator
59. tor set is powering Always wear eye protection and Hearing protection when working near the generator set Operate the generator set only with the guards shields and other safety items in place and working properly Do not put hands feet tools or other objects near rotating parts Use reasonable care when moving or lifting the unit The generator set may move around inside the wrap frame creating Pinch Points Do run the generator set while it is being moved Do not support the generator set from the top of the wrap frame Do not operate the generator set while under the influence of alcohol drugs or medication When transporting or using a generator set with the wheel option secure the unit to prevent it from moving around Do not tamper with or change the engine speed as it has been preset at the factory for proper operation Keep hands and face away from the carburetor when the air cleaner is being moved A sudden backfire serious burns Be careful of hot parts The muffler and other generator parts become very hot while the engine is running Do not jump start the generator set Sulfuric acid can cause severe injury and can give off gases which are corrosive and potentially explosive Avoid contact with skin eyes and clothing In case of contact flush area immediately with water When transporting a generator set secure it to prevent it from moving or shifting This Generator
60. tor windings Clean the generator set and its components with a damp cloth or sponge Do not use sprayed water or compressed air to clean the generator set or it s components I NSPECTI NG v Inspect the external wires of the generator set for cuts fraying or loose connections Repair or replace any problems prior to using the unit CUT FRAYED BROKEN OR LOOSELY CONNECTED WI RES CAN N WARNING CAUSE EQUI PMENT DAMAGE SEVERE I NJ URY OR DEATH v Inspect and clean the battery posts and the associated battery cable terminals v Inspect and replace any control box components that are broken or not working properly receptacles circuit breakers switches etc v Inspect the fuel system for leaks v Inspect and replace any fuel line that shows signs of deterioration v Make sure all the fuel clamps are tight Make sure the fuel cap fits snugly on the fuel tank and that the fuel tank contains no leaks lt REPAIR ANY FUEL SYSTEM LEAKS N WARNING PRIOR TO RUNNING THE UNIT Page 7 of 45 ADJUSTMENTS v The engine should be checked for proper speed setting s v Adjust engine speed to 3720 RPM s 62 Hz with no load applied to the generator set ENGI NE MAI NTENANCE MAI NTENANCE SHOULD ONLY BE PERFORMED ON THE GENERATOR SET WARNING N AFTER THE ENGI NE HAS STOPPED AND THE GENERATOR SET HAS COOLED DOWN THE BATTERY AND SPARK PLUG SHOULD ALSO BE DI SCONNECTED PRI OR TO PERFORMI NG MAI NT
61. ve you lower readings GO TO STARTER SOLENOI D ON ENGI NE 3 Checking for Ohms place one meter lead on the solenoid s bracket Place the other on the B in the control box Should have 1 ohm resistance or less Record Actual Bad ground would be open reading or higher resistance 4 Place red meter lead on small terminal at starter solenoid black on bracket Should have 10 VDC more when cranking Record __________ Cranking means operation switch in RUN even if it does not crank right now 5 Place red meter lead on the large solenoid terminal with wire labeled POS Place black meter lead on solenoid bracket Should be same as battery step 1 Record Actual GO TO LOGI C BOARD CONNECTI ON BOX AT ENGI NE END OF GENERATOR 7 On right hand relay there are two black enclosed relays on top of the board unplug wire labeled E1 or 6110 Place meter lead into wire terminal black to ground stud Should have 12 VDC when not cranking 8 12 when cranking Record A low reading indicates a loose wire at the solenoid 8 Remove the other terminal from the left hand relay labeled E3 or 6200 Connect the Red meter lead to the wire black to the ground stud Should be 8 12 VDC when cranking Record Actual Page 29 of 45 GENERATOR RUNS CONTINUOUSLY OR FAILS TO STOP AFTER RETRANSFER Basic Theory Public Service power energizes ATS ATS holds R terminals open Generator test switch or exerciser

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