Winco 25PTOC-3/F, CSA8PTOC-3/C Instructions Manual

READ

ALL INSTRUCTIONS CAREFULLY BEFORE AlTEMPTlNG TO INSTALL, OPERATE OR SERVICE

THE

GENERATOR. PROTECT YOURSELF AND OTHERS BY OBSERVING ALL SAFETY IN-

FORMATION. FAILURE TO COMPLY

WITH

INSTRUCTIONS COULD RESULT IN PERSONAL INJURY

AND/OR PROPERTY DAMAGE!
RETAIN

INSTRUCTlONS

FOR

FUTURE REFERENCE.

Description

7.

This generator must be properly grounded.

These rotating armature power take-off generators
are designed primarily for farm use as a standby
electrical power supply, utilizing the power take-off
of a tractor or truck as the prime mover. The portable
trailer-mounted unit can be used to provide electri­cal power to machinery and out-buildings where
commercial power is not accessible.

NOTE: The prime mover which drives the generator
must be capable of delivering approximately2.2 H.P.
per 1000 watts output from the generator.

Unpacking

NOTE: DO NOT invert generator during unpacking.
Gearcase contains oil.

Unpack the generator as follows:

1. Remove strapping from carton.

2.

Lift off carton.

3. Remove the small

subpack carton.

4.

Open the subpack carton; it contains:

a.

One generator instruction manual

b.

One load disconnect plug (disassambled, in
bag). for

25PTOC-8JF One range/welding

plug, for

CSABPTOC-3IC

c.

One quality control inspection tag.

5. Remove the four bolts which hold down the gen­erator feet to the pallet. (A six inch crescent
wrench is suitable for this job.)

6.

Lift the generator from the pallet by means of the
lifting eye on the top of the generator.

7.

Inspect the generator for freight loss or damage.

Genera Safety Information

1.

Do not allow anyone to operate the generator
without,proper instruction.

2.

Guard against electric shock.

3. Avoid touching live terminals or receptacles.

4.

Be extremely careful

if

operating this generator

in rain or snow.

5. Do not make or break electrical receptacle con­nections under

.load.

6.

Use only grounded receptacles and extension
cords.

8. Hot engine parts, moving partsi aid generator
output all can seriously injure the generator
operator. The operator must use caution and

remain alert when using this generator.

9. Provide safety guards for all drive systems.

10. Keep all safety guards and power shields in po­sition and tightly secured.

11. When operating this generator. do not wear
neckties, loose articles of clothing, or anything
else that can be caught in moving parts.

12. Engine exhaust fumes are poisonous. Do not
inhale them. Provide adequate ventilation if
prime mover for generator is gas or diesel en­gine. Be sure generator itself is well ventilated.

13. The generator manufacturer recommends that
only qualified electrical technicians be allowed
to service (install, maintain. repair, or replace
parts) this generator, and that only factory ap­proved repair parts be used in it.

14. Do not work on this generator when fatigued.

15. Use extreme caution when working on electrical
components. High generator output can cause
injury or death.

16. Installing and wiring a home-standby generator
installation is not a "do it yourself" project.
Consult

a

qualified, licensed electrician or con­tractor. The installation must comply with all
national, state, and local codes.

17. Excessive noise is tiring, and continual expo­sure to it can cause some degree of temporary
and permanent hearing loss. Muffle engine
noise with the best available noise suppression
equipment; wear noise protection devices when
necessary.

18. Keep the generator and the area around it clean.
Remove all material that can create slippery
conditions, such as grease, water, ice, and
snow. Also remove oily rags and other flamma­ble material from the area.

19. Keep a fire extinguisher near the generator. Ex­tinguishers rated ABC by the NFPA are appro­priate for this use. Consult the local fire depart­ment if you have questions regarding fire extin­guisher ratings. Keep the extinguisher properly
maintained and be familiar with its proper use.

Specifications

GEN.RPM

3600
3600

INS.

B

F

PH

1
1

HZ.

60
60

INPUTRPM

540
540

AMPS

66/33

208/104

VOLTS
1201240

120/240

MODEL

-

8PTOC

25PTOC

WATTS

8000

25000

Assembly

The only assembly required after unpacking the
generator is to assemble and/or wire the plugs
packed in the

subpack carton, packed in the

generator carton. The load disconnect plug provided

-.

with

25PTOC-3lF

,is packed in a bag.

The bag contahs an instruction sheet, a plug body,
three brass pins (large pin for neutral), and a manila
envelope. The envelope contains an

allen wrench,

three retainer pins, and three set screws.
To assemble and wire the load disconnect plug,

proceed as follows (See Figure

1):

1.

Cut lead cables to the required length.

2.

Strip off insulation

718"

back from one end of

each cut-to-length cable.

3.

Start a set screw into each pin.

4.

lnsert the stripped end of one cable fully into one
of the brass pins. and tighten the set screw firmly
to secure the cable end in the pin.

CAUTION: If

cable-to-pin connection

is

loose,

arcing and heat damage

io

equipment can re-

sult.

5.

Insert the brass pin (with cable) into the plug
body, and line up the retainer pin holes in the
brass pin with those

in

the plug body.

6.

lnsert the retainer pin, and tap it firmly into place.

The retainer pin will protrude approximately

318"

when fully seated (See Figure

1).

7.

Repeat steps 4 through 6 for each brass pin.
Make sure to connect the neutral lead (cable).

identified and color coded in conformance with
ihe applicable local electrical codes, to the large
diameter pin ("N") on the plug.

WARNING: DURING THE NEXT STEP, THE
LOAD DISCONNECT PLUG SHOULD NOT

BE
PLUGGED INTO ITS RECEPTACLE. ALSO,
MAKE SURE

THATTHE EQUIPMENTTO WHICH

THE PLUG LEADS ARE

BEING CONNECTED IS

NOT ENERGIZED (LIVE).

8.

Strip the insulation off the free end of each of the
plug leads and connect them to the load transfer
switch (or directly to the load).

Installation

FOUNDATION MOUNTING
Mount,the generator on a foundation if it is to be

used as

a

leave-in standby power source.

When planning

a

new foundation. consider ihe fol-

lowing points (See Figure

2):

Figure

2

-

Foundation for Permanent Installation

1.

The foundation location should enable aligning
the tumbling bar (coupling shaft) in

a

straight (or
nearly straight) line with the power take-off and
the generator input shaft. (Misalignment must be
less than

15

degrees even though the mechanical

design of the tumbling bar would allow greater

misalignment.)

2.

The foundation must be solid enough to absorb
generator starting and reflected

load torque

during operation,

3.

The foundation surface should be flat.

4.

Space is required around the generator for
mounting switching devices, making connec­tions, and for servicing.

5.

All four generator mounting pads must rest firmly
on the foundation. Install shims

if

necessary to

even out the foundation under the mounting

pads, then bolt the generator firmly in place.

TRAILER MOUNTING

Mount the generator on a trailer if you plan to use it

as

a

portable power source.

When selecting or building a trailer to mount the

generator, consider the following points (See Figure

3):

1.

The trailer construction must be strong enough

to support the generator.

2.

The design of the trailer must enable the trailer to
remain stable during operation, and to resist tip­ping caused by generator starting and reflected
load torque.

WARNING: TRAILER

MAY

TIP

OVER

AND

CAUSE INJURIES

IF

WHEELS ARE NOT

SPACED FAR ENOUGH APART.

3.

The trailer height and mounting position of the
generator on the trailer should enable aligning
the tumbling bar (coupling shaft) in a straight (or
nearly straight) line with the power take-off and
generator input shafts. (Misalignment must be
less than

15

degrees even though the mechanical
design of the tumbling bar would allow greater
misalignment.)

lnstallation

Opera

tion

4.

The generator mounting area of the trailer bed
should be flat.

5.

AII

four generator mounting pads must rest firmly

on

:the trailer bed. Install shims if necessary to
even out the bed under the mounting pads, then
bolt the generator firmly in place.

Figure 3 - Trailer for Portable Installation

OUTPUT POWER AND LOAD DETERMINATION
The power take-off generators are supplied with

control boxes, receptacles, fuses or circuit break­ers. The maximum load which should ever be
applied to the generator is the KW (kilowatt) or wat­tage rating of the generator. This rating is stamped
on the generator identification nameplate.

De­pending on the generator model, this maximum load
will only be available at the Load Disconnect plug.

restricted to their design

rating. Some models have

protection for the receptacles.

to find the load current of

different appliances.

Load Wattage Rating = Load current in amperes

120 volts

Example:

Food freezer requires 300 watts

300 watts

=

2.5 amps.

120 volts

Refrigerator requires 325 watts

325 watts

=

2.7 amps.

120 volts

Ten 100 watt light bulbs require 1000 watts

1000 watts

=

8.3 amps.

120 volts

Freezer

=

2.5 amps.

Refrigerator

=

2.7 amps.

Lights

=

8.3amps.

Total Load

=

13.5 amps.

Use the same method to figure the load current for
the 240 volt electrical loads.

NOTE: Check applianceimotor nameplate for volt­age. current, and wattage. specifications when
figuring load. current.

USING ELECTRIC MOTORS WITH
GENERATOR SETS
When using an electric motor with the generator set.
consider the starting current of the motor. All single

phase electric motors require more starting current
than running current, and starting currents vary

reatly between different types of motors.

Capacitor­&art motor starting currents are 4 to 4-112 times the
running current, and Split-Phase motor starting cur­rents are 5 to 5-1/2 times the runnina current.

-

-.

NOTE: In applications where several iotors are to be

started, do not start them at the same time to avoid
overloading the generator. Start the motor that re­quires the highest starting current first.

PRE-START CHECKS
WARNING: WHEN WORKING ON OR AROUND

THIS GENERATOR, DO NOT WEAR LOOSE FIT­TING CLOTHING OR ANY ARTICLES THAT MAY
GET CAUGHT IN MOVING PARTS.

1. Visually inspect the generator. Check for:

.

a. correct mounting
b. physical damage

.

c. debris in cooling vents and screens (could

cause generator to overheat).

CAUTION: If the generator has been stored for
any length of time it is recommended that the
control box cover and the end cover be re­moved, and the generator inspected for rodent
nests or other foreign objects that could cause
binding or overheating of the generator. See
"Cleaning" generator maintenance for proce­dures.

2.

Check gear case oil level. See Figure 4. Case
should be filled with oil to plug marked "OIL

LEVEL." Fill or remove oil as required.

OIL

BREATHER,

@

.-

>.,.

L-??

..T---T

*

0

:'.>

.

..

..

c:;

.

o(Q

2oi--T

.:

,

0

?:

I

CAUTION: Either too little or too much oil can
harm the equipment. See "Lubrication" portion
of Maintenance for oil specifications.

3.

Make sure tumbling bar (coupling shaft) is as­sembled with its universal joint knuckles
"synchronized." as illustrated in Figure

5.

If knuck-

les are not synchronized. the bar

will chatter when

rotating, which will cause the generator output
voltage to fluctuate and can also cause tumbling
bar failure or shortened generator life.

Operation (Continued)

WARNING: POWER TAKE-OFF MUST

BE

DIS--

ENGAGED AT

THIS

TIME.

4.

Couple the generator drive (power take-off) to the:
generator with the tumbling bar. Couple the tum­bling bar to the generator input shaft first, then to
the power take-off shaft. Check alignment: power
take-off shaft, tumbling bar, and generator input
shaft should form a straight (or nearly straight)
line, with less than

15"

misalignment between the
shafts. Misalignment will cause generator output
voltage to fluctuate or damage the tumbling bar
and generator.

WARNING: MAKE SURE THAT ALL TUMBLING
BAR LOCK

PINS

ARE ENGAGED ANDTHATALL

SAFETY SHIELDS ARE

IN

PLACE.

5.

Make-sure no binding exists in generator or gear
box by rotating tumbling bar by hand.

If

binding is
found, locate the cause and correct it before pro­ceeding.

6.

Make sure that the electrical loads connected will
not draw more current than the rating of the gen-

erator or receptacle being used.

7.

Check all electrical connections in the system to
be energized by the generator. Make sure the
connections are correct and are tight.

8.

Make sure all loads are turned off.

CAUTION:

Do

not start the generator under

load.

speed governor, it may automatically readjust the

throttle as the load changes and keep the gen-

erator output at

240V.

However, some governors

are not sensitiveenough to maintain

240V

output

under changing load, and in such cases the

throttle will have to be manually readjusted.

IT

Synchronized

-7

GENERATOR STARTING

1.

With the power take-off drive disengaged, start
the engine which will drive thegenerator. Run the
engine long enough to warm it up before pro­ceeding. so that it will run smoothly and achieve
full power under generator load.

2.

With engine idling, engage the power take-off
drive.

3.

Watch the voltmeter on the generator and slowly
increase engine speed until the output reaches
approximately

260

volts (in green portion of

voltmeter scale).

4.

With engine,and generator running smoothly,
switch on

the electrical load while watching the

voltmeter.
Readjust engine throttle to keep generator out­put under load at

240V

(in

green portion of

voltmeter scale).

If

engine

is

equipped with a

.

GENERATOR SHUTDOWN

1.

Switch off electrical load.

2.

Reduce speed of engine driving generator to idle.

3.

Disengage power take-off drive, and allow gen-

erator to coast to a stop.

WARNING: NEVER TRY

TO

MANUALLY

STOP

THE GENERATOR - LET IT COAST UNTIL IT
STOPS!

4.

Disconnect tumbling bar (coupling shaft) power

takeoff end first, then generator end.

Wiring

Diagrams

ELECTRICAL CONNECTIONS
NOTE: Only qualified electricians should .install

electrical wiring. Wiring must conform to all appli­cable national, state, and local codes, (Reference:
National Fire Protection Association Manual No.

70,

National Electrical Code.)

WARNING: IFTHEGENERATOR ISTO BEUSEDAS

A STANDBY POWER PLANT WIRED INTO THE
EXISTING COMMERCIAL. SYSTEM, A

DISCON-

NECTSWITCH MUST BE INSTALLED WHICH WlLL
ISOLATE THE GENERATOR FROM THE COMMER­CIAL POWER WHENEVER THE GENERATOR IS
NOT OPERATED, AND WlLL ISOLATE THE COM­MERCIAL POWER FROM THE GENERATOR WHEN

CAUTION:

When making standby service hook up,

THE GENERATOR IS OPERATING (SEE FIGURE

6).

make sure load to be transferred does not exceed
generator rating.

TYPICAL HOOK UP FOR

SUPPLYING ALL CIRCUITS

WlTH EMERGENCY POWER

TYPICAL HOOK UP FOR

SUPPLYING ONLY ESSENTIAL CIRCUITS

WlTH EMERGENCY POWER

To Power Line Master Switch

Wanhour

,

Emergency
Power
System

L1 L3

I-

--'-

--

1

Studby

Ci.nerolor

I

I

L-----

-J

Te

.

Watw

ktu

To

Air

bnditioner

Te

Ughh

To Refn'g.

1-

Ughk

To Applianc

1e

Ughk

To Fumace

To

Powor Line Morter Switch

Watthour
Meter

Emergency
Distribution

T

1

~3

Panel

I--

-'-------

To

a

Lights

-+

,

,

To

'

'

'1

TO

Lights

+,

4

+

Appliancer

-

To

-i--

"t.

To

Lbhts

=

.L

A

f

Furnace

I

7

1

Figure

6

-