Winco PSS20000C User Manual
PACKAGED
STANDBY
SYSTEM
INSTALLATION AND OPERATORS MANUAL
PSS8000/P
PSS12000/C
PSS20000/C
Model PSS8000
Automatic Transfer
Switch
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.
TROUBLESHOOTING INFORMATION 13
WIRING DIAGRAMS
NON-UL ATS Wiring Diagram 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
UL ATS Wiring Diagram 24
12 MONTH W ARRANTY 25
MAINTENANCE LOG 26
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
Connecting Battery Charge &
Blockheater 7
TRANSFER SWITCH INST ALLATION 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 # ___________________________
PAGE 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
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.
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 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. 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.
Standard Automatic Transfer Switch Sizes
(NON-UL)
UNIT LINE SIDE GENERATOR
CONT ACT OR SIDE CONTACTOR
PSS8000 11 0 AMPS 60 AMPS
PSS12000 110 AMPS 60 AMPS
PSS20000 230 AMPS 150 AMPS
Optional UL Automatic Transfer Switch Sizes
UNIT LINE SIDE GENERA T OR
CONTACTOR SIDE CONTACT O R
PSS8000 100 AMPS 100 AMPS
PSS12000 100 AMPS 100 AMPS
PSS20000 100 AMPS 100 AMPS
or 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 Rep. or the
WINCO Sales Department for a quote.
2) ENGINE/GENERATOR
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 60
Hz, by an electronic governor mounted on the engine.
The 20,000 watt (20kW) generator is a single bearing,
PAGE 2
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 3
second start delay, 3 minute cool down delay and cycle
cranking consisting of five, 12 second on/12 second off
cycles. The ECM has both oil pressure and high water
temperature delays build into the starting circuit. During
initial start up the oil pressure delay is 12 seconds, to
allow the engine time to build oil pressure, before a
shutdown will occur. The high water temperature
shutdown has a 60 to 90 second lockout, allowing the
engine time to clear the hot water out of the block in case
of a hot restart. In addition if the generator should loss
output during a run cycle the engine will continue to run
for about 60 seconds and then shutdown and display
and overcrank light, the starter will not reengage during
this time or until the generator selector switch has been
cycled off and back on. This is the only way to clear a
fault light.
** 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
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 TEMPERA TURE
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 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.
“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.
PAGE 3
**** CAUTION ****
ENGINE GENERATOR SET MOUNTING
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.
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.
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 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.
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.
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 **
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)
PAGE 4
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. This is also true for the single dual stage regulators, they should also be minimum of 10 feet form 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 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.
NA TURAL GAS or LP VAPOR
Size of pipe normally required for generators operating
on NATURAL GAS or LP V APOR
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)*
LP LIQUID WITHDRA W AL (ONL Y)
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. V APOR 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
Tank Regulator Regulator Set
1 2 3 4
SINGLE REGULA TOR 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
Single Regulator (L.P. V apor 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 T ANK 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
PAGE 5
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 LIQUID WITHDRAW AL
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.
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 adjustments 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.
2. Attach a frequency meter to monitor Hz.
Note: The fuel mixture adjustment on the PSS8000 is
the brass load block located on top of the demand
regulator. This load block is a multi-turn needle
valve. On the PSS20000 & PSS12000 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.
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).
PROP ANE (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
NA TURAL 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
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
PAGE 6
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).
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.
PROP ANE TO NA TURAL 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
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.
cold weather starting performance. Use only Maintenance Free batteries, this will reduce the need to refill the
battery with water. Gel batteries should not be used with
the battery tender installed in the generator enclosure.
MINIMUM
Model BCI Group CCA Rating
PSS8000 U1 235
PSS12000 26/70 45 0
PSS20000 24 5 0 0
*****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 - NEVER jump start these units.
Doing so will destroy the engine control module rendering the unit non-operational. Remove and fully recharge
the battery before attempting to start.
CONNECTING THE BATTERY CHARGER &
BLOCKHEATER
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 suggest that this circuit be fused for 15 amps, then
both the battery charger and the block heater can be
connected to the same circuit. The block heater is
optional on the PSS8000 and is installed standard on the
PSS20000. At this time there is no block heater available
for the PSS12000.
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
PAGE 7
The PSS8000 and PSS12000 have a 120 volt receptacle mounted in the generator connection box. The
receptacle is prewired with black, white and green leads
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