Winco PSS12H2W, PSS12H2E, PSS12H2F Installation And Operator's Manual
PSS12H2W/E & /F
GENERATOR
INSTALLATION AND
OPERATORS
MANUAL
WINCO INC. 225 S. CORDOVA AVE. LE CENTER, MN 56057 507-357-6821
SERVICE DEPT. 507-357-6831
www.wincogen.com
TABLE OF CONTENTS
SAVE THESE INSTRUCTIONS 3
TESTING POLICY 3
SAFETY INFORMATION 4
ANSI SAFETY DEFINITIONS
SPECIFICATIONS 5
GENERATOR
ENGINE
INTRODUCTION 5
PRODUCT DESCRIPTION
PREPARING THE UNIT 6
UNPACKING
INSTALLATION 6
ENGINE-GENERATOR SET MOUNTING
FUEL INSTALLATION 6
LIQUID PROPANE VAPOR (LP)
NATURAL GAS (NG)
FUEL PRESSURE
FUEL PRESSURE TABLES
NG/LP FUEL CONVERSION
INSTALLING THE BATTERY 9
SERVICING BATTERIES
BATTERY CHARGING
CONNECTING THE BATTERY CHARGER
SOLAR CHARGER OPTION 10
AC ELECTRICAL CONNECTIONS 11
GENERATOR CONNECTIONS
WINCO UL ATS (ASCO 185)
DC ELECTRICAL INTERCONNECTION 12
ASCO 185 UL SWITCH
INITIAL START UP 12
START UP PROCEDURE
CUSTOMER CONNECTION AREA
SEQUENCE OF OPERATION 16
DSE 3110 17
FRONT PANEL CONFIGURATION
ACCESSING THE FRONT PANEL
EDITING A PARAMETER
DSE 3110 FAULT CODES
DSE 3110 ENGINE CONTROL
MODULE DISPLAY
PREVENTATIVE MAINTENANCE 18
AUTOMATIC TRANSFER SWITCH
ENGINE-GENERATOR SET
TROUBLE SHOOTING TABLES 19
PAD LAYOUT DRAWING 20
AC AND DC GENERATOR SCHEMATIC 21
AC WIRING SCHEMATIC 21
SOLAR CONTROL PANEL 22
EXTERNAL RECEPTACLE ASSEMBLY 22
SOLAR PANEL ASSEMBLY 23
12 MONTH LIMITED WARRANTY 24
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2
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SAVE THESE INSTRUCTIONS
TESTING POLICY
This manual contains important instructions that should be followed
during installation and maintenance of the generator. Read and
understand all instructions in the manual before starting and operating
the generator.
USING THIS MANUAL
Congratulations on your choice of a WINCO generator. You have
selected a high-quality, precision-engineered generator designed and
tested to give you years of satisfactory service.
To get the best performance from your new generator, it is important
that you carefully read and follow the operating instructions in this
manual.
Should you experience a problem please follow the “Troubleshooting
Tables” near the end of this manual. The warranty listed in the manual
describes what you can expect from WINCO should you need service
assistance in the future.
COPY YOUR MODEL AND SERIAL NUMBER HERE
No other WINCO generator has the same serial number as yours.
If you should ever need to contact us on this unit, it will help us to
respond to your needs faster.
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 generator is based on engineering tests of typical units,
and is subject to, and limited by, the temperature, altitude, fuel, and
other conditions specied by the manufacturer of applicable engines.
MODEL __________________________________________________
SERIAL NUMBER _________________________________________
PURCHASE DATE _________________________________________
DEALER NAME ___________________________________________
DEALER PHONE # ________________________________________
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60706-209
SAFETY INFORMATION
This engine generator set has been designed and manufactured to
allow safe, reliable performance. Poor maintenance, improper or
careless use can result in potentially deadly hazards; from electrical
shock, exhaust gas asphyxiation, or re. 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.
D. Keep a re 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. DEADLY EXHAUST GAS -
Exhaust fumes from any gasoline engine contain carbon monoxide, an
invisible, odorless and deadly gas that must be mixed with fresh air.
CALIFORNIA PROPOSITION 65
WARNING: This product contains crude oil, gasoline,
diesel fuel and other petroleum products, Antifreeze to
which can expose you to chemicals including toluene
and benzene, Ethylene glycol (ingested) which are
known to the State of California to cause cancer, birth defects or other
reproductive harm and developmental issues.
For more information go to www.P65Warning.ca.gov.
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.
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.
A. Operate only in well ventilated areas.
B. Never operate indoors including attached garages
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,
oors).
4. NOISE HAZARD -
Excessive noise is not only tiring, but continual exposure can lead to
loss of hearing.
A. Use hearing protection when working around this equipment for
long periods of time.
B. Keep your neighbors in mind when using 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 materials that could create a
potential re hazard.
C. Carefully clean up any gas or oil spills before starting the unit.
1. ELECTRICAL SHOCK -
The output voltage present in this equipment can cause fatal electric
shock. This equipment must be operated by a responsible person.
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-pronged 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 -
Gasoline and other fuels present a hazard of possible explosion and/
or re.
A. Do not refuel when the engine is running or hot.
B. Keep fuel containers out of reach of children.
C. Do not smoke or use open ame near the generator set or fuel
tank.
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6. SERVICING EQUIPMENT -
All service, including the installation or replacement of service parts,
should be performed only by a qualied technician.
A. Use only factory approved repair parts.
B. Do not work on this equipment when fatigued.
C. Never remove the protective guards, covers, or receptacle
panels while the engine is running.
D. Use extreme caution when working on electrical components.
High output voltage from this equipment can cause serious
injury or death.
E. Always avoid hot mufers, exhaust manifolds, and engine parts.
They can cause severe burns instantly.
F. The use of the engine-generator set must comply with all
national, state, and local codes.
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SPECIFICATIONS
INTRODUCTION
GENERATOR
Fuel Watts* Volts Amps HZ PH RPM
LP 12,000 120/240 50 60 1 3600
NG 10,000 120/240 41 60 1 3600
*Continuous rating.
Derate 3.5% per 1000 feet elevation above sea level.
FUEL CONSUMPTION
Natural Gas
1000 BTU/FT³
CF/HR* 194 75.4
BTU/HR* 194,000 190,000
GAL/HR* N/A 2.1
*Based on full load operation.
LP Vapor
2520 BTU/FT³
LP TANK SIZING
Tank Temperature Tank Size
60° F (16° C) 150 Gallons
32° F (0° C) 250 Gallons
0° F (18° C) 500 Gallons
-20° F (-29° C) 1000 Gallons
ENGINE
Make Honda
Model GX690
Displacement 688 CC/OHV
Cylinders/Sleeves V-Twin/Cast Iron
Ignition Electronic
Governor Mechanical
Exhaust Critical Grade, Glass-pack
See engine manual for additional information
PRODUCT DESCRIPTION
The package standby system is designed to automatically provide
standby power to unattended loads during electrical outages. Upon
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 (ATS) 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 transfer 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.
AUTOMATIC TRANSFER SWITCH (not included)
A wall mounted ASCO 185 Automatic Transfer Switch (ATS) designed
for inside or outside installation is recommended. The transfer switch is
UL1008 approved. A fourteen day electronic exerciser circuit is installed
in the ATS as standard equipment. The ATS also contains the power
failure sensing circuitry necessary to start and stop the engine
generator set. The transfer switch is also equipped standard with a 3
second start delay, and a 15 second transfer delay to allow the engine
to warm up before transferring the load to the generator. When the line
power is restored the ATS has a 5 minute transfer delay to allow the
incoming utility to stabilize before transferring back to line power and
then an additional 1 minute engine cool down delay before the engine
shuts down. Read and understand the ATS owners manual before
installing, servicing or operating the transfer switch.
UL Automatic Transfer Switch Sizes
UNIT LINE SIDE GENERATOR
CONTACTOR SIDE CONTACTOR
ULPSS12H2W 100-400 AMPS 100-400 AMPS
The ASCO185 100-400 Amp Switches are available in single phase
only.
ENGINE / GENERATOR
The engine generator set consists of a Honda GX690, twin cylinder,
four cycle air cooled engine. The engine is factory equipped to run
on LP or NG 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 eld design. The
generator is connected to the engine’s tapered (quill) crankshaft
extension. The engine generator is mounted in a drip-proof enclosure
for outside installation. Connection boxes and terminal blocks are
provided for all customer connections (both AC output and DC control).
A customer supplied 12 volt 500 CCA (BCI group 26) battery is required
to complete the installation.
NOTICE:
This unit will automatically transfer if a power outage occurs while
running in an exercise mode.
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PREPARING THE UNIT
INSTALLATION
UNPACKING
CAUTION: EQUIPMENT DAMAGE
When you unpack your new generator, be sure to remove all of the
information sheets and manual from the carton.
1. As you receive your unit, it is critical to check it for any damage. If
any damage is noted, it is always easiest to refuse the shipment and
let WINCO take care of the freight claim. If you sign for the unit, the
transfer of the ownership requires that you le the freight claim
2. Before proceeding with the preparations of your new generator
for operation, take a couple of minutes to ensure the unit you have
received is the correct model and review the specication pages in this
manual to ensure that this unit meets your job requirements.
CAUTION:
These units are shipped with oil. Be sure to check oil levels before
operating. See engine manufacturer’s instruction manual for
recommended oil requirements before initial starting.
WARNING:
Before proceeding with installation, be sure the operation selector
switch is in the stop position.
These engine generator sets are designed to be mounted on a pad
outdoors only. The transfer switch is mounted next to your electrical
entrance or distribution panel inside or outside the building. Consult
a qualied, 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 check 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 nalizing your installation plans.
ENGINE-GENERATOR SET MOUNTING
WARNING: PERSONAL INJURY:
The enclosures on these units can become very hot adjacent to the
exhaust areas. Special care must be taken when installing these units
to insure that the risk of contact by people is minimized.
The unit’s main frame should be bolted to a pad that meets local code.
Various materials, including concrete and composites, are acceptable
as long as they are structurally sound supporting the weight of the
unit and preventing movement during operation. The mounting holes
on the base of this unit is 0.563” in diameter. 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
pad. Engine vibration will be transmitted to the control panel causing
erroneous start/stop cycles and premature control failure.
These units should be mounted a minimum of 24” from a structure. This
will allow for ample room to maintain and work on the generator set.
Units must be installed in accordance with all local, state, and national
codes. Consult your local agency for specic requirements.
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 and information provided
be interpreted to conict with any local, state or national codes. If in
doubt, always consult your local re marshal, gas supplier or building
inspector.
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WARNING: FIRE HAZARD:
All fuel runs should be installed by a licensed fuel supplier.
To connect the fuel line to the generator set you will connect your
incoming fuel line to the 3/4 inch NPT tting located on the left side
of the engine-generator set. This tting is shipped with a plastic plug
installed to insure the fuel system stays clean. 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 pressure can cause many problems ranging from a
unit that will not start to causing damage to the fuel system.
These units are normally tested on Natural Gas and will have a
tag hanging on the fuel hose indicating on what fuel your unit was
factory tested. If you are running on LP or have to change fuel types
at any time, see information on page 8 on NG/LP CONVERSION.
INSTALLING THE FUEL LINE
NOTICE: The engine generator sets are properly adjusted before they
leave the factory. A tag is attached to the unit that species the fuel,
natural gas (NG) or propane vapor (LP) that the unit was set up and
tested on.
NATURAL GAS or LP VAPOR PIPE SIZE
Size of pipe normally required for generators operating on natural gas
or LP vapor. Unit location will determine the size of fuel line that is
required to supply the engine with a constant fuel pressure and volume.
LIQUID PROPANE VAPOR (LP)
Refer to the tables on the following pages for fuel line size and
recommended tank size. For distances of 100 feet or 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 low pressure regulator is installed to
further reduce the fuel pressure to the required four (4) to six (6) oz.
operating pressure. This low pressure 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 low pressure regulator, it should also be a 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) regulator system is used on LP, 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 low pressure regulator. Consult your local fuel
supplier for your exact requirements . The appropriate line size from
the following table is then installed from the low pressure regulator to
the generator set.
Feet* Size of pipe
Up to 25 ft ¾” pipe
25 - 100 ft 1” pipe
Over 100 ft Use a two regulator system
*Allow an additional 3 feet for each standard elbow. DO NOT use
‘street ells’ (restrictive).
LP TANK SIZING
Tank Temperature Tank Size
60° F (16° C) 150 Gallons
32° F (0° C) 250 Gallons
0° F (18° C) 500 Gallons
-20° F (-29° C) 1000 Gallons
NATURAL GAS (NG)
The primary regulator (fuel meter) on the building should deliver the
correct volume and pressure to the generator set. This regulator must
be sized to deliver the required BTU’s to the generator set and all other
appliances in the building. If the primary regulator (fuel meter) is a high
pressure regulator, then a low pressure regulator must be installed
to bring the pressure down to 4-6 oz. (7-11 inches water column) of
pressure. This low pressure 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. If this is not done, the demand
regulator on the unit and the pressure regulator in the fuel line will
interfere with each other. This regulator must be sized to accommodate
the demand of the generator set and any other appliance connected to
it. See the following table for the correct size of pipe to be installed.
Feet* Size of pipe
Up to 25 ft ¾” pipe
25 - 100 ft 1” pipe
Over 100 ft Use a two regulator system
*Allow an additional 3 feet for each standard elbow. DO NOT use
‘street ells’ (restrictive).
WARNING: PERSONAL DANGER:
Do not use galvanized pipe in fuel line runs. The galvanized coating
can become eroded and ake off, causing possible obstructions in the
regulator or fuel valve. The results could range from inoperative engine
to hazardous fuel leaks.
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
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 fuel system. Shown below is a diagram of a typical
LP vapor fuel installation. Notice the following tables give two different
units of measuring fuel pressure. The rst and most accurate is the
use of a simple water manometer. A manometer is calibrated in inches
of water column . The second is with a pressure gauge calibrated in
ounces per square inch.
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60706-209
FUEL PRESSURE TABLES
The following tables are the fuel pressure readings at each reference in
the system.
Single low pressure regulator (LP vapor only)
Ref# 1 3 4
Unit off Line PSI 7-11 in
4-6 oz
Starting Line PSI 7-11 in
4-6 oz
No load Line PSI 7-11 in
4-6 oz
Full load Line PSI 7-11 in
4-6 oz
7-11 in
4-6 oz
7-11 in
4-6 oz
7-11 in
4-6 oz
7-11 in
4-6 oz
Reference numbers 1 through 3 in the diagram above are system parts
supplied by the customer. Reference number 4 is on the generator.
The following diagram is of a natural gas (NG) installation.
Two regulator system (LP vapor only)
Ref# 1 2 3 4
Unit off Line PSI 10-15 lbs 7-11 in
4-6 oz
Starting Line PSI 10-15 lbs 7-11 in
4-6 oz
No load Line PSI 10-15 lbs 7-11 in
4-6 oz
Full load Line PSI 10-15 lbs 7-11 in
4-6 oz
Natural gas
Ref# 2 3 4
Unit off 2 PSI 7-11 in
4-6 oz
Starting 2 PSI 7-11 in
4-6 oz
No load 2 PSI 7-11 in
4-6 oz
Full load 2 PSI 7-11 in
4-6 oz
NG/LP FUEL CONVERSION
7-11 in
4-6 oz
7-11 in
4-6 oz
7-11 in
4-6 oz
7-11 in
4-6 oz
7-11 in
4-6 oz
7-11 in
4-6 oz
7-11 in
4-6 oz
7-11 in
4-6 oz
Reference numbers 2 through 4 in the previous diagram are system
parts supplied by the customer. Reference number 4 is on the
generator.
60706-209
These generator sets are factory tested on NG and will require no
modications for normal operation on NG. The carburetion system
has been preset and anti-tamper plugs have been installed in the
carburetor as required by the EPA.
If you are going to operate on LP, you will need to move the fuel line
from the NG port to the LP port on the fuel outlet tee. These two ports
have different orice inserts installed on them, which provide proper
operation with no further adjustments.
NOTE: When moving the fuel
line from one port to the other,
be sure not to kink or bend
the line. Use a large sweeping
curve as possible and never
shorten the fuel line. For proper
operation, the fuel line must
stay the same length as it was shipped.
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