Winco PSS20000C User Manual

PACKAGED

STANDBY

SYSTEM

INSTALLATION AND OPERATORS MANUAL

PSS8000/P

PSS12000/C

PSS20000/C

Automatic Transfer

Switch

Model PSS8000

Read and understand all instructions in the manual before starting and operating the generator set.

USING THIS MANUAL

Congratulations on your choice of a Winco generator set. You have selected a high-quality, precision-engineered generator set designed and tested to give you years of satisfactory service.

To get the best performance from your new engine generator set, it is important that you carefully read and follow the operating instructions in this manual.

Should you experience a problem please follow the “Things To Check” near the end of this manual. The warranty listed in this manual describes what you can expect from WINCO should you need service assistance in the future.

TABLE OF CONTENTS
INTRODUCTION	i
GUIDE TO PRODUCT SAFETY	1
BASIC INFORMATION	2
Description	2
Specification Table	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 INSTALLATION	8
AC Electrical Connections	9
DC Electrical Connections	11
Exerciser Clock Set Up	11
INITIAL START-UP	12

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 WARRANTY	25
MAINTENANCELOG	26

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 INFORMATION

This engine generator set has been designed and manufactured to allow safe, reliable performance. Poor maintenance, improper or careless use can result in potential deadly hazards; from electrical shock, exhaust gas asphyxiation, or fire. Please read all safety instructions carefully before installation or use. Keep these instructions handy for future reference. Take special note and follow all warnings on the unit labels and in the manuals.

ANSI SAFETY DEFINITIONS

************************************************************

DANGER:

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations.

***********************************************************

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before refueling.

b.Keep fuel containers out of reach of children.

c.Do not smoke or use open flame near the generator set or fuel tank.

d.Keep a fire extinguisher nearby and know its proper use. Fire extinguishers rated ABC by NFPA are appropriate.

e.Store fuel only in an approved container, and only in a well-ventilated area.

f.Follow local codes for closeness to combustible material.

3.DEADLY EXHAUST GAS - Exhaust fumes from any gasoline engine contain carbon monoxide, an invisible, odorless and deadly gas that must be mixed with fresh air.

a.Operate only in well ventilated areas.

b.Never operate indoors.

c.Never operate the unit in such a way as to allow exhaust gases to seep back into closed rooms (i.e. through windows, walls or floors).

	WARNING:		4. NOISE HAZARD - Excessive noise is not only tiring,
	WARNING indicates a potentially hazardous situation
			but continual exposure can lead to loss of hearing.
	which, if not avoided, could result in death or serious
	injury.		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.
	CAUTION:
	CAUTION indicates a potentially hazardous situation		5. CLEANLINESS - Keep the generator and surrounding
	which, if not avoided, may result in minor or moderate
			area clean.
	injury. It may also be used to alert against unsafe
	practices.		a.	Remove all grease, ice, snow or materials that
	************************************************************
				create slippery conditions around the unit.
	NOTE:
			b.	Remove any rags or other material that could
	CAUTION is also used on the unit labels and in this			create potential fire hazards.
			c.	Carefully clean up any gas or oil spills before
	manual to indicate a situation that could result in
				starting the unit.
	serious damage or destruction of the equipment and
			d.	Never allow leaves or other flammable material
	possible personal injury.
				to build up around the engine intake or exhaust
	1. ELECTRIC SHOCK - The output voltage present in this			area.
	equipment can cause a fatal electric shock. This		6. SERVICING EQUIPMENT - All service, including the
	equipment must be operated by a responsible
			installation or replacement of service parts, should be
	person.
			performed only by a qualified technician.
	a. Do not allow anyone to operate the generator		a.	Use only factory approved repair parts.
		without proper instruction.
			b.	Do not work on this equipment when fatigued.
	b. Guard against electric shock.
			c.	Never remove the protective guards, cover, or
	c.	Avoid contact with live terminals or receptacles.
				receptacle panels while the engine is running.
	d. Use extreme care if operating this unit in rain or
			d.	Use extreme caution when working on electrical
		snow.
				components. High output voltages from this
	e. Use only three-prong grounded receptacles and
				equipment can cause serious injury or death.
		extension cords.
			e.	Always avoid hot mufflers, exhaust manifolds,
	f.	Be sure the unit is properly grounded to an
				and engine parts. They all can cause severe
		external ground rod driven into the earth.
				burns instantly.
	2. FIRE HAZARD - Natural gas and L.P. present a hazard		f.	Installing a generator set is not a “do-it-yourself”
				project. Consult a qualified, licensed electrician

of possible explosion and/or fire.	or contractor. The installation must comply
a. Do not refuel when the engine is running or hot.	with all national, state, and local codes.
Allow the engine to cool at least two minutes
PAGE 1

TESTING POLICY:

Before any generator is shipped from the factory, it is fully checked for performance. The generator is loaded to its full capacity, and the voltage, current, and frequency are carefully checked.

Rated output of generators is based on engineering tests of typical units, and is subject to, and limited by, the temperature, altitude, fuel, and other conditions specified by the manufacturer of the applicable engines.

INTRODUCTION AND DESCRIPTION

The package standby system includes all items necessary for a completely automatic standby power system as standard equipment.

DESCRIPTION

This packaged standby system is designed to automatically provide standby power to unattended loads during electrical outages. Upon an interruption of normal electrical service the packaged standby 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
	CONTACTOR	SIDE CONTACTOR
PSS8000	110 AMPS	60 AMPS
PSS12000	110 AMPS	60 AMPS
PSS20000	230 AMPS	150 AMPS

Optional UL Automatic Transfer Switch Sizes

UNIT	LINE SIDE	GENERATOR
	CONTACTOR	SIDE CONTACTOR
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 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.

** 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 ****

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.

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.

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.

NATURAL GAS or LP VAPOR

Size of pipe normally required for generators operating on NATURAL GAS or LP VAPOR

	up to 25 feet*		25 - 100 feet* over 100 feet*
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 WITHDRAWAL (ONLY)

Size of pipe normally required for generators operating onLP 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

	Supply		Primary				Secondary			Generator
	Tank		Regulator				Regulator			Set
	1	2		3						4
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

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

PAGE 5

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

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.

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).

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

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.

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

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.

A customer supplied twelve-volt battery is required to complete the installation. Installation of the highest CCA rated battery, within the correct BCI group, will increase

cold weather starting performance. 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	450
PSS20000	24	500

*****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.

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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