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 SAFETY1
BASIC INFORMATION2
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
2.FIRE HAZARD - Natural gas and L.P. present a hazard of
possible explosion and/or fire.
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 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.
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.
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.
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 install-
ing 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 the
unit.
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.
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 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.
60706-124
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 recep-
tacle panels while the engine is running.
d.Use extreme caution when working on electrical compo
nents. 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.
60541
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 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 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.
a line side contactor and a generator side contactor. The
contactors are both electrically and mechanically interlocked. An
automatic taper battery trickle charger (40 MA max) and 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
PSS20000LS- The engine generator set consists of a Ford
Industrial, four cylinder, liquid cooled engine equipped to run on
L.P./N.G. fuel. The engine operates at 1800 rpm and frequency
regulation is maintained by the electronic governor within .5
cycles varation, from no load to rated load. The 20,000 watt
(20kW) 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 10 second start delay, 3 minute cool
down delay and cycle cranking, featuring 5 cycles of 12 seconds
on/12 seconds off.
PSS35000 - The engine generator set consists of a Ford Industrial, four cylinder, liquid cooled engine equipped to run on L.P./
N.G. fuel. The engine operates at 3600 rpm and frequency
regulation is maintained by the engine governor within .5 cycles
variation, no load to rated load. The 35,000 watt (35kW) 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 10 second start delay, 3 minute cool
down delay and cycle cranking, featuring 5 cycles of 12 seconds
on/12 seconds off.
These Automatic Transfer Switchs (A.T.S.) are wall mount
switches designed for inside installation. The A.T.S. consists of
Page 26054160706-124
PSS70000 - The engine generator set consists of a Ford
Industrial, eight cylinder, liquid cooled engine equipped to run
on L.P./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 70,000 watt
(70kW) 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 10 second start delay, 3 minute cool
down delay and cycle cranking, featuring 5 cycles of 12 seconds
on/12 seconds off.
** NOTICE **
These unit will automatically transfer if a power outage occurs
while running in an exercise mode.
SPECIFICATIONS
GENERATOR
MODEL WATTSVOLTSAMPH ZPHRPM
PSS20000LS20,000120/240836011800
Minimum required L.P. Tank size for L.P. Vapor withdrawal
operating at various outside temperatures given in degrees
Fahrenheit (Celsius)
TANK TEMPERATUREMODEL60 F(16 C) 30 F(0 C) 0 F(-18 C) -20 F(-29 C)
PSS20000100 Gal150 Gal 500 Gal* 1500 Gal*
PSS35000160 Gal.300 Gal. 1000 Gal.* 2000 Gal.*
PSS70000500 Gal.1000 Gal. 2500 Gal.* 9000 Gal.*
*Recommend liquid withdrawal at these temperatures.
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 PSS20000LS, P SS35000 and the
PSS70000 are 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 **
EQUIPMENT DAMAGE - Be sure to check the engine oil level
frequently as specified in the engine manual.
60706-124
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.
Page 3
60541
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 ****
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 convertor mounted on the unit will
handle both vaporization of the fuel and pressure reduction.
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 it’s 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 fuseable disconnect installed before the switch to protect the contacts.
ENGINE GENERATOR SET MOUNTING
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 subframe which is attacted 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.
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 (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.
FUEL INSTALLATION
The fuel supply should be as close as possible to the engine.
This will reduce the installation cost of fuel runs. The information in this manual is offered to assist you in providing the proper
fuel for your engine. However, this information is only provided to
Page 46054160706-124
*************
***** 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*
PSS20000 1" pipe not recommended
PSS35000 1" pipe use a
PSS70000 2" pipe 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 SecondaryGenerator
Tank Regulator Regulator Set
Two (2) Regulator System (L.P. Vapor only)
1234
UNIT OFFTANK PSI 10-15 lbs 7-11 in7-11 in
4-6 oz4-6oz
STARTINGTANK PSI 10-15 lbs7-11 in7-11 in
4-6 oz4-6 oz
NO LOADTANK PSI 10-15 lbs7-11 in7-11 in
4-6 oz4-6 oz
FULL LOAD TANK PSI 10-15 lbs7-11 in7-11 in
4-6 oz4-6 oz
Natural Gas
134
UNIT OFFLINE PSI7-11 in7-11 in
4-6 oz4-6 oz
STARTINGLINE PSI7-11 in7-11 in
4-6 oz4-6 oz
NO LOADLINE PSI7-11 in 7-11 in
4-6 oz4-6 oz
FULL LOADLINE PSI7-11 in.7-11 in
4-6 oz4-6 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.
1 23 4
TWO (2) REGULATOR FUEL SYSTEM
Supply PrimaryGenerator
TankRegulator Se t
123
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 OFFTANK PSI7-11 in7-11 in
4-6 oz4-6 oz
STARTINGTANK PSI7-11 in7-11 in
4-6 oz4-6 oz
NO LOADTANK PSI7-11 in7-11 in
4-6 oz 4-6 oz
FULL LOADTANK PSI7-11 in7-11 in
4-6 oz4-6 oz
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 ran 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. Engine
generators sets equipped for liquid withdrawal will not run
properly when supplied with high pressure vapor fuel.
LUBRICATION
Before starting the engine, check the oil level in the crankcase. If
it is low, refill to the full mark with the proper weight/grade of oil
as recommended by the engine manufacturer’s maintenance
instructions. The necessity of using the correct oil, and keeping
the crankcase full cannot be over emphasized. Failure to use
the proper oil and keep the crankcase properly filled will cause
excessive engine wear and shorten its useful life.
COOLANT
Before starting the engine, check the coolant level in radiator. If it
is low, refill as specified in the engine manufacturer’s maintenance instructions. The radiator should be filled to about 1 inch
below the filler neck.For additonal information on engine coolant
requirements see engine manufacturer’s maintenance instructions.
60706-124
Page 5
60541
INSTALLING THE BATTERY
**** CAUTION ****
EQUIPMENT DAMAGE - In the following battery installation
procedure, check to be sure the selector switch remains in the
“stop” position.
*************
***** WARNING *****
*************
FIRE HAZARD - All wiring must be done by a licensed electrician, and must conform to the national electrical code and comply
with all state and local codes and regulations. Check with the
authorities before proceeding!
A customer supplied twelve-volt BCI group 24 battery rated 650
CCA (minimum) is required to complete the installation. Install
the highest CCA rated battery available for best cold weather
starting performance.
****WARNING*****
EQUIPMENT DAMAGE - Always connect the positive battery
cable first and the negative cable last. When disconnecting a
battery always disconnect the negative cable first and the
positive cable last. Failure to follow these steps can cause
arcing at the battery post which can cause damage to both the
engine and the engine control module.
Observe polarities: Connect the positive (+) battery terminal to
the (+) cable from the control panel; the negative
(-) battery terminal is connected to the negative cable (ground)
from the engine generator assembly.
NOTE: Alway make sure that a new battery is fully charged
before installing it on a generator set. Failure to do so can cause
damage to the engine control module in the generator set.
All connections must be clean and tight. Check the electrolyte
(fluid) in the battery periodically to be sure it is above the plates.
Never allow the battery to remain in a discharged condition.
A self tapering trickle charger, producing up to 40 MA is built into
the Automatic Transfer Switch panel to keep the battery in top
condition during standby periods. A small green light on the
Transfer Switch cover is illuminated to indicate the proper
operation of the charger. Since the charger has an automatic
charge regulation circuit, the charger has no control knob and
requires no adjustment.
** NOTICE **
The trickle charger is not intended to recharge a battery which
has become completely discharged. It is designed to produce
just enough current to maintain a fully charged battery.
MOUNTING THE AUTOMATIC TRANSFER
SWITCH (A.T.S.)
The automatic transfer switch connects the load (lights, furnace,
outlets, etc.) to the normal power line. When normal power fails,
the A.T.S. starts the engine generator set, disconnects the power
line and then connects the load to the standby generator set.
When normal power is restored, the automatic switch retransfers the electrical load to the normal service and stops the
engine. The A.T.S. panel should be mounted as close to the
distribution panel as possible.
PSS20000LS - The Automatic Transfer Switch shipped with the
PSS20000LS system has a 225 Amp line side contactor (the 277/
480 volt transfer switch has 100 Amp contactor instead of the 225
Amp) installed to handle your normal power needs and a 100
Amp generator side contactor to handle the emergency generator
output. Before installing the A.T.S. you must first ensure that the
225 Amp line side contactor will be sufficient to handle your
complete service. See Figure 5. (i.e. the main line breaker must
not be larger than 225 Amps) If you have 250, 300 Amp or larger
system, you will not be able to transfer the complete electrical
system. In this case it will be necessary to install a secondary
emergency distribution panel.
PSS35000 - The Automatic Transfer Switch shipped with the
PSS35000 system has a 225 Amp line side contactor (the 277/
480 volt transfer switch has 100 Amp contactor instead of the
225 Amp) installed to handle your normal power needs and a
225 Amp generator side contactor to handle the emergency
generator output. Before installing the A.T.S. you must first
ensure that the 225 Amp line side contactor will be sufficient to
handle your complete service. See Figure 5. (i.e. the main line
breaker must not be larger than 225 Amps) If you have 250, 300
Amp or larger system, you will not be able to transfer the
complete electrical system. In this case it will be necessary to
install a secondary emergency distribution panel.
PSS70000 - The Automatic Transfer Switch shipped with the
PSS70000 system has a 400 Amp line side contactor (the 277/
480 volt transfer switch has 225 Amp contactor instead of the
400 Amp) installed to handle your normal power needs and a
400 Amp generator side contactor to handle the emergency
generator output. Before installing the A.T.S. you must first
ensure that the 400 Amp line side contactor will be sufficient to
handle your complete service. See Figure 5. (i.e. the main line
breaker must not be larger than 400 Amps). If you have a larger
main line breaker, you will not be able to transfer the complete
electrical system. In this case it will be necessary to install a
secondary emergency distribution panel.
*************
***** WARNING *****
*************
PERSONAL INJURY - Be certain the operation selector switch
on the front of the A.T.S. Control is in the “stop” position and the
main power switch “off”. For your own protection, verify these
important safety precautions yourself with reliable instruments
before proceeding.
Page 66054160706-124
FIGURE 5
Three phase unit shown, for single phase
wiring disregard L-2, T-2, G-2.
A.C. ELECTRICAL CONNECTIONS
Single Phase
The standby generator terminals in the A.T.S are marked
“GENERATOR - G1, G-N, G3”. The “hot” leads G1 and G3 wire
directly to the top lugs on the generator side contactor, terminals
G1 and G3. The G-N connection is made to the lug on the
standoff just to the right of the generator side contactor.
The line terminals in the A.T.S. are marked “LINE - L1, L-N, L3”.
The “hot” leads L1 and L3 will wire directly to the top lugs on the
line side contactor. The L-N connection will be made on the
stand-off just to the left of the line side contactor.
The load terminals in the A.T.S. are marked “LOAD - T1, T-N, T3”.
The “hot” leads T1 and T3 will wire directly to the lower lugs on
the line side contactor. Jumper leads have already been
installed between the lower lugs on the line side and the lower
lugs on the generator side contactors. The T-N connection will
be made on the stand-off just to the left of the contactor.
An equipment grounding lug is provided just above the
T-N connection for your use in grounding the transfer switch..
Three Phase
The standby generator terminals in the A.T.S. are marked
“GENERATOR - G1, G2, G3 and G-N. The “hot” leads G1 G2
and G3 wire directly to the generator side contactor, terminals
G1, G2 and G3. The G-N connection is made to the lug on the
standoff just to the right of the generator side contactor.
The line terminals in the A.T.S. are marked “LINE - L1, L2, L3
and L-N”. The “hot” leads L1, L2 and L3 will wire directly to the
top lugs on the line side contactor. The L-N connection will be
made on the stand-off just to the left of the contactor.
The load terminals in the A.T.S. are marked “LOAD - T1, T2, T3
and T-N”. The “hot” leads T1, T2 and T3 will wire directly to the
lower lugs on the line side contactor. Jumper leads have
already been installed between the lower lugs on the line side
and the lower lugs on the generator side contactors. The T-N
connection will be made on the stand-off just to the left of the
contactor.
An equipment grounding lug is provided just above the
T-N connection for your use in grounding the transfer switch.
All the neutral leads (G-N, L-N and T-N) must be carried through
the A.T.S. These leads are all bonded together within the A.T.S.
and are bonded to GROUND at one common point. If your
system requires an isolated neutral, this neutral to ground bond
can be isolated by removing the copper strap located between
the LINE terminal L-N and the ground lug in the panel. This
action, along with lifting the Neutral to Ground bond in the
generator connection cabinet, will effectively change this unit to a
fully isolated neutral system.
The generator output leads in the generator connection box
follow the same marking pattern. i.e. G1, G-N and G3 on the
single phase and G1, G2, G3 and G-N on the three phase units.
*************
***** WARNING *****
*************
EQUUIPMENT DAMAGE - When installing a Three Phase 240
volt system be sure you know which lead is the high voltage
"wild" leg (208Volt line to neutral). The generator normally carries
the high voltage on the G3 lead.
The load current carrying wires (L) and (T) must be sized to
handle the maximum load current without excessive voltage
drop. By code, the wire must be heavy enough to handle the full
current rating of the main line circuit-breaker (or fuse) in the
entrance (or sub-panel) protecting the contactor switch.
A fused disconnect (circuit breaker or fuses) must be installed
between the engine generator and the A.T.S. panel. See the
table below for disconnect sizing. Failure to install a proper
fused disconnect will void any warranty on the generator end. All
wiring from the engine-generator to the transfer switch must be
of sufficient size to handle the appropriate fused disconnect
amperage.
60706-124
All wires should be installed in rigid or flexible conduit. (Knockouts are provided in the control box)
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60541
Because of the many different types of service, feeder, and
distribution equipment, no specific wiring instructions can be
provided. It is recommended that only copper wire be used. In
all cases it is essential that while the load is connected to the
generator, there can be absolutely no feedback from the
generator to the power line or the power line to the generator.
When properly installed, the normal A.T.S. Control and safety
systems will eliminate all paths for feedback.
To wire the automatic transfer switch into the existing wiring, first
determine which circuits will be on the emergency load circuit. If
the entire load is to be transferred, the transfer switch can be
wired in directly after the watt-hour meter or main entrance.
Providing the service entrance ampere rating is within the
transfer switch’s rated capability.
If only specific circuits are to be powered under emergency
power failure conditions, an additional distribution panel
designated “emergency distribution panel” must be installed.
*************
***** WARNING *****
*************
EQUIPMENT DAMAGE - DC connections between Winco engine
generators and other makes of Automatic Transfer Switches will
vary. The Winco engine generator sets require a relay closure
between Battery Negative (wire #1) and Start ( wire #23) to
operate. The Battery Positive is not used in other A.T.S. panels.
Connecting Battery Positive in any switch other than a Winco can
cause permanent damage to the engine control module
BLOCK HEATER WIRING
A 15 Amp fused power feed is necessary to complete the
installation of the block heater installed on the engine. This
circuit must be wired from an existing breaker box, fed by normal
line power. Do not run this circuit from the transfer switchwiring. These wires should be run in their own conduit, i.e. not
with the power leads or with the control leads.
All selected emergency circuits are removed from main distribution panels and reinstalled in the emergency distribution panel.
Suggested circuits: freezer, refrigerator, furnace, emergency
lights, sump pump, emergency outlet circuits, etc. Total running
load must not exceed generator rating.
D.C. ELECTRICAL INTERCONNECTION
PSS20000LS, PSS35000 and PSS70000
Three control wires are required between the A.T.S. panel and
the generator control terminal box. Depending on the distance,
14 to 16 gauge stranded wire should be used. These wires will
be labeled “Bat +", "Bat -", and "Start".
*************
***** WARNING *****
*************
Be sure both the mode switch on the Engine Generator and the
mode switch in the Automatic Transfer Switch are in the "OFF"
postition before you make any DC interconnections.
The connections to the engine control will be made in a 2" X 4"
connection box mounted on the right hand side of the generator
control box . The wiring from the engine control has already
been stubbed into this connection box for your convenience. The
wires are labeled as follows:
The wiring for the block heater has been terminated in a 2" X 4"
connection box located on the cross rail of the generator frame
on the right hand side. Remove the top cover of this box and you
will find a ground connection point along with two stub leads.
The "hot" lead of the power circuit will be attached to the thermostat/switch mounted in the top cover of the box. The "neutral"
lead will be attached to the other black lead in the connection
box. Use the proper wire nuts to complete this installation.
The water immersion heater is mounted in the engine block.
The thermostat will turn on the heater anytime the air temperature in the enclosure drops below 22 degrees. The thermostat
will turn off the heater anytime the temperature rises above 32
degrees.
INITIAL START UP
*************
***** WARNING *****
*************
EQUIPMENT DAMAGE - DO NOT jump start these engine
generator sets. Starting these units on a low battery or jump
starting them will cause damage to the engine control module.
Use the following check list to verify correct installation before
starting the engine:
The connections in the automatic transfer switch will be made
on a terminal block. This terminal block is located in the lower
right hand corner on the back wall of the switch. The terminals
are labeled BAT + (battery positive), BAT - (battery negative), and
Start (start signal).
These control wires MUST NOT be run in the same conduit as
the AC power leads coming from the generator or the 120 volt
circuit for the block heater.
Page 86054160706-124
1.Engine oil. Fill as required with proper grade/qty.
2.Engine coolant. Fill as required with proper
mixture.
3.Unit mounting base properly bolted down.
4.Clearance for service and maintenance on all
sides.
5.Proper fuel line material and size.
6.All fuel line connections tight.
7.Fuel line protected and a moisture trap installed
(may be required for N.G.).
8.LP/NG pressure O.K. 4-6 Oz. (7-11" Wc).
9.Battery connections clean and tight.
10.Battery fully charged.
11.All A.C. and D.C. wiring installed and properly
protected.
After completing the above checklist, the engine-generator
set is ready for the initial start-up test.
PROCEDURE
Move the selector switch on the engine generator to the “RUN”
position. The engine-generator will crank and start automatically. If the engine fails to start, return selector switch to the
“stop” position and correct the trouble before proceeding.
With the engine running smoothly check the no load voltage and
frequency at meters on the front panel. The voltage should be
240 A.C. and a frequency of 61.5 To 62 hertz (Hz). If you have the
proper voltage at the generator the next step is to check the
voltage at the generator terminals in the Automatic Transfer
Switch. The voltage between the G1 and the G3 terminals should
be the same as it was on the front panel. The voltage should also
be checked between the hot terminals (G1 and G3) and the G-N
to be certain of a balanced voltage output and a solid neutral
connection. The voltage between G1 and G-N should be about
one half of the line to line (G1 to G3) voltage or approximately
120 volts AC. The same approximate voltage should be found
between terminals G3 and G-N (120 volts AC). On three phase
panels the G2 voltage level should also be checked. ON 240
VOLT (DELTA) SYSTEMS BE SURE YOU KNOW WHERE THE
HIGH VOLTAGE "WILD" LEG IS. IT MUST BE IN THE SAME
LOCATION ON THE LINE SIDE AS IT IS ON THE GENERATOR
SIDE. (i.e. if it's on L-3 on the line side it must be on G-3 on the
generator side.
** Notice **
engine generator set. This stop signal will activate the 3 minute
timer circuit and shutdown the unit 3 minutes later.
This completes your installation and unit testing. ALWAYS leave
the system in standby mode unless servicing the unit. For
standby operation, keep both the generator set and transfer
selector switches in the “AUTOMATIC” position.
SETTING THE EXERCISER CLOCK
Setting the current time and date.
1.Position the top right hand (RUN) slide switch to the left
position.
2.Push the clock's "Day Select Button" until the clock displays
a triangle under the number corresponding to the current day of
the week. (Monday is day 1, Sunday is day 7)
3.Push the "Hour Select Button" until the display indicates the
correct time in hours. Note: In the afternoon you should push the
button until a "P" is displayed beside the correct hour.
4.Push the "Minute Select Button" until the display indicates
the correct time in minutes.
5.Position the top right hand (RUN) slide switch to the center
position. The correct time and date should now be displayed.
If for any reason during the check out procedure the voltage and
frequency are not correct, turn the selector switch to the “STOP”
position and correct the trouble before proceeding.
After verifying the that voltage and frequency are correct, turn the
selector switch to the “STOP” position. The unit should shut off
with no time delay. You are now ready to test the automatic start
function.
Move the selector switch on the engine generator set to the
“AUTO” position. Next move the selector switch on the A.T.S.
panel to the “START” position. The unit will go into a 10 second
start delay and then start up. If it fails to start at this time, the DC
interconnection wiring is incorrect. Now when the selector
switch on the A.T.S. is moved to the “DISABLE” position the unit
will go into a 3 minute cool down and then shut off. As long as
line power is still applied to the transfer switch during this test
period the A.T.S. will not transfer the load to the generator.
Next you need to test the complete system. To accomplish this
you will have to fail the incoming line power to the A.T.S. panel.
First move both selector switches to the automatic position.
Then fail the incoming power. All the loads connected to the
A.T.S. should now be dead. The engine generator set will go
into a 10 second start delay. At the end of the start delay the unit
will start-up. As soon as the engine generator set reaches
operating speed the generator side contactor will close and the
load will be applied to the engine generator.
Setting the Exerciser Program:
NOTE: The programs on this clock are grouped. i.e. 1 and 2, 3
and 4, etc. The start time is programed on the odd number and
the stop time is programed on the even number in each program set.
1.Position the top right hand (RUN) slide switch to the right
hand position.
2.Position the top left hand (AUTO) slide switch to the center
postion.
3.Press the "Program Select Button" until No 1 is displayed on
the clock to the right of the time.
4.Push the "Day Select Button" to select the day you want the
engine generator set to start up and run. Note: You can get
more than one triangle displayed on the clock. If this happens
just keep pressing the button and it will work back through the
cycle and display only one traingle under whichever day you
desire.
5.With the "Hour" and "Minute" buttons select the time of day
you want the engine to start up.
6.Press the "Program Select Button" until number 2 is displayed on the clock.
Restoring the line power will cause the generator side contactor
in the A.T.S. to open and the line side to close as soon as the
generator side is open. This sequence is controlled by the
electrical and mechanical interlocks in between the two contactors in the A.T.S. panel. These interlocks ensure that you get a
clean 'break before make' action in the transfer switch.
The restoration of line power also sends a stop signal to the
60706-124
7.Push the "Day Select Button" to select the day you want the
engine to stop. This must be the same day you selected in step
4 above.
Page 9
60541
8.With the "Hour" and "Minute" buttons, select the time you
want the engine to stop. It is recommended you let the engine
run at least 15 minutes during any exercise period.
9.Position the top right hand (RUN) slide switch to the center
(RUN) position.
CLOCK NOTES:
This seven day exerciser clock has seven additional program
cycles available. Always keep in mind the odd number turns the
unit on and the even number shuts the unit off. (i.e. (3 on, 4 off)
(5 on, 6 off) etc.
The relay in the clock will not work unless the transfer switch is
installed and powered up. The clock relay needs 120 volts AC to
operate.
If, when you finish programing the clock, you get an EEEE on the
display, it stands for error. The most common error is that the
day of operation has not been properly set at each step or a
progam has been turned on and not turned off. i.e. programs not
properly grouped 1& 2, 3 & 4, 5 & 6, etc.
On the face of the clock is a small button marked "R". This is a
reset switch. Depressing this switch will remove all programing
in the clock including the time, Use a small screwdriver or the
tip of a pencil to depress this button. This should be used only
as a last resort.
TROUBLESHOOTING TABLES
3.3/4 amp fuse blown inside control module.
4.Defective engine controller.
5.Circuit breaker tripped on engine control.
6.Loose or dirty battery terminals.
7.Defective "Run/Auto" switch on generator.
8.Defective starter.
9.Defective start solenoid.
10.Defective remote start solenoid.
11.Locked up engine genset.
ENGINE CRANKS BUT WILL NOT START
1.Improper fuel pressure being delivered to
unit.
2.Fuel supply shut off.
3.Fuel tank empty.
4.Defective spark plug.
5.Defective engine ignition module.
6.Dirty air cleaner filter.
7.Defective fuel solenoid valve.
ENGINE STARTS AND THEN STOPS AND FAULT LIGHT
COMES ON
1.Engine is low on oil.
2.Engine has high water temperature.
3.Engine has oversped.
4.Engine has gone into overcrank.
5.No output from engine alternator to engage
stop crank circuit.
UNIT WILL NOT CRANK WHEN THE POWER FAILS.
1.Generator control switch not in "AUTOMATIC"
position.
2.Transfer control switch not in "AUTOMATIC"
position.
3.Incorrect wiring between transfer switch and
generator.
4.Defective start stop relay in the transfer
switch.
5.Circuit breaker tripped on engine control.
6.3/4 amp fuse blown inside engine control.
7.Defective engine control module.
8.Loose or dirty battery terminals.
9.Defective "Run/Auto" switch on generator or
transfer switch.
10.Defective starter.
11.Defective start solenoid.
12.Defective remote start solenoid.
ENGINE WILL NOT CRANK WITH GENERATOR
SELECTOR SWITCH IN THE RUN POSITION.
1.Battery dead.
2.DC circuit breaker on control panel tripped.
ENGINE WILL NOT COME UP TO SPEED AFTER IT
STARTS
1.Insufficent fuel volume getting to the unit.
a.Too small of fuel line.
b.Fuel pressure too low/high.
2.Fuel load block needs to be adjusted.
3.Governor is out of adjustment.
4.AC short in generator components.
ATS PANEL WILL NOT TRANSFER TO EMERGENCY
SUPPLY (GENERATOR)
1.No AC generator output from generator.
2.Broken or defective mechanical/electrical
interlocks.
3.Defective holding coil in the generator side
contactor.
4.Wiring error between generator and transfer
switch.
ATS PANEL WILL NOT RETRANSFER TO NORMAL
POWER
1.Proper normal line power not available at line
terminals in ATS panel.
2.Defective holding coil in line side contactor.
3.Broken or defective mechanical/electrical
interlocks.
Page 106054160706-124
NO AC OUTPUT FROM GENERATOR
1.Defective rectifier.
2.Defective surge suppressor.
3.Defective voltage regulator.
4.Defective rotor.
5.Defective stator.
6.Defective excitor rotor.
7.Defective excitor stator.
8.AC short in the output leads.
9.Defective field circuit breaker.
LP/NG FUEL ADJUSTMENTS
4.See your engine manual for governor adjustment procedures.
**** CAUTION ****
EQUIPMENT DAMAGE - Under full load do not adjust the Hz
above 60. If a higher Hz reading is used, as the load is decreased the Hz will go out of upper limits (61 to 62 Hz).
PROPANE (LP)
A generator set factory tested on LP will normally require no
adjustment. If for some unforeseen reason the machine should
require adjustment, follow the above procedure.
**** CAUTION ****
EQUIPMENT DAMAGE - 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 ****
EQUIPMENT DAMAGE - 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.Ensure the unit is operating under an 80 to 100% load or at
the highest anticipated load.
2.Attach a frequency meter to monitor Hz.
Note: On these unit the mixture adjustment is located on the
carburator just behind the fuel inlet hose. This mixture adjustment is a partial turn, lean to rich, load block.
3.Begin making a mixture adjustment, observing the Hz
meter. If the meter begins to drop you have the mixture set too
lean. Adjust the valve in the opposite direction. Adjustments
should be made very slowly. Adjust back and forth until the
highest Hz is achieved. Do not turn the valve richer after the Hz
quits rising. This would cause the engine to run rich. If the Hz is
out of upper or lower limits, a governor adjustment will be
necessary.
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.
NOTE: For conversion to/from liquid withdrawal LP consult the
factory. Additional parts will be required for this conversion.
NATURAL GAS TO PROPANE VAPOR
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 monometer 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.
60706-124
Page 11
60541
PROPANE VAPOR TO NATURAL GAS
1.Turn off fuel supply.
2.Remove the fuel line from the carburetor at the demand
regulator.
3.Invert the regulator so the column is in the upright position.
Remove the cap on the upright column of the regulator. This will
expose the pressure spring adjusting screw. Turn the screw all
the way out (CCW) and then back in (CW) about 8 turns. The
plug should be approximately half way down for initial starting.
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 bottom of the regulator. Connect a
fuel pressure meter or a monometer 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. 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 to 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.
8.You are now ready to make the final fuel mixture adjustment.
Refer to adjustment section in this manual.
Page 126054160706-124
CONTROL PANEL
60706-124
Page 13
60541
HIGH AND LOW WYE
THREE PHASE AC WIRING
Page 146054160706-124
THREE PHASE AC WIRING - DELTA
SINGLE PHASE AC WIRING
60706-124
Page 15
60541
VOLTAGE REGULATOR WIRING
THREE PHASE AND SINGLE PHASE
Page 166054160706-124
60706-124
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60541
Page 186054160706-124
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60541
Page 206054160706-124
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60541
Page 226054160706-124
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Page 23
60541
12 MONTH LIMITED W ARRANTY
WINCO, Incorporated warrants to the original purchaser for 12 months that goods manufactured or
supplied by it will be free from defects in workmanship and material, provided such goods are installed,
operated and maintained in accordance with Winco written instructions.
WINCO’s sole liability, and Purchaser’s sole remedy for a failure under this warranty, shall be limited to
the repair of the product. At WINCO’s option, material found to be defective in material or workmanship
under normal use and service will be repaired or replaced. For warranty service, return the product within
12 months from the date of purchase, transportation charges prepaid, to your nearest WINCO Authorized
Service Center or to WINCO, Inc. at Le Center Minnesota.
THERE IS NO OTHER EXPRESS WARRANTY.
To the extent permitted by law, any and all warranties, including those of merchantability and fitness for a
particular purpose, are limited to 12 months from date of purchase. In no event is WINCO liable for
incidental or consequential damages.
Note: Some states do not allow limitation on the duration of implied warranty and some states do not
allow the exclusion or limitation of incidental or consequential damages, so the above limitations may not
apply in every instance. This warranty gives you specific legal rights which may vary from state to state.
WINCO reserves the right to change or improve its products without incurring any obligations to make
such changes or improvement on products purchased previously.
EXCLUSIONS:
WINCO does not warrant engines, batteries, or other component parts that are warranted by their re-
spective manufacturers.
WINCO does not warrant modifications or alterations which were not made by WINCO, Inc.
WINCO does not warrant products which have been subjected to misuse and/or negligence or have
been involved in an accident.
60541
60706-124
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