Winco PSS20000E User Manual

PACKAGED
STANDBY
SYSTEM
INST ALLA TION AND OPERA TORS MANUAL
PSS20000/E
Automatic Transfer
Switch
PSS20000/E Engine Generator
Read and understand all instructions in the
manual before starting and operating the generator set.
USING THIS MANUAL
Congratulations on your choice of a Winco generator set.
You have selected a high-quality, precision-engineered generator set designed and tested to give you years of satisfactory service.
To get the best performance from your new engine
generator set, it is important that you carefully read and follow the operating instructions in this manual.
Should you experience a problem please follow the
“Things To Check” near the end of this manual. The warranty listed in this manual describes what you can expect from WINCO should you need service assis-
tance in the future. TABLE OF CONTENTS INTRODUCTION i
GUIDE TO PRODUCT SAFETY 1 BASIC INFORMATION 2
Description 2 Specification Table 3
PREPARING THE UNIT 3
Unpacking the Unit 3
ENGINE GENERA TOR INST ALLATION 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 Charger & Blockheater 7
TRANSFER SWITCH INST ALLATION 7
AC Electrical Connections 8 DC Electrical Connections 10 Exerciser Clock Set Up 10
INITIAL ST ART-UP 11
TROUBLESHOOTING INFORMATION 12 WIRING DIAGRAMS
NON-UL ATS Wiring Diagram 14 Arm Connections 1 5 Voltage Regulator Connections 15 AC Schematic 16 DC Schematic 17 ATS Dimensions 18 PSS20000 Layout 18 UL ATS Wiring Diagram 19
12 MONTH W ARRANTY 20 MAINTENANCE LOG 21
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.
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 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)
UNIT LINE SIDE GENERATOR
CONT ACT OR SIDE CONTACT OR
Optional UL Automatic Transfer Switch Sizes
UNIT LINE SIDE GENERA TOR
CONTACTOR SIDE CONTACTO R
PSS20000 100 AMPS 100 AMPS
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
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.
PSS20000 230 AMPS 150 AMPS
PAGE 2
SPECIFICATIONS
UNPACKING INSTRUCTIONS
GENERATOR
MODEL WATTS* VOLTS AMPS* HZ pH RPM
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* 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) 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" pipe 1.25" 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
Supply Primary Secondary Generator Tan k Regulator Regulator Set 1 2 3 4
SINGLE REGULA TOR FUEL SYSTEM
Supply Primary Generator Tan k 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
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
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 OFF TANK 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
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
PAGE 5
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.
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
Loading...
+ 16 hidden pages