Page 1
PACKAGED
STANDBY
SYSTEM
INSTALLA TION AND OPERATORS MANUAL
PSS12H4W/D
SAVE THESE INSTRUCTIONS
Page 2
SAVE THESE INSTRUCTIONS
This manual contains important instructions that
should be followed during installation and maintenance of the generator and batteries.
PROPER USE AND
INSTALLATION
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 assistance in the future.
TABLE OF CONTENTS
INTRODUCTION i
GUIDE TO PRODUCT SAFETY 1
BASIC INFORMATION 2
Description 2
Specification Table 2
PREP ARING THE UNIT 3
Unpacking the Unit 3
ENGINE GENERA TOR INSTALLATION 3
Installation 3
Fuel Installation 4
Vapor Fuel Pressure Tables 5
Fuel Conversions 5
Lubrication 5
Battery Installation 6
Connecting Battery Charger 7
TRANSFER SWITCH INSTALLATION 7
AC Electrical Connections 7
DC Electrical Connections 9
INITIAL START-UP 10
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 12
PREVENTIVE MAINTENANCE 13
WIRING DIAGRAMS
AC & DC Generator Schematic 14
UL ATS Wiring Diagram 15
Generator Layout 16
12 MONTH WARRANTY 17
MAINTENANCE LOG 18
Page 3
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 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.
***********************************************************
***********************************************************
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.
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
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. 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.
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60706-183
Page 4
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:
UL Automatic Transfer Switch Sizes
UNIT LINE SIDE GENERATOR
CONTACTOR SIDE CONTACTO R
PSS12H 100 AMPS 100 AMPS
200 AMPS 200 AMPS
Both the 100 amps and the 200 amps UL Switches are
available in single only.
2) ENGINE/GENERATOR
The engine generator set consists of a Honda, twin
cylinder, four cycle air cooled engine. The engine is
factory equipped 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 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.
SPECIFICATIONS
GENERATOR
MODEL WATTS* VOLTS AMPS * HZ PH RPM
PSS12H 12,000 120/24 0 50.0 60 1 3600
*Derate 16% for Natural Gas operation. Derate 3.5%
per 1000 feet elevation above sea level.
1) AUTOMATIC TRANSFER SWITCH
A wall mounted ASCO 165 Automatic Transfer Switch
(A.T.S.) designed for inside installation. The transfer
switch is UL1008 approved. A fourteen day electronic
exerciser circuit is installed in the A.T.S. as standard
equipment. The A.T.S. 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 retransfer 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 is shuts down. Read
and understand the owners manual before installing,
servicing or operating the transfer switch.
PAGE 260706-183
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*
PSS12H 190 190,000 9.0 2.10 76.6 194,000
*Based on full load operation
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)
PSS12H 150 Gal. 250 Gal. 500 Gal. 1000 Gal.
ENGINE SPECIFICATIONS:
Refer to engine operating and maintenance instructions.
8009-30
Page 5
** 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. Units should
not be operated in ambient temperature greater than 110
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.
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.
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 . As an option
a prefab pad maybe used as long as proper attention is
paid to site preparation to insure the unit will not move
after installations. 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 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 ****
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.
8009-30
PAGE 3
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 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 enginegenerator to vibrate without affecting the control panel on
the main frame.
60706-183
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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 five (5) feet
clearance on all sides. See NFPA Code 37 for additional
clearance requirements.
FUEL INSTALLATION
When moving the fuel line from one port to the other be
sure not to kink or bend the line. Use as large a 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.
Connect fuel line from
engine here for LP
operation.
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.
To connect the fuel line to the generator set you will have
to remove the access panel on the air intake end of the
enclosure. With this panel remove you will be able to
access the complete fuel system on the unit. You will
need to do two things with this panel removed.
First you will connect your incoming fuel line to the 3/4
inch NPT fitting provided inside the enclosure. This is
shipped with a plastic cap 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 fuel pressure can cause
many problems ranging from a unit that will not start to
causing damage to the fuel system.
The second thing you need to do is ensure that your unit
is connected for the correct fuel. These units come
capably of working on either LP or NG fuel. It just
depends on where the fuel line from the engine is
connected to the demand regulator.
Connect fuel line from
engine here for NG
operation.
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
specifies the fuel, natural gas (NG) or propane vapor (LP)
that the unit was set up and tested on.
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 secondary regulator
to the generator set.
These units are normally tested on Natural gas and will
have the fuel line connected to the N.G. port on the fuel
outlet tee. If you are going to operate on LPG you will
need to move the fuel line from the NG port to the LPG
port on the fuel outlet tee. These two ports have different
orifice inserts installed in them, which provide proper
engine operation with no further adjustments.
PAGE 460706-183
*************
***** 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.
8009-30
Page 7
NATURAL GAS or LP VAPOR
Size of pipe normally required for generators operating on
NATURAL GAS or LP VAPOR
up to 25 feet* 25 - 100 feet* over 100 feet*
use a two
PSS12H 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
fuel system. Shown below is a block diagram of a
typical L.P. or N.G. vapor fuel installation.
Notice the following tables give two (2) different units of
measuring fuel pressure. The first 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.
Reference numbers 1 through 3 in the block diagrams
above are system parts supplied by customer.
Reference number 4 is the engine generator set.
Below is a table of the fuel pressure reading at each
reference in the system.
Fuel Pressure Table
Single Regulator (L.P. Vapor only)
1 3 4
UNIT OFF TANK PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
STARTING TANK PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
NO LOAD TANK PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
FULL LOAD TANK PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
Two (2) Regulator System (L.P. Vapor only)
1 2 3 4
UNIT OFF TANK PSI 10-15 lbs 7-11 in 7-11 in
4-6 oz 4-6 oz
STARTING TANK PSI 10-15 lbs 7-11 in 7-11 in
4-6 oz 4-6 oz
NO LOAD TANK PSI 10-15 lbs 7-11 in 7-11 in
4-6 oz 4-6 oz
FULL LOAD TANK PSI 10-15 lbs 7-11 in 7-11 in
4-6 oz 4-6 oz
Natural Gas
1 3 4
UNIT OFF LINE PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
STARTING LINE PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
NO LOAD LINE PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
FULL LOAD LINE PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
8009-30
PAGE 5
LP/NG FUEL CONVERSION
The PSS12H2W/A generator systems have been
tested on NATURAL GAS prior to shipment. If you are
going to use them on LP vapor, follow the procedures
outline in fuel installation.
LUBRICATION
Before starting the engine, check and fill the crankcase
with the proper weight/grade of oil, as recommended by
the engine manufacturer’s maintenance instructions. The
necessity of using the correct oil, and keeping the
crankcase full cannot be over emphasized. Do Not
Overfill the Engine Use the Dipstick.
60706-183
Page 8
INSTALLING THE BATTERY
**** CAUTION ****
In the following battery installation procedure, check to be
sure the selector switch remains in the “stop” position.
This should be your last step before initial start-up.
A customer supplied twelve-volt battery is required to
complete the installation. Installation of the highest CCA
rated battery, within the correct BCI group, will increase
cold weather starting performance. Gel batteries should
not be used with the battery tender installed in the
generator enclosure.
MINIMUM
Model Voltage BCI Group CCA Rating
PSS12H 12 26 500
Installation and servicing of batteries must be performed
or supervised only by personnel knowledgeable of
batteries and the required precautions. Keep unauthorized personnel away from batteries.
* Always wear full eye protection and protective
clothing.
* Where electrolyte contacts the skin, wash off immediately with water.
* If electrolyte contacts the eyes, flush thoroughly and
immediately with water and seek immediate medical
attention.
* Spilled electrolyte is to be washed down with an acid
neutralizing agent. A common practice is to use a
solution of one pound of bicarbonate of soda (baking
soda) to one gallon of water. The bicarbonate of soda
solution is to be added until the evidence of reaction,
foaming, has ceased. The resulting liquid is to be
flushed with water and the area dried.
DANGER – Explosive Fire Risk
* Never smoke when near batteries
* Do not cause a flame or spark in the battery area
* Always discharge static electricity from your body
before touching batteries by first touching a grounded
metal surface.
When installing or replacing batteries, use the proper
group/size starting battery. The battery should be a
Maintenance Free lead acid design. Deep cycle batteries
will
not work for this application.
CAUTION – PERSONAL DANGER
CAUTION - NEVER dispose of a battery in a fire. The
battery is capable of exploding.
CAUTION - DO NOT open or mutilate the battery.
Released electrolyte is known to be harmful to the skin
and eyes and to be very toxic.
These engine generator sets are all NEGATIVE ground.
Be very careful not to connect the battery in reverse
polarity, as this may short circuit the battery charging
system on the engine.
CAUTION – A battery presents a risk of electrical shock
and high short circuit current. The following precautions
must be observed when working with batteries.
1. Remove watches, rings and other metal objects.
2. Use tools with insulated handles.
3. Check both the battery cable ends and the battery
posts to be sure they are free of corrosion.
3. Always connect the battery positive cable first and
then connect the battery negative cable. When removing
the battery cables from the battery reverse the procedure,
disconnect the negative cable first and then the positive
cable.
4. Be sure all connections are tight and coat the
terminals and cable end with dialectic grease.
WARNING – The electrolyte is a diluted sulfuric acid that
is harmful to the skin and eyes. It is electrically conductive and corrosive. The following precautions must
always be taken.
SERVICING BATTERIES
Batteries used on these units may over time lose water.
This is especially true if you are using a trickle charger to
maintain your battery. When refilling the battery with
water use only distilled water. Tap water will shorten the
service life of the battery.
Never fill the battery above the fill line. Over filling above
the upper level line may cause the electrolyte to overflow,
resulting in corrosion to the engine or nearby parts.
Immediately wash off any spilled electrolyte following the
procedure above..
BATTERY CHARGING
Units equipped with electric start have a small flywheel
charger built into the engine flywheel assembly for
recharging the starting battery. This flywheel charger
generates a small AC current that passes through a
rectifier/regulator assembly on the engine to produce a
DC charging current. This circuit is not designed to be
used as a battery charging circuit to recharge dead
batteries.
*****CAUTION*****
EQUIPMENT DAMAGE - Always connect the positive
cable first and the negative cable last, when disconnecting, it is negative cable first and positive last. Failure to
connect and disconnect in the proper sequence can
cause equipment damage.
Observe polarities: connect the positive (+) battery
terminal to the (+) cable from the control panel; the
negative (-) battery terminal is connected to the negative
cable (ground) from the engine generator assembly.
All connections must be clean and tight. Check the
electrolyte (fluid) in the battery periodically to be sure it is
above the plates. Never allow the battery to remain in a
discharged condition.
PAGE 660706-183
8009-30
Page 9
*****CAUTION*****
EQUIPMENT DAMAGE -
units. Doing so will destroy the engine control module
rendering the unit non-operational. Remove and fully
recharge the battery before attempting to start.
NEVER JUMP START these
CONNECTING THE BATTERY CHARGER
A two-stage battery tender is provided on all PSS series
generators. This battery tender charges at a rate of 750
mA until the battery is fully charged and then automatically switches to a 13.2 VDC float charger. The charger
has an indicator light on it, red indicates it is charging,
and green indicates it is in the storage mode (float
charge). This charger is mounted on the engine generator set in the same location as the other AC and DC
connections.
The battery tender receptacle is to be powered by a GFCI
circuit and installed in accordance wth the United Startes
National Electric Code. These AC wires can be run in the
same conduit as the other AC leads from the generator. It
is suggested that this circuit be fused for 15 amps.
Terminal block connections have been provide in the
customer connection area of the engine generator set.
See Page 8 for diagram.
** NOTICE **
The battery tender is not intended to recharge a battery
which has become completely discharged. It is designed to produce enough current to recharge a slightly
low battery, maintaining it fully charged.
Before installing the A.T.S. you must first ensure that the
transfer switch is large enough to handle your complete
distribution panel. See Figure 3. i.e. If you are installing a
100 amp transfer switch the main line breaker must not
be larger than 100 Amps. If you have a 125, 150 , 200
Amp or larger system and want to use a 100 amp
transfer switch, you will not be able to transfer the
complete electrical system. In this case it will be
necessary to install a secondary emergency distribution
panel. See Figure 4. NOTE: THE MAXIMUM OUTPUT OF
THE GENERA TOR IS 50 AMPS A T 240 VOLTS. You must
also take this into consideration when deciding whether
to install an emergency distribution panel.
A.C. ELECTRICAL
CONNECTIONS
NOTICE - CLASS 1 WIRING METHODS ARE TO BE USED
FOR ALL FIELD WIRING CONNECTIONS TO TERMINALS OF A CLASS 2 CIRCUIT
*************
***** WARNING *****
*************
A main line circuit breaker has been provided inside the
generator housing. During all wiring installation make
sure the breaker is in the off position and the generator
operation switch is in the off position.
Note: This symbol always indicates ground
where used.
MOUNTING THE AUTOMATIC
TRANSFER SWITCH (A.T.S.)
*************
***** WARNING *****
*************
EQUIPMENT DAMAGE- Protect the switch from construction grit and metal chips to prevent a malfunction or
shortened life of the switch. Contactors returned for
warranty consideration with foreign material inside of them
will not be warranted.
The Automatic Transfer Switch connects the load (lights,
furnace, outlets, etc.) to the normal power line during
standby. When normal power fails, the A.T.S. starts the
engine generator set, disconnects the power line and
then connects the load to the standby generator set.
When normal power is restored, the automatic switch
retransfers the electrical load to the normal service and
stops the engine. The A.T.S. panel should be mounted
as close to the distribution panel as possible.
*************
***** WARNING *****
*************
All wiring must be done by a licensed electrician, and
must conform to the national electrical code and comply
with all state and local codes and regulations. Check with
your electrical inspectors before proceeding!
Generator Connections
Minimum Conductor Sizes between the Generator and the
ATS. Based on wire type and temperature rating. Wire
has been derated for 40
CU Conductor AL Conductor
C/B Wire Temperature Rating
kW Amp 75
12 50 #6 AWG #8 AWG #4 AWG #6 AWG
To gain access to the customer connections remove the
end panel opposite the hot air discharge end. All
connections including AC & DC connections to the ATS,
120 Volt power connection for battery charger, and battery
installation are made behind this panel. After removing
the end panel you will need to remove the cover over the
connection box in the upper right hand corner. Knockouts
are provided on the outside of the enclosure for your
convenience. See page 13 for unit layout.
Four AC power leads are required between the generator
and the A.T.S.; Two hot leads a neutral and a ground
lead. You will then need to run both a neutral and a
ground lead in addition to the two power leads all the way
back to your distribution panel. The two power leads
from the generator are marked G1 and G3.
0
o
C ambient temperatures.
C90
0
C75
0
C90
0
C
8009-30
PAGE 7
60706-183
Page 10
CUSTOMER AC AND DC
CONNECTION POINTS
TORQUE SPECIFICATIONS
FOR CONNECTIONS
PAGE 860706-183
8009-30
Page 11
In addition to the power leads you will also need to run a
three wire 120 volt, 15 amp circuit from your distribution
panel to the generator. This circuit will be used to power
the battery charger.
The last four wires you will need are the DC control leads
(14 or 16 gauge) for the start circuit in the A.T.S. These
last two connections will be discussed later in more detail.
WINCO UL ATS (ASCO165)
See the ASCO installation manual for additional details
on proper wiring of the Automatic Transfer Switch.
The standby generator terminals in the A.T.S are marked
“ALTERNATE L2 & L6”. The “hot” leads G1 and G3 from
the generator are connected to the terminals L2 & L6.
The normal line power terminals in the A.T.S. are marked
“PREFERRED - L1 & L5”. The “hot” line power leads are
L1 and L3 from your normal power supply are connected
to terminals L1 and L5.
The load terminals in the A.T.S. are marked “LOAD - L3 &
L7”. The leads to the load distribution panel are connect
to terminals L3 & L7.
The neutral leads from all three locations are connected
to the isolated terminal lugs on the sidewall of the
cabinet. This terminal block is labeled “NEUTRAL” and
the terminal lugs are mounted on red isolation standoffs.
The ground leads from all locations are connected to the
grounded terminal lugs, also on the side wall. This set
of terminals is labeled “GROUND”.
INSTALLATION NOTES
The load current carrying wires (L) and (T) must be sized
to handle the maximum load current without excessive
voltage drop. By code, the wire must be heavy enough to
handle the full current rating of the main line circuitbreaker (or fuse) in the entrance (or sub-panel) protecting the contactor switch.
All wires should be installed in rigid or flexible conduit.
(Knockouts are provided in the control box)
Because of the many different types of service, feeder,
and distribution equipment, no specific wiring instructions can be provided. It is, however, recommended that
only copper wire be used. In all cases it is essential that
while the load is connected to the generator, there can be
absolutely no feedback from the generator to the power
line or the power line to the generator. When properly
installed, the normal A.T.S. control and safety systems
will eliminate all paths for feedback. Check with your
local electrical inspector on applicable local, state and
federal codes.
*************
***** WARNING *****
*************
A service disconnect must be installed in front of the
A.T.S. panel as the A.T.S is not service entrance rated.
This will allow you to test the generator under load.
Should you ever have to work on the switch, you will be
able to disconnect the power and work on the switch cold
without having the power company pull your meter.
To wire the automatic transfer switch into the existing
wiring, first determine which circuits will be on the
emergency load circuit. If the entire load is to be transferred, the transfer switch can be wired in directly after the
watt-hour meter and the service entrance, providing the
service entrance ampere rating is within the transfer
switch’s rated capability.
If only specific circuits are to be powered under emergency power failure conditions, an additional distribution
panel designated “emergency distribution panel” must
be installed.
All selected emergency circuits are removed from main
distribution panels and reinstalled in the emergency
distribution panel. Suggested circuits: freezer, refrigerator, furnace, emergency lights, sump pump, emergency
outlet circuits, etc. Total running load must not exceed
generator rating.
D.C. ELECTRICAL
INTERCONNECTION
*******CAUTION******
Never run the AC and DC wiring in the same conduit.
ASCO 165 UL SWITCH
Your DC connection points in the ASCO 165 UL ATS are
on the terminal block in the upper right hand corner of the
ATS panel. The terminal block (TB7) is numbered 1
through 9. These terminals will accept #22 - #14 stranded
wire. It is recommended that you use #16 for distances
up to 200 feet.
You need to run four (4) wires from the engine generator
set to the transfer switch, see table below.
Wire # Purpose Recommended Color
#5 Battery positive Black
#1 Battery Negative White
#24 Fuel Solenoid Red
#22 Start Orange
You can use any color you want, these color codes are
just a recommendation. The wires terminate on TB7 as
follows:
Wire # Color TB7 Terminal
#5 Black #3
#1 White #2
#24 Red #4
#22 Orange #7
Jumpers will need to be installed as follows:
Wire # Color TB7 Terminals
#5 Black #3 & #5
#5 Black #5 & #8
8009-30
PAGE 9
60706-183
Page 12
The following is an optional way to interconnect the
Generator and the Transfer Switch. The wires terminate
on TB7 as follows:
Wire # Color TB7 Terminal
#1 White #2
#24 Red #4
#22 Orange #7
The following leads are wire nutted together:
Wire # Color From
#5 Black Generator
#5 Black TB7 #3
#5 Black TB7 #5
#5 Black TB7 #8
F Battery connections clean and tight.
F Battery fully charged.
F All A.C. and D.C. wiring installed and properly
protected.
* Refer to engine owners manual for proper
levels and type.
After completing the above checklist, the engine generator
set is ready for the initial start-up test.
PROCEDURE
Engine Generator Set only
Move the right hand toggle switch from stop to the normal
position. The alarm light should go out. Next move the left
hand toggle switch from the auto to the run position. You
should hear the fuel solenoid engage at this time. Next lift
the toggle switch to the start position and hold. The
starter should engage and the engine will start. As soon
as the engine starts release the toggle switch and it will
return to the run position. If the engine does not start after
15 seconds release the switch and let the starter rest for
15 seconds and reattempt to start. If the unit still will not
start, consult the troubleshooting guide in the back of this
manual.
With the engine running smoothly, check the no load
voltage and frequency at wire #1 and #4 (L2 and L6 in the
ASCO ATS) on the generator terminal block in the A.T.S.
The voltage should be 240 volts plus or minus nominal.
The frequency should be between 61.5 to 62 hertz (Hz).
The voltage should also be checked between the hot
terminals (L2 and L6) and the neutral to be certain of a
balanced voltage output and a solid neutral connection.
The voltage should be about one half of the line to line
voltage.
INITIAL START UP
*************
***** WARNING *****
*************
DO NOT jump start these engine generator sets. Starting
these units on a low battery or jump starting them will
cause damage to the engine control module.
Use the following checklist to verify correct installa-
tion before starting the engine:
F Engine oil.* Check level & fill as required with
proper grade/qty.
F Unit mounting base properly bolted down.
F Clearance for service and maintenance on all
sides.
F Proper fuel line material and size.
F All fuel line connections tight.
F Fuel line protected and a moisture trap installed
(may be required for N.G.).
F LP/NG pressure O.K. 4-6 Oz. (7-11" WC).
** Notice **
If for any reason during the check out procedure the
voltage and frequency are not correct, move the toggle
switch to the “STOP” position and correct the trouble
before proceeding.
After verifying the voltage and frequency are correct,
move the left hand toggle switch to the auto position. The
unit should shut off with no time delay. The left hand
toggle switch must be left in the AUTO position for
proper operation of the generator. If you leave it in the
run position the fuel solenoid will remain open and it will
not shutdown properly after the next exercise period.
Transfer Switch & Engine Generator
This procedure checks the electrical operation of the
automatic transfer switch. If the actual operation does not
follow this procedure, consult the troubleshooting section
in the transfer switch manual.
1. Move the right hand toggle switch from the stop
position to the normal position. The alarm light should
go out. The unit is now ready to be operated from the
Automatic Transfer Switch.
PAGE 1060706-183
8009-30
Page 13
*************
***** WARNING *****
*************
PERSONAL INJURY HAZARD - Install front cover in
transfer switch before operation. An electrical system
fault could cause a flash and severe personal injury
2. Turn on the preferred source (utility) circuit breaker.
The utility source acceptable light should now come on
as well as the transfer switch on utility light. If these
lights fail to come on recheck your incoming power to
insure you have 240 volts nominal. If not, troubleshoot
your utility source before continuing.
3. Turn on the alternate source (generator) circuit
breaker.
7. After the load retransfers to the utility the generator
will continue to run for about 1 minute (without a load)
and then shut down. The Generator acceptable light
will go off indicating the generator set has shut down.
This completes the functional test of the transfer switch
and the generator set. If you want to leave the generator
in the Automatic Start mode you can leave the right hand
toggle switch on the generator in the normal position. If
you have additional work to do or don’t want to leave the
engine generator set in the automatic start mode move
the toggle switch to the stop position. In the stop position
the alarm light will come on and the engine generator set
will not start or run.
GENERATOR EXERCISER CIRCUIT
The automatic generator exerciser is configured to
automatically exercise to generator for 20 minutes once
every fourteen days .
In order to set and test the exercise circuit the right
hand toggle switch on the generator control panel
must be in the normal position.
SETTING THE EXERCISER CIRCUIT
Press and release the Automatic Generator Exerciser
button. After about 8 seconds the exerciser light flashes
14 times to indicate that the exerciser circuit has been set.
The number of flashes indicates the number of days until
the next exercise period. This 20 minute period will occur
at approximately the same time of the day the button was
pressed.
4. Press and hold the Push to Test button until the
generator (alternate source) acceptable light comes on
and stays on. Then release the button. This will start
up your generator set.
This light indicates that the generator is running and
the output voltage and frequency are within acceptable
limits. Under normal conditions this light should come
on in 5 to 10 seconds. If the light does not come on
and stay on a malfunction has occurred. Either the
unit didn’t start or the voltage or frequency is incorrect.
Correct the problem before continuing.
5. About 15 seconds after the generator (alternate
source) acceptable light comes on , the automatic
transfer switch should transfer the load from the utility
to the generator. At that time the Transfer Switch on
generator light should come on.
6. The generator will stay connected to the load for
about 5 minutes at which time the transfer switch will
transfer the load back to the utility. At the time it
transfers back to utility the Transfer Switch on Utility
light should come on and the Transfer Switch on
generator light should go out. To bypass this five
minute time delay you can press and release the Push
to Test button again at any time.
DISABLING THE EXERCISER CIRCUIT
Press and hold the Automatic Generator Exerciser
button until the light above the button goes off, the light
flashes and then goes off.
ENABLING THE EXERCISER CIRCUIT
Press and hold the Automatic Generator Exerciser
button until the light goes off, the light flashes then goes
off. After about 8 seconds the exerciser light flashes
fourteen times to indicate that the exerciser circuit has
been re-enabled.
*************
***** WARNING *****
*************
WITH A TOTAL POWER FAILURE (UTILITY POWER
FAILS AND THE GENERATOR FAILS TO ST ART AND
RUN) THE EXERCISER MUST BE RESET AFTER THE
POWER IS RESTORED.
This completes your installation and unit testing.
ALWAYS leave the system in automatic mode unless
servicing the unit. For automatic operation, the right hand
toggle switch on the generator control panel must be left
in the “NORMAL” position.
8009-30
PAGE 11
60706-183
Page 14
TROUBLESHOOTING
TABLES
*************
***** WARNING *****
*************
NEVER JUMP START THESE UNITS.
JUMP STARTING THESE UNITS WITH
LOW OR BAD BATTERIES WILL CAUSE
PERMANENT DAMAGE TO THE ENGINE
CONTROL MODULE.
UNIT WILL NOT CRANK WHEN THE
POWER FAILS.
1. Left generator control switch not in “AUTO”
position.
2. Low or dead battery, must hold 12 volts during
cranking.
3. Incorrect wiring between transfer switch and
generator.
4. Circuit breaker tripped on engine control.
5. Loose or dirty battery terminals.
6. Defective “ON/DISABLE” switch.
7. Defective starter.
8. Defective start solenoid.
9. Defective start/stop control in the transfer switch.
10. ATS panel in fault from previous run cycle.
11. Blown 3/4 amp fuse on generator control panel.
ENGINE WILL NOT CRANK USING AUTO/RUN
START SWITCH IN GENERATOR.
ENGINE CRANKS BUT WILL NOT START.
1. Improper fuel pressure being delivered to unit.
2. Fuel supply shut off.
3. Fuel tank empty.
4. Defective spark plug.
5. Defective engine ignition module.
6. Dirty air cleaner filter.
7. Defective fuel solenoid valve.
8. Low voltage from battery to fuel solenoid, must
hold 12 volts during cranking.
9. Oil in the bottom of air cleaner from crankcase
breather.
ENGINE STARTS AND THEN STOPS AND
FAULT LIGHT COMES ON.
1. Engine is low on oil.
2. No AC output from generator to engage stop
crank circuit.
ENGINE WILL NOT COME UP TO SPEED
AFTER IT ST ARTS.
1. Insufficient fuel volume getting to the unit.
a. Fuel line too small.
b. Low fuel pressure.
2. AC short circuit.
3. Wiring to the A.T.S. panel crossed or shorted.
4. Unit is overloaded, check load amperage.
ATS P ANEL WILL NOT TRANSFER T O
EMERGENCY SUPPL Y (GENERATOR).
1. No AC generator output from generator.
2. See Automatic Transfer Switch Manual
ATS PANEL WILL NOT PULL IN ON
NORMAL POWER.
See Automatic Transfer Switch Manual
1. Low or dead battery, must hold 12 volts during
cranking.
2. DC circuit breaker on control module tripped.
3. Blown 3/4 amp fuse on generator control panel.
4. Loose or dirty battery terminals.
5. Defective “AUTO/RUN/START” switch.
6. Defective starter.
7. Defective start solenoid.
8. Locked up engine generator set.
PAGE 1260706-183
NO AC OUTPUT FROM GENERATOR.
1. Diodes on rotor blown.
2. Defective capacitor(s).
3. Defective rotor.
4. Defective stator.
5. AC short in the output leads.
6. Unit has lost its residual voltage.
7. Rotor loose on engine crankshaft.
8. Low engine speed, must be 3600 RPM.
9. AC short on output leads.
8009-30
Page 15
PREVENTIVE
MAINTENANCE
Reasonable care in preventive maintenance will insure
high reliability and a long life for the engine generator set
and the Automatic Transfer Switch.
*************
***** WARNING ****
*************
When performing any type of maintenance on this
equipment make sure the selector switch on the engine
generator is in the off position. If you are working in the
Automatic Transfer Switch, confirm with a reliable meter
that all power has been disconnected.
AUTOMA TIC TRANSFER SWITCH
Clean and inspect the switch once a year. De-energize all
power sources, both line and engine generator set, then
brush and vacuum away any excessive dust and dirty
accumulation. You can at this time with the contactor deenergized remove the contactor covers and check the
contacts. Make sure the contacts are clean and not
burned or pitted.
ENGINE GENERA TOR SET
Service the engine in accordance with the engine manufacturers manual provided with your new equipment.
Routinely remove debris and dirt from around and inside
generator enclosure. Insure that the air intakes are free
from leaves and other debris at all times.
Clean and inspect battery terminals at least twice a year.
Check the battery water level at least twice a year also.
Other than keeping the generator clean and free of debris
there is no other routine or preventive maintenance
required, as long as the generator is run biweekly to keep
it dry and in good working order.
8009-30
PAGE 13
60706-183
Page 16
AC AND DC GENERATOR SCHEMA TIC
PAGE 1460706-183
8009-30
Page 17
WINCO UL ATS
Complete installation instructions for WINCO UL Automatic Transfer Switches are contained in
the operator manual with each switch. Read the complete instructions before installing.
8009-30
CUSTOMER DC CONNECTION POINT
All control wires (18-12 AWG) must be torqued to 19 in-lbs.
PAGE 15
60706-183
Page 18
GENERATOR LAYOUT
PSS12H4W
PAGE 1660706-183
8009-30
Page 19
12 MONTH LIMITED WARRANTY
WINCO, Incorporated warrants to the original purchaser for 12 months or 1000 hours
which ever occurs first, that goods manufactured or supplied by it will be free from defects in workmanship and material, provided such goods are installed, operated and
maintained in accordance with WINCO written instructions.
WINCO’s sole liability, and Purchaser’s sole remedy for a failure under this warranty,
shall be limited to the repair of the product. At WINCO’s option, material found to be
defective in material or workmanship under normal use and service will be repaired or
replaced. For warranty service, return the product within 12 months or 1000 hours which
ever occurs first from the date of purchase, transportation charges prepaid, to your
nearest WINCO Authorized Service Center or to WINCO, Inc. at Le Center Minnesota.
THERE IS NO OTHER EXPRESS WARRANTY.
To the extent permitted by law, any and all warranties, including those of merchantability
and fitness for a particular purpose, are limited to 12 months or 1000 hours which ever
accurs first, from date of purchase. In no event is WINCO liable for incidental or consequential damages.
Note: Some states do not allow limitation on the duration of implied warranty and some
states do not allow the exclusion or limitation of incidental or consequential damages, so
the above limitations may not apply in every instance. This warranty gives you specific
legal rights which may vary from state to state.
WINCO reserves the right to change or improve its products without incurring any obligations to make such changes or improvement on products purchased previously.
EXCLUSIONS:
WINCO does not warrant Engines. Engines are covered exclusively by the warranties of their
respective manufacturers, see enclosed warranties.
WINCO does not warrant Batteries, or Other Component Parts that are warranted by their respective manufacturers.
WINCO does not warrant modifications or alterations which were not made by WINCO, Inc.
WINCO does not warrant products which have been subjected to misuse and/or negligence or have been involved in an accident.
225 SOUTH CORDOVA AVE
LE CENTER MN 56057
Phone: 507-357-6831
8009-30
PAGE 17
60706-183
Page 20
MAINTENANCE LOG
DATE ITEM
WORK PERFORMED
P/N 60706-183-8009-30
225 SOUTH CORDOVA A VE
LE CENTER MN 56057
Phone: 507-357-6831
www.wincogen.com
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