Winco PSS75LSA User Manual

PACKAGE
STANDBY
SYSTEMS

PSS50LS/C
PSS75LS/A

INSTALLATION AND

OPERATIONS MANUAL

for UNITS EQUIPPED

WTH BASLER DIGITAL

GENSET CONTROLS

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 standby 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 4

Unpacking the unit 4

ENGINE GENERATOR INSTALLATION 4

Installation 4
Fuel Line Installation 5
Fuel Pressure Tables 5
LP Liquid Withdrawal 6
Lubrication 6
Coolant 6
Battery Installation 6
Battery Charger/Bloack Heater Wiring 6

TRANSFER SWITCH INSTALLATION (NON-UL) 6

AC Electrical Connections 7
DC Electrical Connections 8

TRANSFER SWITCH INSTALLATION (UL) 8

AC Electrical Connections 8
DC Electrical Connections 8

INITIAL START-UP 9
EXERCISER CLOCK 10
TROUBLESHOOTING INFORMATION 10
LP/NG CONVERSION 11
AC WIRING - THREE PHASE

277/480 Volt 12
120/208 Volt 12
120/240 Volt 13

AC WIRING - SINGLE PHASE

120/240 Volt 13

VOLTAGE REGULATOR WIRING 14
DC SCHEMATIC - WIRING DIAGRAM 15
OUTLINE DRAWING 16
12 MONTH WARRANTY 17

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

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.

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.

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.
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.

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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.

g. Always make sure unit is disabled before placing your

hands anywhere near the fan, belts, alternator or water
hoses.

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TESTING POLICY:

2) ENGINE/GENERATOR

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 system
performance and reliability.

DESCRIPTION

This package power system is designed to automatically provide
standby power to unattended loads during electrical outages.
Upon an interruption of normal electrical service this package
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 A.T.S. will sense return of the normal
commercial power and 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 package power systems consist of two major components:

1) WINCO AUTOMATIC TRANSFER SWITCH

(Non-UL model)

The table below shows the different Automatic Switch sizes
typically used with each unit.

CONTACTOR RATING
MODEL VOLTAGE LINE GENERATOR
PSS50LS-3 120/240 230 230
PSS50LS-4 120/208 230 230
PSS50LS-17 120/240 230 230
PSS50LS-18 277/480 * *
PSS75LS-3 120/240 400 320
PSS75LS-4 120/208 400 320
PSS75LS-17 120/240 400 320
PSS75LS-18 277/480 * *
*Special order UL Transfer Switches

These Automatic Transfer Switches (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 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.

PSS50LS- The engine generator set consists of a GM 5.7L V-8
industrial, 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 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
Digital Genset Controller (DGC) mounted in the engine generator
enclosure.

PSS75LS - The engine generator set consists of a GM 5.7L ,
Turbo charged V-8 iIndustrial, 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, no load to rated load. The 75,000 watt (75kW)
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 Digital Genset Controller (DGC) mounted in the
engine generator enclosure.

** NOTICE **

These units will automatically transfer if a power outage occurs
while running in an exercise mode.

Digital Genset Controller

The Digital Genset Controller (DGC) is a programmable engine
control module utilizing the latest technology in digital control.
The DCGs in these units have been programmed to meet the
more sophisticated needs of today's generator users.

The following system settings have been programmed into the
DCG:

Start Delay 10 Seconds
Generator Cranking Style Cycle
Number of Cranking Cycles 3
Cycle Crank Duration 15 Seconds
Crank Disconnect 30% of Rated Speed
Cool Down Timer 5 Minutes
High Coolant Lockout 60 Seconds
Low Oil Pressure Delay 10 Seconds

The following pre-alarm and alarm setting have been pro­grammed in the DCG:

Pre-Alarm Alarm
High Coolant Temp (Deg F) 210 230
Low Oil Pressure 25 PSI 15 PSI
Overspeed N/A 115%

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Battery Overvoltage 15 VDC N/A
Low Battery Voltage 10 VDC N/A
Weak Battery Voltage 7.5 VDC N/A
Coolant Temperature Sender Failure Enabled
Oil Pressure Sender Failure Enabled
Magnetic Pickup Failure Enabled

During normal operation the DGC will continuously display the
engine oil pressure, coolant temperature and the battery voltage
reading. By pressing the "Phase Toggle" push-button you can
toggle through the different phases checking the generator output
and amperage reading on each phase.

The DGC has three operational push-buttons. You can tell which
position has been activated by the LEDs positioned just under the
push-buttons:

SPECIFICATIONS

GENERATOR

MODEL WATTS VOLTS AMP HZ PH RPM
PSS50LS 50,000 120/240 208* 60 1 1800

PSS50LS-4 50,000 120/208 151* 60 3 1800
PSS50LS-17 50,000 120/240 174* 60 3 1800
PSS50LS-18 50,000 277/480 75* 60 3 1800
PSS75LS 75,000 120/240 312** 60 1 1800
PSS75LS-4 75,000 120/208 225** 60 3 1800
PSS75LS-17 75,000 120/240 261** 60 3 1800
PSS75LS-18 75,000 277/480 113** 60 3 1800

*Derate 11% for Natural Gas operation. Derate 3.5% per
1000 feet elevation above sea level.
**Derate 7% for LP operation. Derate 3.5% per 1000 feet
elevation above sea level.

FUEL CONSUMPTION

RUN - Will start the unit locally at the engine generator set and

allow you to perform any necessary checks prior to connecting
your loads.

STOP - Will disable the engine-generator set making it safe to
perform routine maintenance.

AUTO - Will allow the unit to be started from a remote location.
This is the position you will use in conjunction with an Automatic
Transfer Switch. This is also the push-button you depress to
leave the unit in "Standby Mode"

There are three additional LED lights on the panel:
NOT IN AUTO - Indicates that the engine generator set has not

been left in the "AUTO" mode and will not start if there is a line
power failure.

ALARM - This red LED lights continuously during alarm condi­tions and flashes during pre-alarm conditions.

SUPPLYING LOAD - Indicates the generator is supplying more
than 2% of rated current to whatever is connected to it. In such
cases you should not shut the unit down for routine maintenance
or you will disrupt your loads.

There are seven additional push-buttons on this control panel,
only two of them should routinely be used. The "LAMP TEST"
push-button tests the DCG indicator by exercising all LCD
segments and lighting all LEDs. The "ALARM SILENCE" push-
button would reset an audio alarm if the control is equipped with
one. These controllers are not.

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
PSS50LS 725 725,000 36.0 8.5 300 756,000
PSS75LS 1000 1,000,000 43.2 10.2 360 907,200

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)
PSS50LS 500 Gal 1000 Gal 1500 Gal* 5000 Gal*
PSS75LS 500 Gal. 1000 Gal. 2000 Gal.* 5000 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.

** CAUTION **

EQUIPMENT DAMAGE - Be sure to check the engine oil level
frequently as specified in the engine manual.

The last five push-buttons, "Raise/Scroll". "Lower/Scroll",
"Select/Enter", "Previous", and Display Toggle, are not used

during normal operation. These push-buttons allow the service
personnel to gain access to some of the programming and
change it in the field. PLEASE NOTE OPENING UP THE

PROGRAMMING VIA THESE PUSH-BUTTONS AND ENTER­ING AN IMPROPER CODE CAN DISABLE YOUR GENERA­TOR. If you should push one of these push-buttons by mistake

and get the programming opened up, back out of it by depressing
the display toggle. If it should become necessary to change the
baseline setting programmed into this controller please contact
the WINCO Inc. Service Department at 507-357-6831 for
assistance.

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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.

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UNPACKING INSTRUCTIONS

***** CAUTION ****

** 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 consignees’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 - These units 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.

UNPACKING:

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 fusible disconnect (circuit
breaker) 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 attached with special shock mounts to 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.

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 and wiring diagram.
b. Engine manufacturer’s instruction manual.

3. Remove main frame hold down bolts, (4).

4. Unit can now be lifted from shipping rails.

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 an unhoused, 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.

The unit should be mounted to allow for ample working room
around it. A general rule to follow is three (3) feet of clearance on
all sides.

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
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 fuellock strainer mounted on the
generator rails. The fuel converter mounted on the unit will
handle both vaporization of the fuel and pressure reduction.

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