PACKAGED
STANDBY
SYSTEM
INST ALLATION AND OPERA TORS MANUAL
PSS10H/B
PSS12H/A
Automatic Transfer
Switch
Engine Generator Set
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 6
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.
***********************************************************
***********************************************************
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
3063-10
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.
60706-157
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.
UL Automatic T ransfer Switch Sizes
UNIT LINE SIDE GENERA T OR
CONTACTOR SIDE CONTACT OR
PSS10H & 100 AMPS 100 AMPS
PSS12H 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 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 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.
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.
Automatic T ransfer Switch Sizes
(NON-UL)
UNIT LINE SIDE GENERATOR
CONT ACT OR SIDE CONTACTOR
PSS10H 1 10 AMPS 60 AMPS
PSS12H 1 10 AMPS 60 AMPS
** 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
PSS10H 9,600 120/240 40.0 60 1 3600
PSS12H 12,000 120/240 50.0 60 1 3600
*Derate 16% for Natural Gas operation. Derate 3.5%
per 1000 feet elevation above sea level.
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*
PSS10H 160 160,000 7.7 1.80 70.2 180,000
PSS12H 190 190,000 9.0 2.10 76.6 194,000
*Based on full load operation
PAGE 260706-157
3063-10
L.P. TANK SIZING
Required L.P. Tank size for L.P. Vapor withdrawal
operating at various outside temperatures given in
degrees Fahrenheit (Celsius)
chandise 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.
TANK TEMPERA TURE
MODEL 60 f(16 c) 32 f(0 c) 0 f(-18 c) -20 f(-29 c)
PSS10H 150 Gal. 250 Gal. 500 Gal. 1000 Gal.
PSS12H 150 Gal. 250 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.
**** CAUTION ****
These units 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
time of delivery by the carrier, but which is discovered
later. The carrier or carriers are responsible for mer-
3063-10
PAGE 3
60706-157
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.
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 LP
operation.
Connect fuel line from
engine here for NG
operation.
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.
To connect the fuel line to the generator set you will
have to remove the access panel on the right hand side
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 elbow provided inside the enclosure. This
elbow is shipped with a plastic cap plug installed to
insure the fuel system stays clean.
Fuel Inlet 3/4” NPT
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.
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.
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
PAGE 460706-157
3063-10
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.
*************
***** 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 NA TURAL GAS or LP VAPOR
up to 25 feet* 25 - 100 feet* over 100 feet*
PSS10H 3/4” pipe 1” pipe 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)*
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
ST ARTING TANK PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
NO LOAD T ANK 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
T wo (2) Regulator System (L.P . V apor only)
1 2 3 4
UNIT OFF TANK PSI 10-15 lbs 7-11 in 7-11 in
4-6 oz 4-6 oz
ST ARTING TANK PSI 10-15 lbs 7-11 in 7-11 in
4-6 oz 4-6 oz
NO LOAD T ANK 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
**** 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.
TWO (2) REGULA TOR FUEL SYSTEM
Supply Primary Secondary Generator
Tan k Regulator Regulator Set
1 2 3 4
SINGLE REGULAT OR FUEL SYSTEM
Natural Gas
1 3 4
UNIT OFF LINE PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
ST ARTING 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
LP/NG FUEL CONVERSION
The PSS10H/B & PSS12H/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, 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.
Supply Primary Generator
Tan k Regulator Set
1 3 4
3063-10
PAGE 5
60706-157
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 BCI Group CCA Rating
PSS10H U1 235
PSS12H U1 235
*****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.
*****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.
This battery tender requires a circuit breaker protected
AC circuit from your distribution panel be run out to the
engine generator set. 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.
A 120 volt receptacle is mounted in the generator
connection box. The receptacle is prewired with black,
white and green leads attached to it, this is where you
will connect your 120 volt fused power feed.
** 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.
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 wilth 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.
*****NOTE*****
EQUIPMENT DAMAGE- The NON-UL Winco ATS does
not protect against undervoltage. If you are in an area
that is susceptible to brown outs (low voltage) you may
want to consider adding an undervoltage sensor to
standard ATS panel. Contact your dealer or WINCO.
*************
***** 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!
The non UL Automatic Transfer Switch shipped with
these systems has a 110 Amp line side contactor
installed to handle your normal power needs and a 60
Amp generator side contactor to handle the emergency
generator output. Before installing the A.T.S. you must
first ensure that the 110 Amp line side contactor will be
sufficient to handle your complete service. See Figure 3.
(i.e. the main line breaker must not be larger than 110
Amps) If you have a 125, 150 , 200 Amp or larger
system, 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
PAGE 660706-157
3063-10
Figure 4. NOTE: THE MAXIMUM OUTPUT OF THE
GENERAT OR IS 40 AMPS AT 240 VOLTS. Y ou must also
take this into consideration when deciding whether to
install an emergency distribution panel.
FIGURE 3
************
***** DANGER *****
*************
Be certain the operation selector switch on the front of the
A.T.S. Control is in the “stop” position and the main power
switch “off”. For your own protection, verify these important safety precautions yourself with reliable instruments
before proceeding.
A.C. ELECTRICAL CONNECTIONS
*************
***** WARNING *****
*************
A FUSED DISCONNECT OR CIRCUIT BREAKER
MUST BE INSTALLED BETWEEN THE GENERATOR
AND THE A.T.S. PANEL TO PREVENT OVERLOADING
AND BURNING OUT THE GENERATOR. FAILURE TO
PROVIDE A FUSED DISCONNECT OR CIRCUIT
BREAKER, RATED AT GENERATOR RATING WILL VOID
YOUR WARRANTY IN CASE OF GENERATOR FAILURE.
Generator Connections
To gain access to the customer connections first
remove the top cover and then remove the end panel
opposite the muffler. All connections including AC & DC
connections to the ATS, 120 Volt power connection for
battery charger, fuel line connection 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. Three AC power leads are required between the
generator and the A.T.S. a fourth lead will be required if
you are required by code to provide an isolated neutral.
The units are shipped with the neutral bonded to ground.
If you need to run an isolated neutral, you will need to
remove the generator neutral leads from the ground lug
mounting bolt where they are attached. 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.
All power leads from the generator to the A.T.S. must
be sized to handle rated generator output amperage at a
minimum, the type of wire you use will determine the
gauge required. Consult your local wire supplier for
proper gauge and type for your area.
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 two wires you will need are the DC control
leads for the start circuit in the A.T.S. These last two
connections wil be discussed later in more detail.
Service Entrance
Circuit Breaker
FIGURE 4
A.T .S .Connections - for standard Non-UL WINCO ATS
The standby generator terminals in the A.T.S are
marked “GENERATOR - G1, G-N, G3”. The “hot” leads #1
and #4 from the generator are wired to the generator side
contactor, terminals G1 and G3.
The line terminals in the A.T.S. are marked “LINE - L1,
L-N, L3”. The “hot” line leads L1 and L3 are wired to the
line side contactor, terminals L1 and L3.
The load terminals in the A.T.S. are marked “LOAD - T1,
T-N, T3”. The “hot” leads T1 and T3 are wired to the
bottom side of both the line side and the generator side
contactor.
If you are using a separate ground lead it is routed to
the ground lug in the A.T.S.
3063-10
PAGE 7
60706-157
WINCO UL ATS
The only significant difference when making your AC
connections in the ULATS, is the AC terminals are
labeled differently. Instead of labeling the incoming
power line L1 and L3, the ULATS identifies the normal
power connection as N1 and N3. Likewise the generator
connection terminals are labeled E1 and E3 versus G1
and G3 in the standard WINCO Non-UL panels. The
load terminals are labeled T1 and T3, same as in the
Non-UL switches.
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
circuit-breaker (or fuse) in the entrance (or sub-panel)
protecting the contactor switch.
tor, 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.
WINCO NON-UL ATS
Two control wires are required to be installed between
the A.T.S. panel and the generator control terminal box.
Depending on the distance 14 to 16 gauge stranded wire
should be used. These wires will be labeled “Bat -”, and
“Start”.
The control wires will be connected as follows in the
generator control terminal box:
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.
ATS Panel Generator Control Panel
Start 1 to Wire # S1, (Bat Neg)
Start 23 to Wire # S23 (Start)
WINCO UL ATS
Your DC connection points in the UL ATS are marked
differently than the terminal markings in the Non-UL ATS.
Instead of being marked “Start 1” and Start 23” they are
marked start contacts “11” and “12”. The wire labeled
“S1” is routed to start contact “11” and the wire labeled
“S23” is routed to start contact “12”
SETTING THE EXERCISER CLOCK
WINCO Non-UL Only
Setting the current time and date.
1. Position the top right hand (RUN) slide switch to the
left position.
2. Push the clock’s “Day Select Button” until the clock
displays a triangle under the number corresponding to
the current day of the week. (Monday is day 1, Sunday is
day 7)
3. Push the “Hour Select Button” until the display
indicates the correct time in hours. Note: In the afternoon
you should push the button until a “P” is displayed
beside the correct hour.
4. Push the “Minute Select Button” until the display
indicates the correct time in minutes.
5. Position the top right hand (RUN) slide switch to the
center position. The correct time and date should now
be displayed.
All selected emergency circuits are removed from main
distribution panels and reinstalled in the emergency
distribution panel. Suggested circuits: freezer, refrigera-
PAGE 860706-157
3063-10
Setting the Exerciser Program:
1. Position the top right hand (RUN) slide switch to the
right hand position.
2. Position the top left hand (AUTO) slide switch to the
center position.
3. Press the “Program Select Button” until No. 1 is
displayed on the clock to the right of the time.
4. Push the “Day Select Button” to select the day you
want the engine generator set to start up and run. Note:
You can get more than one triangle displayed on the
clock. If this happens just keep pressing the button and it
will work back through the cycle and display only one
triangle under whichever day you desire.
5. With the “Hour” and “Minute” buttons select the time
of day you want the engine to start up.
6. Press the “Program Select Button” until No. 2 is
displayed on the clock.
7. Push the “Day Select Button” to select the day you
want the engine to stop. This must be the same day you
selected in step 4 above.
8. With the “Hour” and “Minute” buttons, select the time
you want the engine to stop. It is recommended you let
the engine run at least 15 minutes during any exercise
period.
9. Position the top right hand (RUN) slide switch to the
center (RUN) position.
CLOCK NOTES:
This seven day exerciser clock has seven additional
program cycles available. Always keep in mind the odd
number turns the unit on and the even number shuts the
unit off. (i.e. (3 on, 4 off) (5 on, 6 off) etc.)
The relay in the clock will not work unless the transfer
switch is installed and powered up. The relay needs 120
volts AC to operate.
If, when you finish programming the clock, you get an
“EEEE” on the display, it stands for error. The most
common error is that the day of operation has not been
properly set at each step or a program has been turned
on and not turned off. (i.e. programs not properly grouped
1& 2, 3 & 4, 5 & 6, etc.)
On the face of clock is a small button marked “R”, this
is a reset switch. Depressing this switch will remove all
programming in the clock including the time, Use a
small screwdriver or the tip of a pencil to depress this
button. This should be used only as a last resort.
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 check list 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. (7-1 1" WC).
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
Move the selector switch on the engine generator to the
“RUN” position. The engine-generator will crank and
start automatically. If the engine fails to start, return
selector switch to the “stop” position and correct the
trouble before proceeding.
With the engine running smoothly, check the no load
voltage and frequency at terminals G1 and G3 on the
generator terminal block in the A.T.S. The voltage
between G1 and G3 should be between 242 to 248 volts.
The frequency should be between 61.5 to 62 hertz (Hz).
The voltage should also be checked between the hot
terminals (G1 and G3) and the G-N to be certain of a
balanced voltage output and a solid neutral connection.
The voltage between G1 and G-N should be about one
half of the line to line (G1 to G3) voltage or approximately
121 to 124 volts AC. The same approximate voltage
should be found between terminals G3 and G-N.
** Notice **
If for any reason during the check out procedure the
voltage and frequency are not correct, turn the selector
switch to the “STOP” position and correct the trouble
before proceeding.
3063-10
PAGE 9
After verifying the voltage and frequency are correct, turn
the selector switch to the “STOP” position. The unit
should shut off with no time delay. You are now ready to
test the automatic start function.
60706-157
Move the selector switch on the engine generator set to
the “AUTOMATIC” position. Next move the selector switch
on the A.T.S. panel to the “START” position. The unit will
go into a 3 to 10 second start delay and then start up. If it
fails to start at this time, check your DC interconnection
wiring. When the selector switch on the A.T.S. is moved to
the “DISABLE” position the unit will go into a cool down
period and then shut off. As long as line power is still
applied to the transfer switch during this test period the
A.T.S. will not transfer the load to the generator.
Next you need to test the complete system. To accomplish this you will have to fail the incoming line power to
the A.T.S. panel. First move both selector switches to the
automatic position. Then fail the incoming power. All the
loads connected to the A.T.S. should now be dead. The
engine generator set will go into a 3 to 10 second start
delay. At the end of the start delay the unit will start up. As
soon as the engine generator set reaches operating
speed the generator side contactor will close and the
load will be applied to the engine generator.
Restoring the line power will cause the generator side
contactor in the A.T.S. to open. The line side contactor will
close as soon as the generator side contactor clears the
mechanical interlock and closes the electrical interlock.
These interlocks ensure that you get a clean ‘break
before make’ action in the transfer switch.
The restoration of line power also sends a stop signal
to the engine generator set. This stop signal will activate
a cool down timer circuit. The engine generator will shut
down 90 seconds later.
This completes your installation and unit testing.
ALWAYS leave the system in automatic mode unless
servicing the unit. For automatic operation, keep both the
generator set and transfer selector switches in the
“AUTOMA TIC” position.
TROUBLESHOOTING TABLES
UNIT WILL NOT CRANK WHEN THE
POWER FAILS.
1. Alarm light on, from previous run cycle.
2. Generator control switch not in “AUTOMATIC”
position.
3. Transfer control switch not in “AUTOMATIC”
position.
4. Low or dead battery, must hold 12 volts during
cranking.
5. Incorrect wiring between transfer switch and
generator.
6. Defective start/stop relay in the transfer switch.
7. Circuit breaker tripped on engine control.
8. 3/4 amp fuse blown on engine control.
9. Defective engine control module.
10. Loose or dirty battery terminals.
11. Defective “Run/Auto” switch.
12. Defective starter.
13. Defective start solenoid.
ENGINE WILL NOT CRANK WITH GENERATOR
SELECTOR SWITCH IN THE RUN POSITION.
1. Low or dead battery, must hold 12 volts during
cranking.
2. DC circuit breaker on control module tripped.
3. 3/4 amp fuse blown on control module.
4. Defective engine controller.
5. Loose or dirty battery terminals.
6. Defective “Run/Auto” switch.
7. Defective starter.
8. Defective start solenoid.
9. Locked up engine generator set.
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.
PAGE 1060706-157
3063-10
ENGINE ST ARTS 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.
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.
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 TO
EMERGENCY SUPPL Y (GENERATOR).
1. No AC generator output from generator.
2. Broken or defective mechanical/electrical interlocks.
3. Defective holding coil in the generator side
contactor.
4. Wiring error between generator set and transfer
switch.
5. Defective start/stop relay in ATS.
ATS PANEL WILL NOT PULL IN ON
NORMAL POWER.
1. Proper normal line power not available at line
terminals in ATS panel.
2. Defective holding coil in line side contactor.
3. Broken or defective mechanical/electrical interlock.
4. Defective start/stop relay in ATS.
*************
***** 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
de-energized 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.
NO AC OUTPUT FROM GENERA TOR.
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.
3063-10
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 once a
week to keep it dry and in good working order.
PAGE 11
60706-157
110/60ATS-3/D
230/150ATS-3/D
NON-UL ATS SCHEMATIC
LEGEND
LTS Line Side Contactor GTS/AUX Generator Side Auxiliary
GTS Generator Side Contactor LTS/AUX Line Side Auxiliary
SSR Start/Stop Relay UV R Under V oltage Relay
E C Exerciser Clock SSS Start/Stop Switch
Indicates Wire Number
PAGE 1260706-157
3063-10
NON-UL ATS PANEL
OUTLINE DIMENSIONS
A TS SIZE REF A REF B REF C REF D REF E
110/60 ATS 17.00” 8.00” 8.10” 20.00” 12.375”
230/150 ATS 22.90” 14.00” 10.63” 28.00” 18.375”
400/320 ATS 28.00” 16.00” 12.68” 36.00” 23.875”
3063-10
GENERATOR LAYOUT
PAGE 13
60706-157
AC AND DC GENERATOR SCHEMATIC
PAGE 1460706-157
3063-10
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.
ULATS100-3 120/240 1 Phase
ULATS100-17 120/240 3 Phase
ULATS100-4 120/208 3 Phase
ULATS200-3 120/240 1 Phase
ULATS200-17 120/240 3 Phase
ULATS200-4 120/208 3 Phase
3063-10
CUSTOMER DC CONNECTION POINT
All control wires (18-12 AWG) must be torqued to 19 in-lbs.
PAGE 15
60706-157
WINCO, Incorporated warrants to the original purchaser for 12 months 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 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 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, 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 A VE
LE CENTER MN 56057
Phone: 507-357-6831
PAGE 1660706-157
3063-10
MAINTENANCE LOG
DATE ITEM
WORK PERFORMED
P/N 60706-157-3063-10
225 SOUTH CORDOV A A VE
LE CENTER MN 56057
Phone: 507-357-6831
www.wincogen.com
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