Winco PSS65LSB User Manual
PACKAGE
STANDBY
SYSTEMS
PSS50LS-*/A
PSS65LS-*/A
PSS50LS-*/B
PSS65LS-*/B
INSTALLATION AND
OPERATIONS MANUAL
Automatic Transfer
Switch
Engine Generator Set
225 SOUTH CORDOVA AVE
LE CENTER MN 56057
507-357-6831
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 portable 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
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____________________________________
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 Line Installation 4
Fuel Pressure Tables 5
Lubrication 6
Coolant 6
Battery Installation 6
BATTERY TNDER & BLOCK HEATER WIRING 6
TRANSFER SWITCH INSTALLATION 7
AC Electrical Connections 7
DC Electrical Connections 9
INITIAL START-UP 9
EXERCISER CLOCK 10
TROUBLESHOOTING INFORMATION 11
LP/NG ADJUSTMENT 12
FUEL TYPE CONVERSION 12
WIRING DIAGRAMS 14
12 MONTH WARRANTY 20
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
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
2. FIRE HAZARD - Natural gas and L.P. present a hazard
of possible explosion and/or fire.
a. Do not smoke or use open flame near the generator
set.
b. Keep a fire extinguisher nearby and know its proper
use. Fire extinguishers rated ABC by NFPA are
appropriate.
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.
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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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WARNING:
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
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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.
a. Do not allow anyone to operate the generator with
out 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.
a. Operate only in well ventilated areas.
b. Never operate indoors without adequate ventilation
and fresh air.
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 wipe up any gas or oil spills before starting
theunit.
d. Never allow leaves or other flammable material to
build up around the engine exhaust area.
6. SERVICING EQUIPMENT - All service, including the
installation or replacement of service parts, should be
performed only by a qualified technician.
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, and
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.
60706-144 Page 1 1017-10
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 engine-generator set includes all
items necessary for a completely automatic standby power
system as standard equipment. The entire package is
then tested to insure proper operation of all components
and the total systems performance and reliability.
DESCRIPTION
This packaged power system is designed to automatically provide standby power to unattended loads during
electrical outages. Upon an interruption of normal electrical service this packaged power system 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 3 minute cool-down cycle, after which the fuel
supply will be shut off and the engine ignition system disabled.
These packaged power systems consist of two major
components:
1) AUTOMATIC TRANSFER SWITCH
The table below shows the different Automatic Switch
sizes shipped with each unit.
CONTACTOR RATING
MODEL VOLTAGE LINE GENERATOR
PSS50000-3 120/240 400 320
PSS50000-4 120/208 230 230
PSS50000-17 120/240 230 230
PSS50000-18 277/480 100 100
PSS65000-3 120/240 400 320
PSS65000-4 120/208 230 230
PSS65000-17 120/240 230 230
PSS65000-18 277/480 225 225
These Automatic Transfer Switchs (A.T.S.) are wall
mount switches 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 are 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.
2) ENGINE/GENERATOR
PSS50000 - The engine generator set consists of a GM
Industrial, eight cylinder, liquid cooled , 5.7L engine
equipped to run on L.P. or N.G. fuel. The engine operates
at 1800 rpm and frequency regulation is maintained by the
engine governor within .5 cycles variation, from no load to
rated load. The 50,000 watt (50kW) generator is a single
bearing, direct drive, rotating field design. The generator is
connected to the engine flywheel via flexible drive disks.
The engine generator is mounted in a drip proof enclosure
for outside installation. Connection boxes are provided to
all customer connections (both AC output and DC control).
A customer supplied 12 Volt, 650 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
built 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 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.
PSS65000 - The engine generator set consists of a GM
Industrial, eight cylinder, liquid cooled , 7.4L engine
equipped to run on L.P. or N.G. fuel. The engine operates
at 1800 rpm and frequency regulation is maintained by the
engine governor within .5 cycles variation, from no load to
rated load. The 65,000 watt (65kW) generator is a single
bearing, direct drive, rotating field design. The generator is
connected to the engine flywheel via flexible drive disks.
The engine generator is mounted in a drip proof enclosure
for outside installation. Connection boxes are provided to
all customer connections (both AC output and DC control).
A customer supplied 12 Volt, 650 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
built 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
Page 21017-10 60706-144
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 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 **
These units will automatically transfer if a power outage
occurs while running in an exercise mode.
SPECIFICATIONS
GENERATOR
MODEL WATTS VOLTS AMP HZ PH RPM
PSS50000 50,000 120/240 208 60 1 1800
PSS50000-4 50,000 120/208 174 60 3 1800
PSS50000-17 50,000 120/240 151 60 3 1800
PSS50000-18 50,000 277/480 72 60 3 1800
PSS65000 65,000 120/240 271 60 1 1800
PSS65000-4 65,000 120/208 226 60 3 1800
PSS65000-17 65,000 120/240 196 60 3 1800
PSS65000-18 65,000 277/480 98 60 3 1800
*Derate 10% for Natural Gas operation. Derate 3.5% per
1000 feet elevation above sea level.
FUEL CONSUMPTION
NG (1,000 BTU/CU FT) L.P. VAPOR (2,520 BTU/CU FT)
MODEL CF/HR BTU/HR #/HR GAL/HR CF/HR BTU/HR
PSS50000 725 725,000 42.3 10.0 353 889,560
PSS65000 940 940,000 48.7 11.5 406 1,024,000
L.P. TANK SIZING
Minimum 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) 30 F(0 C) 0 F(-18 C) -20 F(-29 C)
PSS50000 500 Gal. 1000 Gal. 1500 Gal.* 9000 Gal.*
PSS65000 500 Gal. 1000 Gal. 2500 Gal.* 9000 Gal.*
*Recommend liquid withdrawal at these temperatures.
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.
The engine manufacturer has established an excellent
world-wide 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 consigner’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.
“Concealed Damage” is understood to mean damage to
the contents of a package which is not in evidence 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 FOB factory, and only the consignee can legally file a claim.
**** CAUTION ****
EQUIPMENT DAMAGE - The PSS50000 and the
PSS65000 are shipped with oil, and a 50/50 mix of cool-
ant. 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 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 rails.
** CAUTION **
EQUIPMENT DAMAGE - Be sure to check the engine oil
level frequently as specified in the engine manual.
60706-144 Page 3 1017-10
INSTALLATION
FUEL INSTALLATION
General Information
*************
***** WARNING ****
*************
PERSONAL INJURY - Before proceeding with the installation, be sure the operation selector switch is in the "stop"
position.
These engine/generator sets are available as a skid
mounted unit for indoor installation or a skid mounted unit
with a standard or accoustical housing for outdoor installation. All versions of these units must be bolted solidly to a
concrete pad. The transfer switch is mounted next to your
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 - These units must be mounted
on a 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.
should have a service entrance installed before the switch
to protect the contacts.
ENGINE GENERATOR SET MOUNTING
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). The pressure at
the secondary demand regulator must be four to six
ounces psi (per square inch) or 7 to 11 inches W.C. (Water
column) for vapor withdrawal units. On units equipped
with liquid withdrawal fuel systems full tank pressure is
plumbed to the fuel lock strainer mounted on the generator
rails. The fuel converter mounted on the unit will handle
both vaporization of the fuel and pressure reduction. 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.
The unit’s main frame should be bolted solidly to a 4 to 6
inch thick cement pad. The engine-generator is mounted
on a sub-frame which is attached with special shock
mounts on the main frame. This allows the engine-generator free movement without affecting the control panel which
is mounted on the main frame.
Do not shock mount the main frame. 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.
Page 41017-10 60706-144
Line Size (vapor system)
Unit location will determine the size of fuel line that is
required to supply the engine with a constant fuel pressure. 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 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. 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 3/4 to 1 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.
Size of pipe normally required for generators operating
on NATURAL/LP gas.
up to 25 feet* over 25 feet*
PSS50000 1-1/4" pipe Not recommended use
PSS65000 1-1/4" pipe a two regulator
system
* Allow an additional 3 feet for each standard elbow.
Do not use ‘street ells’ (restrictive)*
**** CAUTION ****
EQUIPMENT DAMAGE - Be careful when sealing gas
joints. Excessive sealing compound can be drawn into the
solenoid, regulator or carburetor causing an engine malfunction.
FUEL PRESSURE (vapor system)
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. Installation.
Supply Primary Secondary Generator
Tank Regulator Regulator Set
1 2 3 4
TWO (2) REGULATOR FUEL SYSTEM
Supply Primary Generator
Tank Regulator Set
1 2 4
SINGLE REGULATOR FUEL SYSTEM
Reference numbers 1 through 3 in the block diagrams
above are fuel lines 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)
123
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)
1234
UNIT OFF TANK PSI 10-15 lbs 7-11 in 7-11 in
4-6 oz 4-6oz
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
Natural Gas
13 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
Notice the preceding tables give two (2) different units
of measuring fuel pressure. The first is with a pressure
gauge calibrated in ounces per square inch. The second
and most accurate is the use of a simple water manometer. A manometer is calibrated in inches of water column.
LP LIQUID WITHDRAWAL SYSTEMS
When installing a unit equipped the LP liquid withdrawal
a primary regulator is not required on the supply tank.
The supply line is connected to a liquid withdrawal valve
on the supply tank and run directly to the fuellock strainer
mounted on the engine generator set. Normally a 3/8 inch
copper line is acceptable for this type of fuel installation.
You must be sure that the valve you have connected to on
the supply tank is in fact a liquid supply valve and has a
drop tube inside the tank that is pulling fuel from the bottom of the supply tank. Before starting the unit you must
confirm that you have a good liquid supply at the unit. En-
gine generator sets equipped for liquid withdrawal will
not run properly when supplied with high pressure vapor fuel.
The following is a block diagram of a typical L/P Liquid
Withdrawal fuel system.
60706-144 Page 5 1017-10
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