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Automatic Emergency
Generator
AE8, AE10, AE11 and AE25
Installation & Operating Manual
5/05 MN2415
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WARNING: CALIFORNIA PROPOSITION 65 WARNING: Engine exhaust from this product contains chemicals known to the state of California to cause cancer, birth defects and other reproductive harm. WARNING: CALIFORNIA PROPOSITION 65 WARNING: Battery posts, terminals and related accessories are known to the state of California to cause cancer, birth defects and other reproductive harm.
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Table of Contents Section 1 Product Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Appendix A Series AE8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Operator Panel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Section 1 Product Safety Information Safety Notice Be sure that you are completely familiar with the safe operation of this equipment. This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment. Improper use can cause serious or fatal injury. Always disconnect all electrical loads before starting the generator. Installation and repair procedures require specialized skills with electrical generating equipment and liquid cooled engi
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Symbols This symbol is shown throughout the manual to indicate a connection to ground reference point. Indicates a potentially hazardous situation which, if not avoided, could result in injury or death. Indicates a potentially hazardous situation which, if not avoided, could result in injury or death. Precaution Statements Used In This Manual There are three classifications of precautionary statements used in this manual. The most critical is a WARNING statement, then the Caution statement an
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Operation Warning Statements Continued WARNING: Never connect or disconnect loads during operation. Always connect load circuits before starting the engine and use external branch disconnects etc. to switch loads On/Off. WARNING: Be sure that you understand how to stop the engine quickly in case of an emergency situation. Become familiar with the controls and safety systems provided with this generator set. WARNING: Always wear safety glasses with side shields and hearing protection when worki
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Warning Statements Continued Installation WARNING: Installation and servicing of batteries is to be performed or supervised by personnel knowledgeable of batteries and the required precautions. Keep unauthorized personnel away from batteries. WARNING: Disconnect the battery’s ground terminal before working in the vicinity of the battery or battery wires. Contact with the battery can result in electrical shock when a tool accidently touches the positive battery terminal or wire. The risk of
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Warning Statements Continued Maintenance WARNING: Before servicing the generator set, be sure to disconnect the battery terminals to prevent accidental engine rotation or starting. WARNING: Disconnect the battery’s ground terminal before working in the vicinity of the battery or battery wires. Contact with the battery can result in electrical shock when a tool accidently touches the positive battery terminal or wire. The risk of such shock is reduced when the ground lead is removed during in
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Caution Statements Caution: Avoid installing the generator set beside heat generating equipment, or directly below water or steam pipes or in the vicinity of corrosive substances or vapors, metal particles and dust. Heat can cause engine problems to develop and unwanted substances can cause rust or generator failure over time. Caution: Do not apply high voltage to windings (do not start the generator) in a moisture −saturated condition. Moisture can cause insulation breakdown, making it necessar
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Section 2 General Information Thank you for purchasing your Baldor Generator Set. This manual contains information you need to safely and efficiently install and operate your generator set. During the preparation of this manual every effort was made to ensure the accuracy of its contents. This manual describes only very basic engine information. A separate owner’s manual for the engine is supplied with this unit for your use. Please refer to the engine manual for information relative to engine
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2-2 General Information MN2415
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Section 3 Receiving & Installation Receiving & Inspection When you receive your generator, there are several things you should do immediately. 1. Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered your system. 2. Verify that the part number of the system you received is the same as the part number listed on your purchase order. 3. If the system is to be stored for several weeks before use, be sure that it is stored in a loc
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Physical Location The mounting location of the system is important. It should be installed in an area that is protected from direct harmful gases or liquids, dust, metallic particles, shock and vibration. It should be installed in an outdoor location so the exhaust fumes are vented to the atmosphere. WARNING: An open bottom stationary engine generator set must be installed over noncombustible materials and shall be located such that it prevents combustible materials from accumulating under
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Indoor Location Continued It is recommended that the cool air intake have at least three (3) times the cross −sectional area of the power ventilation system. It is also recommended that the cool air intake be located as close as possible to the top of the generator set. The exhaust fan must be connected to the AC power terminals of the generator set so that when the generator set starts it will provide immediate cooling air flow. The fan will operate until the generator set stops. Ventilation T
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Indoor Location Continued 4. Keep all fuel and its associated piping away from all components of the engine exhaust system. 5. The exhaust system should be inspected on a regular basis to assure there are no toxic exhaust gas leaks. In some areas this inspection may be provided by your local public service. 6. A carbon monoxide tester may be installed to detect the presence of the deadly gas during times when you are in the building with the engine running (during testing or maintenance). Insta
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Fuel Connections The AE Series generators will run on Natural Gas or LPG (Liquid Propane Gas). If natural gas supply is used, follow the “Natural Gas Connections” procedure. If LPG supply is used, follow the “LP Gas Connections” procedure. Table 3-2 defines the flow rate required for each fuel type. Note: The AE25 must be ordered for use with Natural gas or LPG. Table 3-2 Fuel Consumption Natural and LPG Generator Model Required Flow Rate (cubic feet per hour) Pressure oz. ( (ih inches w
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Natural Gas Connections The incoming pressure must be as indicated in Table 3-2. Note: Almost all operation problems are related to the installation techniques used. Do Not guess, be sure pipe size is adequate for required flow rate. Table 3-3 Natural Gas Flow Rate (Cubic Feet per Hour) per Pipe Length Pipe Iron Pipe Size Length Length 1 3 1 1 1 / ″ / ″ 1 ″ 1 − / ″ 1 − / ″ 2 ″ 2 − / ″ 3 ″ 4 ″ 6 ″ 8 ″ 2 4 4 2 2 (Feet) 15 73 165 332 722 1174 2386 3704 6253 13352 37229 30 50 115 232 515 818 1712
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Example: Determining Pipe Size for LPG An AE8 has a 16Hp engine. For LP fuel, determine the supply pipe size for 60 feet run. 16 x 10,000 = 160,000 BTU’s / per hour for proper operation. 160, 000 63.5 cubic feet per hour. 2, 516 From Table 3-4, a 60 foot run requires a minimum 1” pipe at full engine load. LP Gas Connections (vapor withdrawal only) The LPG connections should only be made if your generator is setup to run on LPG. If it is setup to run on Natural Gas, contact your Baldor re
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Electrical Connections Class 1 wiring methods must be used for field wiring connections to terminals of a class 2 circuit. It is the responsibility of the owner/operator to arrange for these procedures to be performed by a licensed electrical contractor and ensure conformance to all applicable codes including local codes peculiar to your municipality/city/county and state. Wire size and insulation type should be as required by NEC (National Electrical Code) and local codes. Warning: Never co
