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
INTRODUCTIONi
AC Electrical Connections8
DC Electrical Connections10
Exerciser Clock Set Up10
INITIAL ST ART-UP11
TROUBLESHOOTING INFORMATION12
WIRING DIAGRAMS
NON-UL ATS Wiring Diagram14
Arm Connections1 5
Voltage Regulator Connections15
AC Schematic16
DC Schematic17
ATS Dimensions18
PSS20000 Layout18
UL ATS Wiring Diagram19
12 MONTH W ARRANTY20
MAINTENANCE LOG21
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 # ___________________________
P AGE i
SAFETY INFORMA TION
This engine generator set has been designed and
manufactured to allow safe, reliable performance.
Poor maintenance, improper or careless use can
result in potential deadly hazards; from electrical
shock, exhaust gas asphyxiation, or fire. Please read
all safety instructions carefully before installation or
use. Keep these instructions handy for future
reference. Take special note and follow all warnings
on the unit labels and in the manuals.
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.
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 package standby system is designed to automatically provide standby power to unattended loads
during electrical outages. Upon an interruption of normal
electrical service the package 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)
UNITLINE SIDEGENERATOR
CONT ACT ORSIDE CONTACT OR
Optional UL Automatic Transfer Switch Sizes
UNITLINE SIDEGENERA TOR
CONTACTORSIDE CONTACTO R
PSS20000100 AMPS100 AMPS
200 AMPS200 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
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,
direct drive, rotating armature design. It has compound
fields with an automatic voltage regulator installed to
maintain normal voltage under full load conditions. 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
lose output during a run cycle the engine will continue to
run for about 60 seconds and then shutdown and display
an overcrank light, the starter will not re-engage 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.
Required L.P. Tank size for L.P. Vapor withdrawal
operating at various outside temperatures given in
degrees Fahrenheit (Celsius)
TANK TEMPERA TURE
MODEL60 f(16 c) 32 f(0 c)0 f(-18 c) -20 f(-29 c)
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.
** NOTICE **
When unpacking the generator set, be sure to inspect it
carefully for freight loss or damage. If loss or damage is
noted at the time of delivery, require that the person
making the delivery make note of the loss or damage on
the freight bill, or affix his signature under the consignor’s
memo of the loss or damage. Contact the carrier for
claim procedures.
When loss or damage is noted after delivery, segregate
the damaged material, and contact the carrier for claim
procedures. Be sure to retain the packaging material for
carrier inspection.
“Concealed Damage” is understood to mean damage
to the contents of a package which is not evident at the
time 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 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.
3. Remove main frame hold down bolts, (4).
4. Unit can now be lifted from shipping pallet.
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.
PAGE 3
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.
NOTE: All PSS20000 units are tested on Natural Gas
and shippped configured for Natural Gas. See page 6 for
conversion to LP
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).
Units 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
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.
** NOTICE **
The engine generator sets are properly adjusted before
they leave the factory. A tag is attached to the unit that
specifies the fuel, natural gas (NG) or propane vapor (LP)
that the unit was set up and tested on. 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 reser-
PAGE 4
voir. This is also true for the single dual stage regulators, they should also be minimum of 10 feet from the
unit. If this is not done the demand regulator on the unit
and the pressure regulator in the fuel line will interfere
with each other. When 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 V APOR
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*
use a two
PSS20000 1" pipe1.25" pipe regulator system
*Allow an additional 3 feet for each standard elbow. Do not use
‘street ells’ (restrictive)*
LP LIQUID WITHDRAW AL (ONL Y)
TWO (2) REGULA TOR FUEL SYSTEM
SupplyPrimarySecondaryGenerator
Tan kRegulatorRegulatorSet
1 2 3 4
SINGLE REGULA TOR FUEL SYSTEM
SupplyPrimaryGenerator
Tan kRegulatorSet
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 OFFTANK PSI7 -11 in7-11 in
4-6 oz4-6 oz
ST ARTINGTANK PSI7-11 in7 -11 in
4-6 oz4-6 oz
NO LOADT ANK PSI7-11 in7-11 in
4-6 oz4-6 oz
FULL LOAD TANK PSI7-11 in7-11 in
4-6 oz4-6 oz
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.
T wo (2) Regulator System (L.P . V apor only)
1 2 3 4
UNIT OFFTANK PSI10-15 lbs 7-11 in7-11 in
4-6 oz4-6 oz
ST ARTINGTANK PSI10-15 lbs 7-11 in7-11 in
4-6 oz4-6 oz
NO LOADT ANK PSI10-15 lbs 7-11 in7-11 in
4-6 oz4-6 oz
FULL LOAD TANK PSI10-15 lbs 7-11 in7-11 in
4-6 oz4-6 oz
Natural Gas
1 3 4
UNIT OFFLINE PSI7-11 in7-11 in
4-6 oz4-6 oz
ST ARTINGLINE PSI7-11 in7-11 in
4-6 oz4-6 oz
NO LOADLINE PSI7-11 in7-11 in
4-6 oz4-6 oz
FULL LOAD LINE PSI7-11 in7-11 in
4-6 oz4-6 oz
PAGE 5
LP LIQUID WITHDRAW AL
The following is a block diagram of a typical L/P Liquid
Withdrawal fuel system for the PSS20000.
TankFuel SolenoidConverterEngine
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.
Note: . The mixture adjustment is located on the carbure-
tor just behind the fuel inlet hose. This mixture
adjustment is a partial turn, lean to rich, load block.
2. Begin making a mixture adjustment,. Adjustments
should be made very slowly. Adjust back and forth until
the engine is running as smooth as possible.
3. The PSS20000 is equipped with an electronic
governor which requires no speed adjustment.
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.
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
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.
PAGE 6
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