OPERATOR'S MANUAL FOR YOUR AUTOMATIC EMERGENCY POW'R PRODUCTS MODEL AE12 GENERATOR BALDOR GENERATORS 3815 Oregon Street • Oshkosh WI 54902 Telephone 236-4200 • Fax 920-236-4219 FORM#: S-PSG-002-13 EFFECTIVE DATE: 4/2/97 AE12 COVER \MSW'00 REVISION DATE: 8/13/02
Safety Warnings ? Place protective covers and guards over the rotating parts, if rotating parts such as the drive shaft, pulley, belt, etc. are left exposed, they are potentially hazardous. ? When cleaning, repairing or inspecting, make sure all moving parts have stopped. ? Prior to working on the generator set, disconnect the spark plug and battery to prevent accidental starting. ? Use only original equipment or authorized replacement parts.
? Never permit anyone to operate the generator set without proper instructions. ? Never allow children to operate the generator set. ? Children and pets must be kept away from the area of operation due to the possibility of burns from hot engine components or injury from any equipment the generator set is powering. ? Always wear eye protection and Hearing protection when working near the generator set.
? 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.
???? FOR GASOLINE OR DIESEL POWERED GENERATOR SETS ???? ? Check all fuel supply piping and their connections on a monthly basis for fuel leaks. ? Use only approved piping and componentry in your fuel supply system. ? A professional, experienced technician should only install the fuel supply system. ? Do not run the fuel line up against any sharp objects. ? Comply with NFPA regulations and your local codes in regard to shut-off valves, regulators, etc.
TABLE OF CONTENTS SECTION PAGE Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . Prefix Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Generator Specifications . . . . . . . . . . . . . . . . . . . 2 Location Information . . . . . . . . . . . . . . . . . . . . . . 3 Connection Information . . . . . . . . . . . . . . . . . . . 4 Engine Information . . . . . . . . . . . . . . . . . . . . . . . 6 Basic Generator Maintenance . . . . . . . . . . . . . .
Customer Connection Wiring Diagram . . . . . . . . . . . . 33 AE12 Base Outline Drawing . . . . . . . . . . . . . . . . . . . . 34 AE12 OPEN - Connection Diagram . . . . . . . . . . . . . . . . 35 AE12 Enclosed - Wiring Diagram . . . . . . . . .. . . . . . . . . 36 AE12 Enclosed - Connection Diagram . . . . . . . . . . . . . 37 Gen End Componentry Diagram . . . . . . . . . . . . . . .. . 40 Parts Break Down for AE12 . . . . . . . . . . . . . . . . . . 41 Warranty Information . . . . . . . . .
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.
SPECIFICATIONS FOR YOUR AE12 bBALDOR GENERATOR SET RATINGS: 12 KW FUEL TYPE: LP/Natural Gas ELECTRICAL CHARACTERISTICS: Voltage: 120/240 Phase: 1 Power Factor: 1 Amps: 100/50 Hertz: 60 Voltage Regulation (+/-): 1% Frequency Regulation: 5% Total Harmonic Distortion: <8% Motor Starting (HP): 6 Dimensions w/ enclosure - IN. (LxWxH) : Dimensions w/o enclosure - IN. (LxWxH) : ENGINE CHARACTERISTICS: Make: ONAN Model: P224 Cooling: Air No. Cylinders 2 H.P. 24.0 R.P.M.
LOCATION The following information is provided to assure that you get the best service from your Automatic Emergency Generator. Several factors should be taken into consideration in choosing the best location in which to permanently mount this unit.
CONNECTION INFORMATION Your new Baldor Pow'R Gard Generator has all interconnecting wiring, which is terminated at a junction box. All wiring will be clearly labeled as being load, remote start contacts, and AC input terminals and are to be connected as described below: LOAD - These connections are rated and sized according to the KW of the generator. Proper lead wire from these points to the automatic transfer switch (or load switching device) is mandatory.
Do not connect the ground wire from the generator set to a water pipe or a ground used by a radio system. IMPROPER GROUNDING CAN CAUSE EQUIPMENT DAMAGE, SEVERE INJURY OR DEATH. INSPECT AND MAINTAIN THE GROUNDING SYSTEM IN ACCORDANCE WITH ALL APPLICABLE CODES.
ENGINE INFORMATION This operator's manual only covers basic day -to -day engine operating instructions. However, the engine manufacturer's manual is included with your generator set and should be referred to for any additional information you may need. Become familiar with and follow all the engine manufacturer's operation, safety and maintenance guidelines. OIL: Use a high quality oil of the type specified in the engine owner's manual for your specific operating conditions.
MAINTENANCE MAINTENANCE SHOULD ONLY BE PERFORMED ON THE GENERATOR SET AFTER THE ENGINE HAS STOPPED AND THE GENERATOR SET HAS COOLED DOWN. THE BATTERY AND SPARK PLUG SHOULD ALSO BE DISCONNECTED PRIOR TO PERFORMING MAINTENANCE. GENERATOR END MAINTENANCE Generator end maintenance consists of cleaning the generator set, inspecting the wiring and fuel system, and making any necessary adjustments. Generator end maintenance should be performed on a monthly basis (or sooner if needed).
ADJUSTMENTS: v The engine should be checked for proper speed setting(s). v Adjust the engine speed to 3720 RPM's (62 Hz) with no load applied to the generator set. ENGINE MAINTENANCE MAINTENANCE SHOULD ONLY BE PERFORMED ON THE GENERATOR SET AFTER THE ENGINE HAS STOPPED AND THE GENERATOR SET HAS COOLED DOWN. THE BATTERY AND SPARK PLUG SHOULD ALSO BE DISCONNECTED PRIOR TO PERFORMING MAINTENANCE.
STORAGE OR LONG TERM NON-USAGE If you will not be using the generator set for a significant amount of time (3 months or longer) you should store the generator to prevent any problems that could arise from sitting idle. Please fully read the following guidelines prior to storing the unit. 1 Drain the used oil from the engine's crankcase and refill it with fresh, clean oil (if your engine is diesel proceed to step 4). 2. Remove the spark plug and pour1 oz. of clean engine oil into the cylinder.
ORDERING PARTS When Generator repair parts are needed, they may be obtained by calling the Customer Service Department at Baldor Generators or the nearest local office of Baldor Electric Motors, Drives and Generators. Accurate information such as the following will assure that you 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.
GENERAL INSTALLATION & SITE SELECTION GUIDELINES This information is for general reference only! It must not be used as the single source of information for installing the generator set. For more specific/detailed information read the installation manual that accompanied the generator set. Incorrect installation of the generator set could result in property damage, injury, or death! Installation of this generator set must be performed by qualified / professional technicians or contractors.
COOLING CONSIDERATIONS 1. when installing the generator set, it should be mounted no closer than 5 feet away from any wall or object that would inhibit the cooling air flow that is necessary to operate the unit properly. 2. When installing the generator set inside a non-occupied building, an adequate supply of cooling air must be directed/ducted to the cooling air intake of the engine.
ELECTRICAL INSTALLATION GUIDELINES Incorrect installation of the generator set could result in property damage, injury, or death! Installation of this generator set must be performed by qualified / professional technicians or contractors. This information is for general reference only! It must not be used as the single source of information for installing the generator set.
AC POWER CONNECTIONS These terminal block connections are used to interface the wires/cables from the emergency power supply input terminals located inside the transfer switch. BATTERY CHARGER CONNECTIONS (OPTIONAL) If you purchased a Master Control Systems Inc. Battery charger with your generator set you must run two sets of wires from the battery charger to the generator set.
UNITS WITHOUT ENCLOSURE The wires from the terminals labeled DK1 and DK2 on the battery charger must be connected across the starter motor. One lead must go to ground and the other must go to the starter motor (or the 'switched' B+ on the Starter Solenoid). DK1 and DK2 are not polarity sensitive and are therefore interchangeable with one another. Wires from the terminals labeled B+ and B- on the Battery Charger go to the battery on the generator set.
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.
GASEOUS FUEL INFORMATION INCORRECT INSTALLATION OF THIS GENERATOR SET COULD RESULT IN PROPERTY DAMAGE, INJURY, OR DEATH! INSTALLATION OF THIS GENERATOR SET MUST BE PERFORMED BY A QUALIFIED, PROFESSIONAL TECHNICIAN OR CONTRACTOR. THIS INFORMATION IS FOR GENERAL REFERENCE ONLY! IT MUST NOT BE USED AS THE SINGLE SOURCE OF INFORMATION FOR INSTALLING THE GENERATOR SET. FOR MORE SPECIFIC/DETAILED INFORMATION READ THE INSTALLATION MANUAL THAT ACCOMPANIED THE GENERATOR SET.
natural gas. A pressure drop of 0.3' (water column) is used to account for a nominal number of fittings and metering equipment. Referring to the fuel consumption figures, we can use this chart to calculate proper sizing.
Because tank pressures range from 0 to 200 PSI in LPG tanks, these tanks cannot be filled to capacity. ASME tanks are filled to 90% capacity to allow for expansion of gases during increases in temperature. The recommendation of the local certified professional fuel supplier should be followed when installing storage vessels and fuel piping.
PROPANE GAS FLOW CHART Pipe Capacity in Cubic Feet An engine needs 10,000 BTU's / HP For Propane there are 91,547 BTU's /Gal For Propane there are 2,516 BTU's / Cubic Ft.
NATURAL GAS FLOW CHART Pipe Capacity in Cubic Feet An Engine needs 10,000 BTU's / HP For Natural Gas there are 1,000 BTU's / Cubic Ft.
OPERATION PRIOR TO STARTING THE UNIT: 1. Locate and set up the generator set in an open, dry, well ventilated and reasonably level location. OPERATING THIS UNIT IN AN AREA NOT SUITABLE FOR IT'S PROPER USE MAY CAUSE DAMAGE TO THE UNIT, SEVERE INJURY, OR DEATH. SEE "LOCATION INFORMATION" SECTION LOCATED ELSEWHERE IN THIS MANUAL. 2. If grounding is required for your application, check to make sure your unit is grounded properly. 3.
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 the engine will shut down after a 60-90 second 'Cool Down' time delay.
SIMPLE TROUBLESHOOTING Listed below are the more simple solutions to some of the more common problems that are reported to the Customer Service Department at Baldor Generators. These troubleshooting solutions are meant to be an aid for a person who has minimal electrical knowledge and experience.
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.
TROUBLESHOOTING FOR GASEOUS FUEL SYSTEM GASEOUS FUELS ARE HIGHLY COMBUSTIBLE AND CAN CAUSE EXPLOSIONS, FIRE, INJURY, OR DEATH! THE FUEL SUPPLY SYSTEM MUST ONLY BE INSTALLED AND ADJUSTED BY AN EXPERIENCED, PROFESSIONAL TECHNICIAN USING APPROVED PIPING AND COMPONENTRY. PRIOR TO MAKING ANY ADJUSTMENTS THAT WILL TAKE THE GENERATOR SET OUT OF IT'S FACTORY PRESET CONDITION, PLEASE NOTE THE CONDITION / SETTING OF THE ADJUSTING DEVICE.
PROBLEMS AND POSSIBLE SOLUTIONS In Order of Occurrence Inadequate Fuel Supply v Undersized piping - check pressure at secondary regulator, 6 oz. Minimum. v Condensation in line - check for flow potential, water traps and lines that run in and out of buildings. Improper Fuel Mixture v Check main adjustment - see adjustment section (below). v Check auto prime adjustment - see adjustment section (below). Inoperative Fuel Valve v Check function by connecting leads to generator battery.
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.
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.
GENERATOR RUNS CONTINUOUSLY OR FAILS TO STOP AFTER RETRANSFER Basic Theory – Public Service power energizes ATS ATS holds “R” terminals open Generator test switch or exerciser can start generator, as programmed. Public Service power drops, ATS closes “R” terminals, generator starts. Ground fault problems in the conduit lead to the majority of continued run problems. 1. Disconnect both the “R” wires at the generator. Put generator control switch into “AUTO”. A. Generator should start. B.
AE SERIES INTERCONNECTION THE FOLLOWING ARE PRINCIPLES OF INSTALLATION. PLEASE NOTE: LOCAL, FEDERAL, OR NEC CODES PREVAIL OVER THESE SUGGESTIONS. Abbreviations: GEN ATS Load Center Emergency Load Center = = = = Public Service = Generator Assembly Automatic Transfer Switch Customer's Normal Panel Those circuits in a separate load box that will be powered by the generator. Normal Power Supplier GEN to ATS Wiring: ? ? ? 3 wires for AC load (4 if three phase) sized for the generator's load amperage.
Normal Operation: ? ? ? Public Service power feeds the ATS which connects to the Emergency Load Center. When Public Service power fails, the ATS closes a contact causing GEN to start. Once AC power from generator is observed at the ATS, the ATS will switch the Emergency Load Center over 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).
FOR AE12 UNITS WITHOUT ENCLOSURE OLD PART # 120.00500 47.00121A 67.00120 230.80010 387.09056 400.21300A 440.92000 480.10000 361.00010P 120.00401 520.01100 550.00435 610.00060 670.00007 671.00200 950.01700 120.00110 670.00005 671.
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.
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.
Owner’s Responsibilities: The owner is obligated to operate and maintain the generator in accordance with the recommendations . The owner is responsible for published by Baldor Generators in the Operator 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. 2. 3. 4. 5.
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: Diesel engine exhaust and some constituents are known to the state of California to cause cancer, birth defects and other reproductive harm.
