Page 1
PACKAGED
STANDBY
SYSTEM
INSTALLATION AND OPERATORS MANUAL
PSS8000
PSS12000
PSS20000
Model PSS8000
Automatic Transfer
Switch
Page 2
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 3
PREPARING THE UNIT 3
Unpacking the Unit 3
ENGINE GENERATOR INSTALLATION 4
Installation 4
Fuel Installation 4
Vapor Fuel Pressure Tables 5
Liquid Withdrawal 6
Fuel Adjustments 6
Fuel Conversions 6
Lubrication 7
Battery Installation 7
TRANSFER SWITCH INSTALLATION 8
AC Electrical Connections 9
DC Electrical Connections 11
Exerciser Clock Set Up 11
INITIAL START-UP 12
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 13
WIRING DIAGRAMS
ATS PANELS 16
PSS8000 AC & DC Schematic 17
PSS12000 AC Schematic 18
PSS12000 DC Schematic 19
PSS20000 AC Schematic 20
PSS20000 DC Schematic 21
ATS Dimensions 22
PSS8000 Layout 22
PSS12000 Layout 23
PSS20000 Layout 23
MAINTENANCE LOG 24
12 MONTH WARRANTY 25
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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.
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.
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.
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:
2) ENGINE/GENERATOR
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 automati-
cally provide standby power to unattended loads
during electrical outages. Upon an interruption of
normal electrical service the packaged standby
systems 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 normal commercial power source. The engine
control circuits will begin a cool-down cycle, after
which the fuel supply will be shut off and the engine
ignition system disabled.
These packaged standby systems consist of two major
components:
1) AUTOMATIC TRANSFER SWITCH
A wall mounted Automatic Transfer Switch (A.T.S.)
designed for inside installation. The A.T.S. consists of
a line side contactor and a generator side contactor.
The contactors are both electrically and mechanically
interlocked. An automatic taper battery trickle charger
(40 MA max.) and a seven day electronic exerciser
clock are installed in the A.T.S. as standard equipment. The A.T.S. also contains the power failure
sensing circuitry necessary to send a start/stop signal
to the engine generator set.
Standard Automatic Transfer Switch Sizes
UNIT LINE SIDE GENERATOR
CONTACTOR SIDE CONTACTOR
PSS8000 100 AMPS 50 AMPS
PSS12000 100 AMPS 100 AMPS
PSS20000 225 AMPS 100 AMPS
Optional A.T.S. sizes are available to meet specific needs.
If you need a switch of a different size contact WINCO,
Inc.
PSS8000 - The engine generator set consists of a Briggs
& Stratton Vanguard, two cylinder, air cooled engine
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 8000 watt (8kW) 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.
PSS12000 - The engine generator set consists of a Onan
Performer, two cylinder, air cooled engine 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 12000 watt
(12kW) generator is a single bearing, direct drive,
rotating armature design with external voltage regulation. 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 450 CCA (BCI group 26/
70) 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.
PSS20000 - The engine generator set consists of a Ford
Industrial, four cylinder, water cooled engine equipped
to run on L.P. or N.G. fuel. The engine operates at
3600 rpm and frequency regulation is maintained at
60Hz, by an electronic governor mounted on the
engine. The 20,000 watt (20kW) generator is a single
bearing, direct drive, rotating armature design. The
generator is connected to the engine flywheel via a
flexible drive disk. The engine generator is mounted in
a water tight enclosure for outside installation. Connection boxes are provided for all customer connections (both AC output and DC control). A customer
supplied 500 CCA (BCI group 24) 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, 3 minute cool down delay and cycle
cranking consisting of five, 12 second on/12 second off
cycles.
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** 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
PSS8000 8,000 120/240 33.3 60 1 3600
PSS12000 12,000 120/240 50.0 60 1 3600
PSS20000 20,000 120/240 83.0 60 1 3600
PSS20000-4 20,000 120/208 55.6 60 3 3600
PSS20000-17 20,000 120/240 48.1 60 3 3600
*Derate 10% for Natural Gas operation. Derate 3.5%
per 1000 feet elevation above sea level.
FUEL CONSUMPTION
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.
NG L.P. VAPOR
1000 BTU/CU FT 2520 BTU/CUFT
MODEL CF/HR BTU/HR #/HR* GAL/HR CF/HR BTU/HR*
PSS8000 200 200,000 11.4 2.7 97.6 246,000
PSS12000 245 245,000 13.9 3.3 119 301,000
PSS20000 325 325,000 16.8 4.0 142 366,000
*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 TEMPERATURE
MODEL 60 f(16 c) 32 f(0 c) 0 f(-18 c) -20 f(-29 c)
PSS8000 150 Gal. 150 Gal. 250 Gal. 500 Gal.
PSS12000 150 Gal. 250 Gal. 500 Gal. 1000 Gal.
PSS20000* 250 Gal. 500 Gal. 500 Gal. 1000 Gal.
* Fuel tank sizes for PSS20000 on liquid withdrawal are
considerably smaller consult your local fuel supplier.
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.
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 in 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.
**** CAUTION ****
The PSS8000 and PSS12000 are shipped without oil.
The PSS20000 is shipped with oil, and a 50/50 mix of
coolant. Be sure to check all fluid 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.
** CAUTION **
Be sure to check the engine oil level frequently, as
specified in the engine manual.
The engine manufacturer has established an excellent
world-wide 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.
a. Owner’s manual, wiring diagram and parts list.
b. Engine manufacturer’s instruction manual.
c. USDA approved spark arrestor (PSS8000 only)
3. Remove main frame hold down bolts, (4).
4. Unit can now be lifted from shipping pallet.
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INSTALLATION
FUEL 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.
***** CAUTION ****
EQUIPMENT DAMAGE - The PSS20000 must be
mounted on a full length solid concrete pad to prevent
air from exiting under the unit. Allowing air to exit
under the unit may cause the unit to overheat from
lack of proper air flow.
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.
The fuel supply should be as close as possible to the
engine. This will reduce the installation cost of fuel
runs. The information in this manual is offered to
assist you in providing the proper fuel for your engine.
However, this information is only provided to inform
you of the engine’s requirements and assist in making
you aware of the decisions you must make. In no
case should the instructions or information provided be
interpreted to conflict with any local, state or national
codes. If in doubt, always consult your local fire
marshal or gas supplier.
*************
***** WARNING ****
*************
FIRE HAZARD - All fuel runs should be installed by a
licensed fuel supplier.
Connect the fuel supply to the inlet of the fuel solenoid
(see table for recommended line size). For all vapor
fuel systems the delivery pressure of the fuel to the
fuel solenoid on the unit must be four to six ounces psi
(per square inch) or 7 to 11 inches W.C. (Water
column). PSS20000 equipped with liquid withdrawal
kits must be connected to the liquid withdraw valve on
the tank. Full tank pressure must be delivered to the
3/8” fuel fitting on the fuel lock strainer at the generator. 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 **
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. 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.
The engine generator sets are properly adjusted before
they leave the factory. A tag is attached to the unit
that specifies the fuel, natural gas (NG) or propane
vapor (LP) that the unit was set up and tested on. A
slight adjustment may be necessary on NG depending
on local BTU content. This adjustment will be discussed later.
Line Size
Unit location will determine the size of fuel line that is
required to supply the engine with a constant fuel
pressure and volume. Refer to the tables below for
fuel line size, fuel consumption and recommended
tank size. For distances of 50 feet and over, a two
regulator fuel system is recommended. This is
accomplished by installing a primary regulator at the
tank which will reduce the tank pressure down to 10 to
15 lbs. A secondary regulator is installed to further
reduce the fuel pressure to the required four (4) to six
(6) oz operating pressure. This secondary regulator
must be at least 10 feet from the engine generator set,
any closer installation will require a larger line be
installed to provide a fuel reservoir. If this is not done
the demand regulator on the unit and the pressure
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regulator in the fuel line will interfere with each other.
When this two (2) stage regulator system is used, a
fuel line size of 1/2 to 5/8 inch is generally adequate
for distances up to 300 feet from the primary to the
secondary regulator. (Consult your local fuel supplier
for your exact requirements.) The appropriate line size
from the table below is then installed from the second
regulator to the generator set.
*************
***** WARNING ****
*************
PERSONAL DANGER - Do not use galvanized pipe in
fuel line runs. The galvanized coating can become
eroded and flake off, causing possible obstructions in
the regulator or fuel valve. The results could range
from inoperative engine start to hazardous fuel leaks.
SINGLE REGULATOR FUEL SYSTEM
Supply Primary Generator
Tank Regulator Set
1 3 4
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
Size of pipe normally required for generators operating on
NATURAL GAS or LP vapor
up to 25 feet* 25 - 100 feet* over 100 feet*
PSS8000 3/4" pipe 1" pipe not recommended
PSS12000 3/4” pipe 1” pipe use a two
PSS20000 1" pipe 1.25" pipe regulator system
*Allow an additional 3 feet for each standard elbow. Do not use
‘street ells’ (restrictive)*
Size of pipe normally required for generators operating on
LP liquid withdrawal
PSS20000 - 3/8” line for all distances.
**** 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) REGULATOR FUEL SYSTEM
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
Supply Primary Secondary Generator
Tank Regulator Regulator Set
1 2 3 4
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LP LIQUID WITHDRAWAL
The following is a block diagram of a typical L/P Liquid
Withdrawal fuel system for the PSS20000.
Tank Fuel Solenoid Converter Engine
1 2 3 4
Reference number 1 is the fuel tank. No regulator is
required but the tank must have a liquid withdrawal
drop tube installed in it and a liquid valve on the tank.
Reference number 2 through 4 are installed on the engine
generator set.
Adjust back and forth until the highest Hz is achieved.
Do not turn the valve richer after the Hz quits rising,
this would cause the engine to run rich. If the Hz is out
of upper or lower limits, a governor adjustment will be
necessary.
4. On the PSS8000 & PSS12000 see your engine
manual for governor adjustment procedures. The
PSS20000 is equipped with an electronic governor
which requires no adjustment.
**** CAUTION ****
Under full load do not adjust the Hz above 60. If a higher
Hz reading is used, as the load is decreased the Hz
will go out of upper limits (61 to 62 Hz).
Liquid fuel is delivered from the tank directly to the fuel
solenoid on the generator at full tank pressure. This
system requires no pressure regulator be installed
any where in the system. The converter mounted on
the engine generator set will take the liquid fuel at tank
pressure and convert it to vapor at the proper delivery
rate.
LP/NG FUEL ADJUSTMENTS
**** CAUTION ****
Do not make any fuel adjustments or governor adjust-
ments until all pressure readings are in compliance
with specification. See fuel pressure charts (tables 1,
2, and 3).
NATURAL GAS (NG)
Due to variations in NG fuel characteristics and BTU
levels throughout the country, it may be necessary to
readjust the fuel mixture once the engine has been
installed and serviced.
**** CAUTION ****
Never make a fuel mixture adjustment on a unit when it is
stopped or running no load. A mixture adjustment is
only effective when the engine is operating under load.
ADJUSTMENT PROCEDURE
1. Insure the unit is operating with an 80 to 100% load or
at the highest anticipated load.
PROPANE (LP)
A generator set factory tested on LP will normally require
no adjustment. If for some unforeseen reason the
machine should require adjustment, follow the NG
procedure.
FUEL TYPE CONVERSION
If it should be necessary to change the type of fuel used
after a unit is received, the following procedures are
provided.
PSS8000
These units require no changes to the regulator. After
plumbing in the fuel lines the only thing necessary is to
reset your mixture as detailed in the adjustment
section above.
PSS12000 & PSS20000
NATURAL GAS TO PROPANE
1. Turn off fuel supply.
2. Remove the fuel line from the carburetor at the
demand regulator.
3. Remove the cap on the upright column of the regulator. This will expose the pressure spring adjusting
screw. Back off the spring adjusting screw so there is
just enough room to replace the cover. Replace the
cover
2. Attach a frequency meter to monitor Hz.
Note: The fuel mixture adjustment on the PSS8000 &
PSS12000 is the brass load block located on top of the
demand regulator. This load block is a multi-turn
needle valve. On the PSS20000 it is located on the
carburetor just behind the fuel inlet hose. This mixture
adjustment is a partial turn, lean to rich, load block.
3. Begin making a mixture adjustment, observing the Hz
meter. If the meter begins to drop you have the mixture
set too lean or to rich . Adjust the valve in the opposite
direction. Adjustments should be made very slowly.
4. Invert the regulator so it is positioned with the column
pointing down.
5. Reconnect the fuel line at the regulator.
6. Remove the 1/8 NPT plug (the one closest to fuel
solenoid) located on what is now the top of the
regulator. Connect a fuel pressure meter or a manometer where the plug has been removed. Move the
generator control switch to the run position. As the unit
starts to crank the fuel solenoid will open and you
should get a pressure reading of between 4 to 6
ounces (7 to 11 inches of water column).
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7. If the pressure is correct, remove the meter and
reinstall the pipe plug.
8. You are now ready to make the final fuel mixture
adjustment. Refer to adjustment section in this manual.
PSS8000 - A customer supplied twelve-volt BCI group U1
battery rated 235 CCA (minimum) is required to
complete the installation. Install the highest CCA rated
battery available for best cold weather starting
performance.
PROPANE TO NATURAL GAS
1. Turn off fuel supply.
2. Remove the fuel line from the carburetor at the
demand regulator.
3. Invert the regulator so the column is in the upright
position. Remove the cap on the upright column of the
regulator. This will expose the pressure spring
adjusting screw. Turn the screw all the way out (CCW)
and then back in (CW) about 8 turns. The plug should
be approximately half way down for initial starting.
4. Reconnect the fuel line at the regulator.
5. Remove the 1/8 NPT plug (the one closest to fuel
solenoid) located on what is now the bottom of the
regulator. Connect a fuel pressure meter or a manometer where the plug has been removed. Move the
generator control switch to the run position. As the unit
starts to crank the fuel solenoid will open and you
should get a pressure reading of between 4 to 6
ounces (7 to 11 inches of water column).
6. If the pressure is correct, remove the meter and
reinstall the pipe plug. Next remove the 1/8 inch NPT
plug on the carburetor side of the regulator and install
the pressure meter. Move the generator switch to the
run position. As soon as the solenoid opens the
pressure should rise 2.5 to 3 oz. just as the engine
starts to crank. If it is within this range replace the cap
on the column. If not, adjust the screw down to
increase and up to decrease and retest.
7. You are now ready to make the final fuel mixture
adjustment. Refer to adjustment section in this manual.
LUBRICATION
PSS12000 - A customer supplied twelve-volt BCI group
26/70 battery rated 450 CCA (minimum) is required to
complete the installation. Install the highest CCA rated
battery available for best cold weather starting
performance.
PSS20000 - A customer supplied twelve-volt BCI group
24 battery rated 500 CCA (minimum) is required to
complete the installation. Install the highest CCA rated
battery available for best cold weather starting
performance.
*****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.
A self tapering trickle charger, producing up to 40 Ma is
built into the Automatic Transfer Switch panel to keep
the battery in top condition during standby periods. A
small green light on the Transfer Switch cover is
illuminated to indicate the proper operation of the
charger. Since the charger has an automatic charge
regulation circuit, the charger has no control knob and
requires no adjustment.
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.
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.
PAGE 7
** NOTICE **
The trickle charger is not intended to recharge a battery
which has become completely discharged. It is
designed to produce just enough current to maintain a
fully charged battery .
Page 10
MOUNTING THE AUTOMATIC
TRANSFER SWITCH (A.T.S.)
*************
***** WARNING *****
*************
EQUIPMENT DAMAGE- Protect the switch from con-
struction grit and metal chips to prevent a malfunction
or shortened life of the switch.
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!
FIGURE 3
FIGURE 4
PSS8000 - The Automatic Transfer Switch shipped with
the PSS8000 system has a 100 Amp line side
contactor installed to handle your normal power needs
and a 50 Amp generator side contactor to handle the
emergency generator output. Before installing the
A.T.S. you must first ensure that the 100 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 100 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 Figure 4. NOTE: THE MAXIMUM OUTPUT OF THE GENERATOR IS 33.3 AMPS
AT 240 VOLTS. You must also take this into consideration when deciding whether to install an emergency
distribution panel.
PSS12000 - The Automatic Transfer Switch shipped with
the PSS12000 system has a 100 Amp line side
contactor installed to handle your normal power needs
and a 100 Amp generator side contactor to handle the
emergency generator output. Before installing the
A.T.S. you must first ensure that the 100 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 100 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 Figure 4. NOTE: THE MAXIMUM OUTPUT OF THE GENERATOR IS 50.0 AMPS
FIGURE 5
PAGE 8
Page 11
AT 240 VOLTS. You must also take this into consideration when deciding whether to install an emergency
distribution panel.
PSS20000 - The Automatic Transfer Switch shipped with
the PSS20000 system has a 225 Amp line side
contactor installed to handle your normal power needs
and a 100 Amp generator side contactor to handle the
emergency generator output. Before installing the
A.T.S. you must first ensure that the 225 Amp line side
contactor will be sufficient to handle your complete
service. See Figure 5. (i.e. the main line breaker must
not be larger than 225 Amps). If you have a larger
main line breaker, 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 GENERATOR IS 83 AMPS AT 240
VOLTS SINGLE PHASE, 56 AMPS AT 208 VOLTS
AND 48 AMPS AT 240 VOLTS THREE PHASE. You
must also take this into consideration when deciding
whether to install an emergency distribution panel.
*************
***** 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 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, RATED AT GENERATOR RATING WILL VOID YOUR WARRANTY IN
CASE OF GENERATOR FAILURE.
PSS8000
Generator Connections
To gain access to the customer connections remove the
end panel opposite the muffler. Both AC and DC
connections are made behind this panel. Three AC
power leads are required between the generator and
the A.T.S. The two power leads are marked G1 and
G3, the neutral lead is shipped bonded to the ground
lug. If your local code requires the generator to be
wired with an isolated neutral, remove this neutral to
ground bond. This will require you to run four AC
leads from the generator to the A.T.S. as you will need
to run both a neutral and a ground lead. All wires must
be sized to handle 33 Amps 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.
A.T.S .Connections
The standby generator terminals in the A.T.S are marked
“GENERATOR - G1, G-N, G3”. The “hot” leads G1 and
G3 are prewired 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” leads L1 and L3 are prewired 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 prewired 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.
PSS12000 SINGLE PHASE
Generator Connections
To gain access to the customer connections remove the
end panel opposite the muffler. Both AC and DC
connections are made behind this panel. Three AC
power leads are required between the generator and
the A.T.S. The power leads coming into this connection box from the generator end are run in parallel.
(i.e. G1-A and G1-B are both connected to the G1
lead and G2-A and G2-B are both connected to the
G3 lead going to the A.T.S.) CAUTION THE G3-A
AND G3-B LEADS ARE NOT USED IN THE SINGLE
PHASE INSTALLATION, JUST LEAVE THEM
CAPPED IN THE BOX. The voltage regulator leads
are currently connected to some of the generator
leads. These leads must remain with the generator
leads they are connected to. The neutral lead (GN-A
& GN-B) are shipped bonded to the ground lug. If
your local code requires the generator to be wired with
an isolated neutral, remove this neutral to ground
bond. This will require you to run four AC leads from
the generator to the A.T.S. as you will need to run
both a neutral and a ground lead. All wires must be
sized to handle 50 amps 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.
A.T.S .Connections
The standby generator terminals in the A.T.S are marked
“GENERATOR - G1, G-N, G3”. The “hot” leads G1 and
G3 are prewired 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” leads L1 and L3 are prewired 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 prewired 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.
PAGE 9
Page 12
PSS20000 Single Phase
Generator Connections
To gain access to the customer connections, remove the
panel the warning light and the selector switch are
mounted on, inside the left hand access door. Both
AC and DC connections are made behind this panel.
Three AC power leads are required between the
generator and the A.T.S. The power leads coming into
this connection box from the generator end are run in
parallel. (i.e. G1-A and G1-B are both connected to
the G1 lead and G3-A and G3-B are both connected
to the G3 lead going to the A.T.S.) The voltage
regulator leads are currently connected to some of the
generator leads. These leads must remain with the
generator leads they are connected to. The neutral
lead (GN-A & GN-B) are shipped bonded to the
ground lug. If your local code requires the generator
to be wired with an isolated neutral, remove this
neutral to ground bond. This will require you to run
four AC leads from the generator to the A.T.S. as you
will need to run both a neutral and a ground lead. All
wires must be sized to handle 83 amps 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.
A.T.S. Connections
The standby generator terminals in the A.T.S are marked
“GENERATOR - G1, G-N, G3”. The “hot” leads G1
and G3 are prewired 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” leads L1 and L3 will wire directly to
the upper lugs on the line side contactor. The L-N
connection will be made on the stand-off just to the left
of the contactor.
The load terminals in the A.T.S. are marked “LOAD - T1,
T-N, T3”. The “hot” leads T1 and T3 will wire directly
to the lower lugs on the line side contactor. Jumper
leads have already been installed between the lower
lugs on the line side and the lower lugs on the generator side contactors. The T-N connection will be made
on the stand-off just to the left of the contactor.
PSS12000 & PSS20000 Three Phase
The three phase units are installed the same as the single
phase units above, except a third power lead is
added, (i.e. a G2 from the generator, L2 on the line
side and a T2 on the load side). In the 120/240 volt
configuration the G3, L3 and T3 will be the high
voltage (wild) leg.
The other difference is a three phase power monitor has
been installed in the A.T.S. to monitor each phase for
low voltage. This three phase monitor is phase
rotation sensitive and comes from the factory set up
for A-B-C phase rotation. If you have trouble getting
the A.T.S. to pick-up the line power on initial installation, try switching the A and B phase on the monitor.
Your rotation may be C-B-A. If so, be sure to match
the generator rotation to your current line rotation or
your three phase motors will try to turn backwards.
*************
***** WARNING *****
*************
When installing a Three Phase 240 Volt Delta system be
sure you know which lead is the high voltage leg (208
Volt line to neutral). The generator has the high
voltage lead connected at G3.
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.
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.
NOTE:
It is an excellent idea to install a disconnect in the
incoming power line wiring directly in front of the A.T.S.
panel. 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 or main entrance providing
the service entrance ampere rating is within the
transfer switch’s rated capability.
If only specific circuits are to be powered under emer-
gency 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.
PAGE 10
Page 13
D.C. ELECTRICAL INTERCONNECTION
Setting the Exerciser Program:
*******CAUTION******
Never run the AC and DC wiring in the same
conduit.
PSS8000
Three 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 +”, “Bat -”, and “Start”.
The control wires will be connected as follows in the
generator control terminal box:
ATS Panel Generator Control Panel
BAT + to Wire #4
Bat - to Wire # 1 & Fuel Solenoid Wire #1
Start to Wire #23
Wire #21 & Fuel Solenoid Wire #21
are just left capped together.
PSS12000 and PSS20000
Three 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 +”, “Bat -”, and “Start”.
The control wires will be connected in the generator
control terminal box and in the A.T.S. to small terminal
blocks. Both are labeled “Bat +”, “Bat -” and “Start”.
The wire are run between identical terminals, i.e.
“start” to “start”.
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:
SETTING THE EXERCISER CLOCK
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.
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.
PAGE 11
Page 14
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:
1 Engine oil.* Check level & fill as required with
proper grade/qty.
2 Engine coolant.* Check level & fill as required
with proper mixture.
3 Unit mounting base properly bolted down.
4 Clearance for service and maintenance on all
sides.
5 Proper fuel line material, and size.
6 All fuel line connections tight.
7 Fuel line protected and a moisture trap installed
(may be required for N.G.).
8 LP/NG pressure O.K. 4-6 Oz. (7-11" WC).
9 Battery connections clean and tight.
10 Battery fully charged.
11 All A.C. and D.C. wiring installed and properly
protected.
* Refer to engine owners manual for proper levels
and type.
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.
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 10 second start delay and then
start up. If it fails to start at this time, the DC inter
connection wiring is incorrect. 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. The cool down period for the PSS8 &
PSS12 is 90 seconds on the PSS20 it is 3 minutes. 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 accom-
plish 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
10 second start delay. At the end of the start delay the
unit will start up. A 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.
After completing the above checklist, the engine-genera-
tor set is ready for the initial start-up test.
PROCEDURE
1. 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.
2. With the engine running smooth, 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 240 and 262
volts A.C. and a frequency of 61.5 To 62 hertz (Hz) on
the PSS8 & PSS12. The frequency on the PSS20
should be 60.0 to 60.5 hertz. 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 120 to 132 volts
AC. The same approximate voltage should be found
between terminals G3 and G-N (120 to 132 volts AC).
** Notice **
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 on the PSS8000 &
PSS12000, 3 minutes later on the PSS20000.
This completes your installation and unit testing. AL-
WAYS leave the system in automatic mode unless
servicing the unit. For automatic operation, keep both
the generator set and transfer selector switches in the
“AUTOMATIC” position.
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.
PAGE 12
Page 15
TROUBLESHOOTING TABLES
PSS8000
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
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 inside 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 COME UP TO SPEED
AFTER IT STARTS.
1. Insufficient fuel volume getting to the unit.
a. Fuel line too small.
b. Low fuel pressure.
2. Fuel load block needs to be adjusted.
3. AC short circuit.
4. Wiring to the A.T.S. panel crossed or shorted.
ATS PANEL WILL NOT TRANSFER TO
EMERGENCY SUPPLY(GENERATOR).
1. No AC generator output from generator.
2. Broken or defective mechanical/electrical inter
locks.
3. Defective holding coil in the generator side
contactor.
4. Wiring error between generator set and transfer
switch
ATS PANEL WILL NOT RETRANSFER TO
NORMAL POWER.
ENGINE WILL NOT CRANK WITH GENERATOR
SELECTOR SWITCH IN THE RUN POSITION.
1. Battery dead.
2. DC circuit breaker on control module tripped.
3. 3/4 amp fuse blown inside control module.
4. Defective engine controller.
5. Circuit breaker tripped on engine control.
6. 3/4 amp fuse blown inside engine control.
7. Defective engine control module.
8. Loose or dirty battery terminals
9. Defective “Run/Auto” switch
10. Defective starter.
11. Defective start solenoid.
12. 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.
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.
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 inter
locks.
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.
PSS12000
UNIT WILL NOT CRANK WHEN THE
POWER FAILS.
1. Alarm light is on from pervious run cycle.
2. Generator control switch not in “AUTOMATIC”
position.
3. Transfer control switch not in “AUTOMATIC”
position.
4. Low or dead battery.
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 inside 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.
PAGE 13
Page 16
ENGINE WILL NOT CRANK WITH GENERATOR
SELECTOR SWITCH IN THE RUN POSITION.
1. Battery dead.
2. DC circuit breaker on control module tripped.
3. 3/4 amp fuse blown inside control module.
4. Defective engine controller.
5. Circuit breaker tripped on engine control.
6. 3/4 amp fuse blown inside engine control.
7. Defective engine control module.
8. Loose or dirty battery terminals.
9. Defective “Run/Auto” switch.
10. Defective starter.
11. Defective start solenoid.
12. 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.
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.
NO AC OUTPUT FROM GENERATOR .
1. AC short in the output leads.
2. Defective voltage regulator.
3. Defective armature.
4. Defective coils.
5. Unit has lost its residual voltage.
6. Rotor loose on engine crankshaft.
PSS20000
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.
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 inside engine control.
9. Defective engine control module.
10. Loose or dirty battery terminals.
11. Defective “Run/Auto” switch on generator or
transfer switch.
12. Defective starter.
13. Defective start solenoid.
14. Defective remote start solenoid
ENGINE WILL NOT COME UP TO SPEED
AFTER IT STARTS.
1. Insufficient fuel volume getting to the unit.
a. Fuel line too small.
b. Fuel pressure too low.
2. Fuel load block needs to be adjusted.
3. AC short circuit
ATS PANEL WILL NOT TRANSFER TO
EMERGENCY SUPPLY(GENERATOR).
1. No AC generator output from generator.
2. Broken or defective mechanical/electrical inter
locks.
3. Defective holding coil in the generator side
contactor.
4. Wiring error between generator set and transfer
switch.
ATS PANEL WILL NOT RETRANSFER TO
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 inter
locks.
ENGINE WILL NOT CRANK WITH GENERATOR
SELECTOR SWITCH IN THE RUN POSITION.
1. Battery dead.
2. DC circuit breaker on control module tripped.
3. 3/4 amp fuse blown inside control module.
4. Defective engine controller.
5. Circuit breaker tripped on engine control.
6. 3/4 amp fuse blown inside engine control.
7. Defective engine control module.
8. Loose or dirty battery terminals
9. Defective “Run/Auto” switch on generator.
10. Defective starter.
11. Defective start solenoid.
12. Defective remote start solenoid.
13. 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.
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ENGINE STARTS AND THEN STOPS AND
A FAULT LIGHT COMES ON.
1. Engine is low on oil.
2. Engine has high water temperature.
3. Engine has gone into overspeed.
4. Engine has gone into overcrank.
5. No output from engine alternator to engage stop
crank circuit.
ENGINE WILL NOT COME UP TO SPEED
AFTER IT STARTS.
1. Insufficient fuel volume getting to the unit.
a. Fuel line too small.
b. Fuel pressure to low.
2. Fuel load block needs to be adjusted.
3. Governor is out of adjustment.
4. AC short in generator components.
ATS PANEL WILL NOT TRANSFER TO
EMERGENCY SUPPLY(GENERATOR).
1. No AC generator output from generator.
2. Broken or defective mechanical/electrical inter
locks.
3. Defective holding coil in the generator side
contactor.
4. Wiring error between generator and transfer
switch
ATS PANEL WILL NOT RETRANSFER TO
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
interlocks.
NO AC OUTPUT FROM GENERATOR
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.
AUTOMATIC 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 GENERATOR SET
Service the engine in accordance with the engine manu-
facture 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 once a week
to keep it dry and in good working order.
1. Defective rectifier.
2. Defective capacitor.
3. Defective armature.
4. Defective field coils.
5. AC short in the output leads.
6. Unit has lost its residual voltage.
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SINGLE PHASE
ATS SCHEMATIC
THREE PHASE
ATS SCHEMATIC
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PSS8000 AC AND DC SCHEMATIC
PAGE 17
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PSS120000 AC CONNECTIONS
PSS12000 AUTOMATIC VOLTAGE REGULATOR
PAGE 18
Page 21
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PSS20000 AC SCHEMATIC
120/240 VOLT SINGLE PHASE
120/240 VOLT THREE PHASE
120/208 VOLT THREE PHASE
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PSS20000 DC SCHEMATIC
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ATS PANEL OUTLINE
DIMENSIONS
ATS SIZE REF A REF B REF C REF D REF E
100/50 ATS 21.00” 8.00” 8.10” 24.25” 12.375”
100/100 ATS 22.88” 14.00” 10.63” 28.25” 18.375”
225/100 ATS 22.88” 14.00” 10.63” 28.25” 18.375”
225/225 ATS 22.88” 14.00” 10.63” 28.25” 18.375”
400/225 ATS 28.00” 16.00” 12.68” 36.00” 23.88”
400/300 ATS 28.00” 16.00” 12.68” 36.00” 23.88”
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”
PSS8000 LAYOUT
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PSS12000 LAYOUT
PSS20000 LAYOUT
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MAINTENANCE LOG
DATE
ITEM
WORK PERFORMED
PAGE 24
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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 AVE
LE CENTER MN 56057
Phone: 507-357-6831
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P/N 60706-126-615801
225 SOUTH CORDOVA AVE
LE CENTER MN 56057
Phone: 507-357-6831
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