Winco PSSRA40LS User Manual
PACKAGE
STANDBY
SYSTEMS
PSSRA27LS
PSSRA40LS
INSTALLATION AND
OPERATIONS MANUAL
for UNITS EQUIPPED
WITH BASLER DIGITAL
GENSET CONTROLS
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 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 3
Unpacking the unit 4
ENGINE GENERATOR INSTALLATION 4
Installation 4
Fuel Line Installation 4
Fuel Pressure Tables 5
LP Liquid Withdrawal 5
Lubrication 6
Coolant 6
Battery Installation 5
Battery Charger/Block 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 8
Sequence of Operation 8
EXERCISER CLOCK 10
TROUBLESHOOTING INFORMATION 10
LP/NG CONVERSION 11
Blank 13
AC WIRING - THREE PHASE
277/480 Volt 14
120/208 Volt 14
120/240 Volt 15
AC WIRING - SINGLE PHASE
120/240 Volt 15
VOLTAGE REGULATOR WIRING 16
DC SCHEMATIC - WIRING DIAGRAM 17
INTERNAL GENERATOR CONNECTIONS
PSS27LS 18
PSS40LS 19
OUTLINE DRAWING
PSS40LS 20
PSS27LS 21
12 MONTH WARRANTY 22
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.
60706-159
Page 1
a. Use only factory approved repair parts.
b. Do not work on this equipment when fatigued.
c. Never remove the protective guards, doors, cover, or
receptacle 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.
3127-00
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 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 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 shut off
the fuel supply and the engine ignition system.
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
PSS27LS-3 120/240 230 150
PSS27LS-4 120/208 230 150
PSS27LS-17 120/240 230 150
PSS27LS-18 277/480 * *
PSS40LS-3 120/240 230 230
PSS40LS-4 120/208 230 150
PSS40LS-17 120/240 230 150
PSS40LS-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.
PSS27LS- The engine generator set consists of a GM 3.0L, I-4
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 variation, from no load to rated load. The 27,000 watt
(27kW) 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.
PSS40LS - The engine generator set consists of a GM 4.3L ,V-6
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 engine governor within .5 cycles variation,
no load to rated load. The 40,000 watt (40kW) 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 be 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
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Page 2
60706-159
The following pre-alarm and alarm setting have been programmed in the DCG:
Pre-Alarm Alarm
Low Coolant Temp (Deg F) 70
High Coolant Temp (Deg F) 210 230
Low Oil Pressure 25 PSI 15 PSI
Overspeed N/A 115%
Battery Overvoltage 15 VDC Enabled
Low Battery Voltage 10 VDC Enabled
Weak Battery Voltage 7.5 VDC Enabled
Coolant Temperature Sender Failure Enabled
Oil Pressure Sender Failure Enabled
Magnetic Pickup Failure Enabled
Battery Chager Failure Enabled
Loss Of Generator Voltage Alarm 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:
RUN - Will start the unit locally at the engine generator set and
allow you to proform any necessary checks prior to connecting
your loads.
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 assis-
tance.
** 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
PSS27LS 27,000 120/240 112.5* 60 1 1800
PSS27LS-4 27,000 120/208 94.0* 60 3 1800
PSS27LS-17 27,000 120/240 81.2* 60 3 1800
PSS27LS-18 27,000 277/480 40.6* 60 3 1800
PSS40LS 40,000 120/240 166.7** 60 1 1800
PSS40LS-4 40,000 120/208 138.9** 60 3 1800
PSS40LS-17 40,000 120/240 120.4** 60 3 1800
PSS40LS-18 40,000 277/480 60.2** 60 3 1800
*Derate 11% for Natural Gas operation. Derate 3.5% per
1000 feet elevation above sea level.
**Derate 18% for Natural Gas operation. Derate 3.5% per
1000 feet elevation above sea level.
FUEL CONSUMPTION
STOP - Will disable the engine-generator set making it safe to
preform 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" pushbutton would reset an audio alarm if the control is equipped with
one. These controllers are not.
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
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
PSS27LS 320 320,000 14.1 3.3 120 302,400
PSS40LS 450 450,000 20.0 4.7 170 428,400
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)
PSS27LS 100 Gal 150 Gal 500 Gal* 1500 Gal*
PSS40LS 160 Gal. 300 Gal. 1000 Gal.* 2000 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.
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3127-00
The engine manufacturer has established an excellent worldwide
engine service organization; engine service is available from a
nearby authorized dealer or distributor; check the Yellow Pages
of the telephone directory under “engines,” or ask the dealer from
whom you purchased the power plant.
The rated power of each engine-generator is limited by the
temperature, altitude and all other ambient conditions specified
by the engine manufacturer. Engine power will decrease 3-1/2%
for each 1000 ft. above sea level, and will decrease an additional
1% for each 10 degrees Fahrenheit above 60 degrees Fahrenheit.
UNPACKING 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 to make a
note of the loss or damage on the freight bill, or affix his signature
under the consignee’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.
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 acoustical 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.
“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:
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).
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. must 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.
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.
4. Unit can now be lifted from shipping rails.
3127-00
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.
Page 4
60706-159
*************
***** 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 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.
INSTALLING THE FUEL LINE
** NOTICE **
The engine generator sets are properly adjusted before they
leave the factory for a specific fuel, either NG (natural gas), LP
(liquid propane vapor) or LPG (liquid withdrawal propane). This
fuel type is noted in your model number. If it becomes necessary
to change the fuel type in the field see information on page 11.
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 25 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 secondary 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*
PSS27LS 1" pipe not recommended
PSS40LS 1" pipe use 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 line 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
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 readings 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. 4-6 oz.
STARTING TANK PSI 10-15 lbs 7-11 in 7-11 in
4-6 oz. 4-6 oz.
NO LOAD TANK PSI 10-15 lbs 7-11 in 7-11 in
4-6 oz. 4-6 oz.
FULL LOAD TANK PSI 10-15 lbs 7-11 in 7-11 in
4-6 oz. 4-6 oz.
Natural Gas
134
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.
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3127-00
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 with 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. 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 additional information on engine coolant
requirements see engine manufacturer’s maintenance instructions.
INSTALLING THE BATTERY
**** CAUTION ****
EQUIPMENT DAMAGE - In the following battery installation
procedure, check to be sure the selector switch remains in the
“stop” position.
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: Always 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 monthly to be sure it is above the plates-refill
as required. Never allow the battery plates to be exposed and
never allow a battery to remain in a discharged condition.
CONNECTING THE BATTERY CHARGER &
BLOCKHEATER
A two-stage battery tender is provided on all PSS series generators. This battery tender charges at a rate of 750 mA until the
battery is fully charged and then automatically switches to a 13.2
VDC float charger. The charger has an indicator light on it, red
indicates it is charging, and green indicates it is in the storage
mode (float charge). This charger is mounted on the engine
generator set just below the engine control panel.
** 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.
This battery tender requires a circuit breaker protected AC circuit
from your distribution panel be run out to the engine generator
set. These AC wires can be run in the same conduit as the other
AC leads from the generator. It is suggested that this circuit be
fused for 15 amps, then both the battery charger and the block
heater can be connected to the same circuit. A 120 volt duplex
receptacle is mounted on the generator just below the engine
control panel, the battery tender is shipped already plugged into
the receptacle.
The engine frost plug heater has been prewired with a 120 volt
plug which can be plugged into the other side of the duplex
receptacle after wiring 120 volt power feed to the receptacle. The
frost plug heater has been prewired through a temperature
sensor which will turn the heater on when the air temperature
drops to 22 degrees F. and off when the air temperature reaches
30 Degrees F.
MOUNTING THE AUTOMATIC TRANSFER SWITCH
(Winco Non-UL only)
The automatic transfer switch (A.T.S.) 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.
3127-00
Page 6
60706-159
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