Winco PSS12A User Manual
PACKAGED
STANDBY
SYSTEM
INST ALLATION AND OPERA TORS MANUAL
PSS8.5/A
PSS8.5/B
PSS10/A
PSS10/B
PSS12/A
Engine Generator Set
Automatic Transfer
Switch
Read and understand all instructions in the
manual before starting and operating the
generator set.
USING THIS MANUAL
Congratulations on your choice of a Winco generator set.
You have selected a high-quality, precision-engineered
generator set designed and tested to give you years of
satisfactory service.
To get the best performance from your new engine
generator set, it is important that you carefully read and
follow the operating instructions in this manual.
Should you experience a problem please follow the
“Things To Check” near the end of this manual. The
warranty listed in this manual describes what you can
expect from WINCO should you need service assis-
tance in the future.
TABLE OF CONTENTS
INTRODUCTION i
GUIDE TO PRODUCT SAFETY 1
BASIC INFORMATION 2
Description 2
Specification Table 2
PREPARING THE UNIT 3
Unpacking the Unit 3
ENGINE GENERA TOR INST ALLATION 3
Installation 3
Fuel Installation 4
Vapor Fuel Pressure Tables 5
Fuel Conversions 5
Lubrication 5
Battery Installation 5
Connecting Battery Charger 6
TRANSFER SWITCH INST ALLATION 6
AC Electrical Connections 7
DC Electrical Connections 8
Exerciser Clock Set Up 9
INITIAL ST ART-UP 9
PROPER USE AND INSTALLATION
You must be sure your new engine generator set is:
* Properly serviced before starting
* Operated in a well ventilated area
* Properly exhausted and gases safely dispersed
* Wired by a qualified electrician
* Operated only for its designed purposes
* Used only by operators who understand its operation
* Properly maintained
COPY YOUR MODEL AND SERIAL
NUMBER HERE
No other WINCO generator has the same serial number
as yours. It is important that you record the number
and other vital information here. If you should ever
need to contact us on this unit it will help us to respond
to your needs faster.
MODEL____________________________________
SERIAL NUMBER____________________________
PURCHASE DATE____________________________
DEALER___________________________________
DEALER PHONE # ___________________________
TROUBLESHOOTING INFORMATION 10
WIRING DIAGRAMS
NON-UL ATS Wiring Diagram 12
ATS Dimensions 13
Generator Layout 13
AC & DC Generator Schematic 14
UL ATS Wiring Diagram 15
12 MONTH W ARRANTY 16
MAINTENANCE LOG 17
P AGE i
SAFETY INFORMA TION
This engine generator set has been designed and
manufactured to allow safe, reliable performance.
Poor maintenance, improper or careless use can
result in potential deadly hazards; from electrical
shock, exhaust gas asphyxiation, or fire. Please read
all safety instructions carefully before installation or
use. Keep these instructions handy for future
reference. Take special note and follow all warnings
on the unit labels and in the manuals.
ANSI SAFETY DEFINITIONS
************************************************************
DANGER:
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death or
serious injury. This signal word is to be limited to the
most extreme situations.
***********************************************************
************************************************************
WARNING:
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
***********************************************************
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CAUTION:
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe
practices.
************************************************************
NOTE:
CAUTION is also used on the unit labels and in this
manual to indicate a situation that could result in
serious damage or destruction of the equipment and
possible personal injury.
1. ELECTRIC SHOCK - The output voltage present in this
equipment can cause a fatal electric shock. This
equipment must be operated by a responsible
person.
before refueling.
b. Keep fuel containers out of reach of children.
c. Do not smoke or use open flame near the
generator set or fuel tank.
d. Keep a fire extinguisher nearby and know its
proper use. Fire extinguishers rated ABC by
NFPA are appropriate.
e. Store fuel only in an approved container, and only
in a well-ventilated area.
f. Follow local codes for closeness to combustible
material.
3. DEADL Y EXHAUST GAS - Exhaust fumes from any
gasoline engine contain carbon monoxide, an
invisible, odorless and deadly gas that must be mixed
with fresh air.
a. Operate only in well ventilated areas.
b. Never operate indoors.
c. Never operate the unit in such a way as to allow
exhaust gases to seep back into closed rooms
(i.e. through windows, walls or floors).
4. NOISE HAZARD - Excessive noise is not only tiring,
but continual exposure can lead to loss of hearing.
a. Use hearing protection equipment when working
around this equipment for long periods of time.
b. Keep your neighbors in mind when permanently
installing this equipment.
5. CLEANLINESS - Keep the generator and surrounding
area clean.
a. Remove all grease, ice, snow or materials that
create slippery conditions around the unit.
b. Remove any rags or other material that could
create potential fire hazards.
c. Carefully clean up any gas or oil spills before
starting the unit.
d. Never allow leaves or other flammable material
to build up around the engine intake or exhaust
area.
6. SERVICING EQUIPMENT - All service, including the
installation or replacement of service parts, should be
performed only by a qualified technician.
a. Do not allow anyone to operate the generator
without proper instruction.
b. Guard against electric shock.
c. Avoid contact with live terminals or receptacles.
d. Use extreme care if operating this unit in rain or
snow.
e. Use only three-prong grounded receptacles and
extension cords.
f. Be sure the unit is properly grounded to an
external ground rod driven into the earth.
2. FIRE HAZARD - Natural gas and L.P. present a hazard
of possible explosion and/or fire.
a. Do not refuel when the engine is running or hot.
Allow the engine to cool at least two minutes
0306-01
PAGE 1
a. Use only factory approved repair parts.
b. Do not work on this equipment when fatigued.
c. Never remove the protective guards, cover, or
receptacle panels while the engine is running.
d. Use extreme caution when working on electrical
components. High output voltages from this
equipment can cause serious injury or death.
e. Always avoid hot mufflers, exhaust manifolds,
an d engine parts. They all can cause severe
burns instantly.
f. Installing a generator set 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.
60706-147
TESTING POLICY:
Before any generator is shipped from the factory, it is
fully checked for performance. The generator is loaded
to its full capacity, and the voltage, current, and frequency
are carefully checked.
Rated output of generators is based on engineering
tests of typical units, and is subject to, and limited by, the
temperature, altitude, fuel, and other conditions specified
by the manufacturer of the applicable engines.
INTRODUCTION AND DESCRIPTION
The package standby system includes all items
necessary for a completely automatic standby power
system as standard equipment.
DESCRIPTION
This packaged standby system is designed to automatically provide standby power to unattended loads
during electrical outages. Upon an interruption of normal
electrical service the packaged standby system electrical
control circuits will automatically start the engine. The
generator will produce electrical power and the Automatic
Transfer Switch (A.T.S.) will automatically transfer the
electrical loads to the engine-generator set. Upon
restoration of normal electrical service the emergency
transfer switch will sense return of the normal commercial power. The Automatic Transfer Switch will retransfer
the load back to the normal commercial power source.
The engine control circuits will begin a cool-down cycle,
after which the fuel supply will be shut off and the engine
ignition system disabled.
These packaged standby systems consist of two
major components:
1) AUTOMATIC TRANSFER SWITCH
A wall mounted Automatic Transfer Switch (A.T.S.)
designed for inside installation. The A.T.S. consists of a
line side contactor and a generator side contactor. The
contactors are both electrically and mechanically
interlocked. A seven day electronic exerciser clock is
installed in the A.T.S. as standard equipment. The A.T.S.
also contains the power failure sensing circuitry necessary to send a start/stop signal to the engine generator
set.
Standard Automatic Transfer Switch Sizes
(NON-UL)
Optional UL Automatic Transfer Switch Sizes
UNIT LINE SIDE GENERATOR
CONTACTOR SIDE CONTACT O R
PSS8.5 100 AMPS 100 AMPS
PSS10 100 AMPS 100 AMPS
PSS12 100 AMPS 100 AMPS
or 200 AMPS 200 AMPS
Both the 100 amps and the 200 amps UL Switches are
available in single and three phase.
Additional optional A.T.S. sizes are available to meet
specific needs. Contact your local WINCO dealer, or the
WINCO Sales Department for a quote.
2) ENGINE/GENERATOR
The engine generator set consists of a Briggs &
Stratton Vanguard, two cylinder, air cooled engine. The
engine is factory equipped and EPA certified to run on L.P.
or N.G. fuel. The engine operates at 3600 rpm and
frequency regulation is maintained by the engine
governor within 4 cycles variation (62.5 Hz - 58.5 Hz) from
no load to rated load. The generator is a brushless,
single bearing, direct drive, rotating field design. The
generator is connected to the engine’s tapered (quill)
crankshaft extension. The engine generator is mounted
in a NEMA 3R enclosure for outside installation. Connection boxes are provided for all customer connections
(both AC output and DC control). A customer supplied
235 CCA (BCI group U1) battery is required to complete
the installation. Engine operation is controlled by an
Electronic Engine Control Module (E.C.M.) mounted in
the engine generator enclosure. The E.C.M. is equipped
standard with a 10 second start delay, 90 second cool
down delay and cycle cranking.
** NOTICE **
This unit will automatically transfer if a power outage
occurs while running in an exercise mode.
SPECIFICATIONS
GENERATO R
MODEL WATTS* VOLTS AMPS* HZ pH RPM
PSS8.5 8,400 120/240 35.0 60 1 3600
PSS10 9,600 120/240 40.0 60 1 3600
PSS12 12,000 120/240 50.0 60 1 3600
*Derate 15% for Natural Gas operation. Derate 3.5%
per 1000 feet elevation above sea level.
UNIT LINE SIDE GENERATOR
CONT ACT OR SIDE CONTACTOR
PSS8.5 11 0 AMPS 60 AMPS
PSS10 110 AMPS 60 AMPS
PSS12 110 AMPS 60 AMPS
FUEL CONSUMPTION
NG L.P. VAPOR
1000 BTU/CU FT 2520 BTU/CUFT
MODEL CF/HR BTU/HR #/HR* GAL/HR CF/HR BTU/HR*
PSS8.5 132 132,000 6.7 1.6 63.0 158,760
PSS10 162 162,000 7.7 1.84 72.0 181,440
PSS12 195 195,000 9.2 2.2 84.0 211,650
*Based on full load operation
PAGE 260706-147
0306-01
L.P. TANK SIZING
Required L.P. Tank size for L.P. Vapor withdrawal
operating at various outside temperatures given in
degrees Fahrenheit (Celsius)
TANK TEMPERA TURE
MODEL 60 f(16 c) 32 f(0 c) 0 f(-18 c) -20 f(-29 c)
PSS8.5 150 Gal. 150 Gal. 250 Gal. 500 Gal.
PSS10 150 Gal. 250 Gal. 500 Gal. 1000 Gal.
PSS12 250 Gal. 500 Gal. 500 Gal. 1000 Gal.
ENGINE SPECIFICATIONS:
Refer to engine operating and maintenance instruc-
tions.
** NOTICE **
Regarding Engines - This manual covers the generator
portion of these units. See the separate engine instruction manual for engine-related problems, detailed engine
information and engine warranty.
** CAUTION **
Be sure to check the engine oil level frequently, as
specified in the engine manual.
The engine manufacturer has established an excellent
worldwide engine service organization; engine service is
available from a nearby authorized dealer or distributor;
check the yellow pages of the telephone directory under
“engines,” or ask the dealer from whom you purchased
the power plant.
The rated power of each engine-generator is limited by
the temperature, altitude and all other ambient conditions
specified by the engine manufacturer. Engine power will
decrease 3-1/2% for each 1000 ft. above sea level, and
will decrease an additional 1% for each 10 degrees
Fahrenheit above 60 degrees Fahrenheit.
UNPACKING INSTRUCTIONS
** NOTICE **
When unpacking the generator set, be sure to inspect it
carefully for freight loss or damage. If loss or damage is
noted at the time of delivery, require that the person
making the delivery make note of the loss or damage on
the freight bill, or affix his signature under the consignor’s
memo of the loss or damage. Contact the carrier for
claim procedures.
When loss or damage is noted after delivery, segregate
the damaged material, and contact the carrier for claim
procedures. Be sure to retain the packaging material for
carrier inspection.
time of delivery by the carrier, but which is discovered
later. The carrier or carriers are responsible for merchandise lost or damaged in transit. The title to goods
rests with the consignee when generators are shipped
F.O.B. factory, and only the consignee can legally file a
claim. Please note, most carriers have a time limit for
filing concealed damage claims.
**** CAUTION ****
The PSS8.5, PSS10 and PSS12 are shipped without oil.
Be sure to check oil levels before operating. See engine
manufacturer’s instruction manual for recommended oil
requirements before initial starting.
UNPACKING:
1. Carefully remove the carton.
2. After inspecting the engine-generator and transfer
switch for external physical damage, check for the
following items packed inside the carton.
a. Owner’s manual, wiring diagram and parts list.
b. Engine manufacturer’s instruction manual.
c. USDA approved spark arrestor
3. Remove main frame hold down bolts, (4).
4. Unit can now be lifted from shipping pallet.
INSTALLATION
General Information
*************
***** WARNING ****
*************
Before proceeding with the installation, be sure the
operation selector switch is in the stop position.
These engine/generator sets are designed to be
mounted on a concrete pad outdoors only. The transfer
switch is mounted next to your electrical entrance or
distribution panel inside the building. Consult a qualified, licensed electrician or contractor to install and wire
the transfer switch. The installation must comply with all
national, state and local codes.
Before beginning the installation process recheck the
rating of the generator set and its transfer switch rating.
Be certain they can handle the intended load and are
compatible with the entrance voltage, phase and current
ratings. Plans for installation should be prepared with
proper attention to mechanical and electrical engineering
detail to assure a satisfactory system installation. The
information in this manual is offered only as a guide to
finalizing your installation plans.
“Concealed Damage” is understood to mean damage
to the contents of a package which is not evident at the
0306-01
PAGE 3
60706-147
ENGINE GENERATOR SET MOUNTING
The unit’s main frame should be bolted solid to a four to
six inch thick cement pad. The engine-generator is
mounted on a sub-frame which is isolated with special
shock mounts on the main frame. This allows the
engine-generator to vibrate without affecting the control
panel on the main frame.
Do not install any shock mounts between the base
frame and the concrete pad. Engine vibration will be
transmitted to the control panel causing erroneous start/
stop cycles and premature control failure.
The unit should be mounted to allow for ample working
room around it. A general rule to follow is three (3) feet
clearance on all sides. NFPA 37 requires at least 3 feet
clearence from any structures having combustible
adjacent walls and 5 feet from openings in walls.
Particular attention should be paid to the direction of the
hot air discharge and exhaust discharge. Unit location
should be such that these discharges are not allowed to
be drawn back in through an open window or door.
FUEL INSTALLATION
The fuel supply should be as close as possible to the
engine. This will reduce the installation cost of fuel runs.
The information in this manual is offered to assist you in
providing the proper fuel for your engine. However, this
information is only provided to inform you of the engine’s
requirements and assist in making you aware of the
decisions you must make. In no case should the
instructions or information provided be interpreted to
conflict with any local, state or national codes. If in doubt,
always consult your local fire marshal or gas supplier.
*************
***** WARNING ****
*************
FIRE HAZARD - All fuel runs should be installed by a
licensed fuel supplier.
Connect the fuel supply to the inlet of the fuel solenoid
(see table for recommended line size). For all vapor fuel
systems the delivery pressure of the fuel to the fuel
solenoid on the unit must be four to six ounces psi (per
square inch) or 7 to 11 inches W.C. (Water column).
These fuel pressures are critical, failure to provide the
proper fuel pressure can cause many problems ranging
from a unit that will not start to causing damage to the
fuel system.
INST ALLING THE FUEL LINE
** NOTICE **
The engine generator sets are properly adjusted before
they leave the factory. A tag is attached to the unit that
specifies the fuel, natural gas (NG) or propane vapor (LP)
that the unit was set up and tested on. A slight adjust-
ment may be necessary on NG depending on local BTU
content. This adjustment will be discussed later.
Line Size
Unit location will determine the size of fuel line that is
required to supply the engine with a constant fuel
pressure and volume. Refer to the tables below for fuel
line size, fuel consumption and recommended tank size.
For distances of 50 feet and over, a two regulator fuel
system is recommended. This is accomplished by
installing a primary regulator at the tank which will reduce
the tank pressure down to 10 to 15 lbs. A secondary
regulator is installed to further reduce the fuel pressure
to the required four (4) to six (6) oz operating pressure.
This secondary regulator must be at least 10 feet from
the engine generator set, any closer installation will
require a larger line be installed to provide a fuel reservoir. This is also true for the single dual stage regulators, it should also be minimum of 10 feet from the unit.
If this is not done the demand regulator on the unit and
the pressure regulator in the fuel line will interfere with
each other.
When the two (2) stage regulator system is used, a fuel
line size of 1/2 to 5/8 inch is generally adequate for
distances up to 300 feet from the primary to the secondary regulator. (Consult your local fuel supplier for your
exact requirements.) The appropriate line size from the
table below is then installed from the second regulator to
the generator set.
*************
***** WARNING ****
*************
PERSONAL DANGER - Do not use galvanized pipe in
fuel line runs. The galvanized coating can become
eroded and flake off, causing possible obstructions in the
regulator or fuel valve. The results could range from
inoperative engine start to hazardous fuel leaks.
NATURAL GAS or LP V APOR
Size of pipe normally required for generators operating
on NATURAL GAS or LP V APOR
up to 25 feet* 25 - 100 feet* over 100 feet*
PSS8.5 3/4" pipe 1" pipe not recommended
PSS10 3/4” pipe 1” pipe use a two
PSS12 3/4” pipe 1” pipe regulator system
*Allow an additional 3 feet for each standard elbow. Do not use
‘street ells’ (restrictive)*
**** CAUTION ****
Be careful when sealing gas joints. Excessive sealing
compound can be drawn into the solenoid, regulator or
carburetor causing an engine malfunction.
FUEL PRESSURE
L.P . & N.G. VAPOR FUEL
Correct fuel pressure cannot be stressed enough. The
most common cause for inoperative systems is an
inadequate or incorrect fuel pressure. Performance of
the engine is in direct relation to the correctness of the
PAGE 460706-147
0306-01
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