Winco PSS25000A User Manual
PACKAGED
STANDBY
SYSTEM
INST ALLA TION AND OPERA TORS MANUAL
PSS25000/A
Automatic Transfer
Switch
PSS25000/A
Engine Generator
P/N 60706-171-5076-10
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 11
INITIAL ST ART-UP 11
PROPER USE AND INSTALLATION
You must be sure your new engine generator set is:
* Properly serviced before starting
* Operated in a well ventilated area
* Properly exhausted and gases safely dispersed
* Wired by a qualified electrician
* Operated only for its designed purposes
* Used only by operators who understand its operation
* Properly maintained
COPY YOUR MODEL AND SERIAL
NUMBER HERE
No other WINCO generator has the same serial number
as yours. It is important that you record the number
and other vital information here. If you should ever
need to contact us on this unit it will help us to respond
to your needs faster.
MODEL____________________________________
SERIAL NUMBER____________________________
PURCHASE DATE____________________________
DEALER___________________________________
DEALER PHONE # ___________________________
TROUBLESHOOTING INFORMATION 12
WIRING DIAGRAMS
NON-UL ATS Wiring Diagram 14
Winco/Zenith UL ATS Schematics 15
ASCO 165 UL ATS Schematics 16
PSS25000 Layout 17
DC Schematic 18
AC Schematic 19
AC Schematic 20
MAINTENANCE LOG 21
12 MONTH WARRANTY 22
P AGE 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.
***********************************************************
************************************************************
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 LP 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
5076-10 60706-171
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 the normal commercial power source.
The engine control circuits will begin a cool-down cycle,
after which the fuel supply will be shut off and the engine
ignition system disabled.
These packaged standby systems consist of two
major components:
1) AUTOMATIC TRANSFER SWITCH
A wall mounted Automatic Transfer Switch (A.T.S.)
designed for inside installation. The A.T.S. consists of a
line side contactor and a generator side contactor. The
contactors are both electrically and mechanically
interlocked. An 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.
Optional UL Automatic Transfer Switch Sizes
UNIT LINE SIDE GENERATOR
CONTACTOR SIDE CONTACTOR
PSS25000 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
PSS25000 - The engine generator set consists of a
Ford Industrial, four cylinder, water cooled engine
equipped to run on LP or NG fuel. The engine operates at
3600 rpm and frequency regulation is maintained at 60
Hz, by an electronic governor mounted on the engine.
The 25,000 watt (25kW) generator is a single bearing,
direct drive, rotating field design, 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 E.C.M. 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 until the
generator selector switch has been cycled off and back
on. This is the only way to clear a fault light.
Standard Automatic Transfer Switch Sizes
(NON-UL)
UNIT LINE SIDE GENERATOR
CONT ACT OR SIDE CONTACTOR
PSS25000 230 AMPS 150 AMPS
** NOTICE **
This unit will automatically transfer if a power outage
occurs while running in an exercise mode.
PAGE 260706-171
5076-10
SPECIFICATIONS
UNPACKING INSTRUCTIONS
GENERATOR
MODEL WATTS* VOLTS Pf AMPS* HZ pH RPM
PSS25000 25,000 120/240 1.0 104.0 60 1 3600
PSS25000-4 25,000 120/208 . 8 86.8 60 3 3600
PSS25000-17 25,000 120/240 .8 75.3 60 3 3600
PSS25000-18 25,000 277/480 .8 36.6 60 3 3600
*Derate 10% for Natural Gas operation. Derate 3.5%
per 1000 feet elevation above sea level.
FUEL CONSUMPTION
NG LP
1000 BTU/CU FT 2520 BTU/CU FT
MODEL CF/HR BTU/HR #/HR GAL/HR CF/HR BTU/HR
PSS25000* 375 375,000 17.1 4.1 148 375,000
*Based on full load operation
LP TANK SIZING
Required LP Tank size for LP 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)
PSS25000* 250 Gal. 500 Gal. 500 Gal. 1000 Gal.
* Fuel tank sizes for PSS25000 on liquid withdrawal are
considerably smaller consult your local fuel supplier.
** 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 PSS25000 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.
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:
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.
5076-10 60706-171
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 PSS25000 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. For full service switching
the A.T.S. must have a fusible disconnect (circuit breaker)
installed before the switch to protect transfer switch.
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. 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. A general rule to follow is five (5) feet of clearance
on all sides. (Code NFPA 37requires five feet from any
combustible surface.)
NOTE: All PSS25000 units are tested on Natural Gas
and shipped 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
** 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 reservoir. This is
PAGE 460706-171
5076-10
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
PSS25000 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)
Size of pipe normally required for generators operating
on LP LIQUID WITHDRAWAL
PSS25000 - 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
Below is a table of the fuel pressure reading at each
reference in the system.
Fuel Pressure Table
Single Regulator (LP 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.
LP & NG 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 LP or NG 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
Two (2) Regulator System (LP 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.
calibrated in inches of water column. The second is with
a pressure gauge calibrated in ounces per square inch.
Reference number 4 is the engine generator set.
5076-10 60706-171
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 WITHDRAW AL
The following is a block diagram of a typical L/P Liquid
Withdrawal fuel system for the PSS25000.
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 numbers 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 PSS25000 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).
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