Winco PSS15B4WD User Manual
PACKAGED
STANDBY
SYSTEM
INST ALLATION AND OPERA TORS MANUAL
PSS15B4W/D
SAVE THESE INSTRUCTIONS
This manual contains important instructions that
should be followed during installation and maintenance of the generator and batteries.
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.
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____________________________________
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 GENERATOR INSTALLATION 3
Installation 3
Fuel Installation 4
Vapor Fuel Pressure Tables 5
Fuel Conversions 5
Lubrication 6
Battery Installation 6
Connecting Battery Charger 7
TRANSFER SWITCH INSTALLATION 7
AC Electrical Connections 7
DC Electrical Connections 10
INITIAL START-UP 10
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
SERIAL NUMBER____________________________
PURCHASE DATE____________________________
DEALER___________________________________
DEALER PHONE # ___________________________
PAGE i
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. DEADLY EXHAUST GAS - Exhaust fumes from any
gasoline engine contain carbon monoxide, an invisible,
odorless and deadly gas that must be mixed with fresh
air.
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,
and 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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TESTING POLICY:
Before any generator is shipped from the factory, it is fully
checked for performance. The generator is loaded to its
full capacity, and the voltage, current, and frequency are
carefully checked.
Rated output of generators is based on engineering tests
of typical units, and is subject to, and limited by, the
temperature, altitude, fuel, and other conditions specified
by the manufacturer of the applicable engines.
INTRODUCTION AND
DESCRIPTION
The package standby system includes all items necessary
for a completely automatic standby power system as
standard equipment.
DESCRIPTION
This packaged standby system is designed to automatically provide standby power to unattended loads during
electrical outages. Upon an interruption of normal
electrical service the packaged standby system electrical
control circuits will automatically start the engine. The
generator will produce electrical power and the Automatic
Transfer Switch (A.T.S.) will automatically transfer the
electrical loads to the engine-generator set. Upon
restoration of normal electrical service the emergency
transfer switch will sense return of the normal commercial
power. The Automatic Transfer Switch will retransfer the
load back to the normal commercial power source. The
engine control circuits will begin a cool-down cycle, after
which the fuel supply will be shut off and the engine
ignition system disabled.
These packaged standby systems consist of two major
components:
1) AUTOMATIC TRANSFER SWITCH
A wall mounted 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.
UL Automatic Transfer Switch Sizes
UNIT LINE SIDE GENERATOR
CONTACTOR SIDE CONTACTOR
PSS15B4W 100 AMPS 100 AMPS
200 AMPS 200 AMPS
Both the 100 amp and the 200 amp UL Switches are
available in single phase only.
2) ENGINE/GENERATOR
The engine generator set consists of a Briggs & Stratton,
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 500 CCA (BCI group
26) battery is required to complete the installation. Engine
operation is controlled by the ASCO 165 Transfer Switch
COLD WEATHER OPERATION
Extreme cold weather operation requires special
considerations. Higher CCA batteries are required for
cold weather starting, 650 CCA or larger are recommended. In addition you should consider installing an
oil heater kit and a battery warmer for reliable starting
during cold weather.
** 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
PSS15B4W 15,000 120/240 60.0 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*
PSS15B4W 260 260,000 2.7 2.96 108 272,160
*Based on full load operation
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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 TEMPERATURE
MODEL 60 f(16 c) 32 f(0 c) 0 f(-18 c) -20 f(-29 c)
PSS15B4W 150 Gal. 250 Gal. 500 Gal. 1000 Gal.
ENGINE SPECIFICATIONS:
Refer to engine operating and maintenance instructions.
** 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.
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.
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
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 temperatures greater than 40
degrees C.
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.
“Concealed Damage” is understood to mean damage to
the contents of a package which is not evident at the time
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 installation. 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.
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60706-185
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.
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
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, locate the 3/4 inch NPT fuel inlet
fitting on the side of the enclosure. This inlet is shipped
with a plastic cap plug installed to insure the fuel system
stays clean.
*************
***** WARNING ****
*************
FIRE HAZARD - DO NOT OVERTIGHTEN THE FUEL
LINE. THIS IS A TAPERED FITTING, OVERTIGHTENING
WILL CAUSE THE FITTING TO CRACK AND LEAK
FUEL.
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.
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.
PAGE 460706-185
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