Winco RP25C User Manual
REDI POWER
MOBILE
DIESEL
RP25/C
INSTALLATION AND OPERATION MANUAL
SAVE THESE INSTRUCTION
This manual contains important instructions that
should be followed during installation and maintenance of the generator and batteries.
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.
PROPER USE AND INSTALLATION
You must be sure your new engine generator set is:
* Properly serviced before starting
* Operated in a well ventilated area
* Exhaust gases are dispersed safely
* Wired by a qualified electrician
* Operated only for its designed purposes
* Used only by operators who understand its operation
* Properly maintained
COPY YOUR MODEL AND SERIAL NUMBER BELOW FOR FUTURE REFERENCE.
TABLE OF CONTENTS
PRODUCT SAFETY 1
SPECIFICATIONS 2
PREPARATION
UNPACKING 2
OIL REQUIREMENTS 2
FUEL REQUIREMENTS 2
COOLANT REQUIREMENTS 3
BATTERY CONNECTIONS 3
CONTROL PANEL LAYOUT & DESCRIPTION
DSE7310 ENGINE CONTROL 4
FRONT PANEL DESCRIPTION 6
RECEPTACLE AND BREAKERS 7
FULL POWER CONNECTIONS 7
CAM-LOCK CONNECTIONS 8
OPERATIONS
OUTPUT VOATAGE TABLE 9
SELECTING THE CORRECT
VOLTAGE 10
START-UP CHECKLIST 10
ELECTRIC STARTING 10
REMOTE STARTING 11
CONNECTING THE LOADS 10
UNIT STORAGE 12
50 CYCLE OPERATION 12
MAINTENANCE 13
PREVENTIVE MAINTENANCE 11
WIRING DIAGRAMS
DC ELECTRICAL SCHEMATIC 14
GENERATOR WIRING 15
SELECTOR SWITCH WIRING 16
CIRCUIT BREAKER WIRING 17
RECEPTACLE PANEL 17
WARRANTY 18
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___________________________________
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GUIDE TO PRODUCT SAFETY
This engine generator set has been designed and
manufactured to insure your personal safety. Improper
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 and in the
manuals.
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CAUTION: Possible Damage to Equipment.
CAUTION notes indicate any condition or practice, which
if not strictly observed or remedied, could result in damage or destruction of the equipment.
************************************************************
************************************************************
WARNING: Personal Danger.
WARNING notes indicate any condition or practice, which
if not strictly observed, could result in personal injury or
possible loss of life.
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ELECTRIC SHOCK - The output voltage present in
1.
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.
2. FIRE HAZARD - Diesel fuel and other fuels always
present a hazard of possible explosion and/or fire.
A. Do not refuel when the engine is running or hot. Allow
the engine to cool at least two minutes before refueling.
B. Keep fuel containers out of reach of children.
C. Do not smoke or use open flame near the generator
set or fuel tank.
D. Keep a fire extinguisher nearby and know its proper
use. Fire extinguishers rated ABC by NFPA are appropriate.
E. Store fuel only in an approved container, and only in a
well-ventilated area.
3. DEADLY EXHAUST GAS - Exhaust fumes from any
internal combustion engine contain carbon monoxide, an
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. Always operate with the housing doors closed to reduce the operational noise level.
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.
A. Use only factory approved repair parts.
B. Do not work on this equipment when fatigued.
C. Never remove the protective guards, cover or receptacle panels while the engine is running. Keep hands away
from all moving parts.
D. Never wear neckties or other loose clothing that can
be caught in moving parts while you are servicing or
operating this equipment.
E. Use extreme caution when working on electrical components. High output voltages from this equipment can
cause serious injury or death.
F. When servicing this unit always avoid hot mufflers,
exhaust manifolds, and engine parts. They all can cause
severe burns instantly.
G. Installing and wiring a mobile diesel generator 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.
7. LIFTING THE EQUIPMENT - When lifting always
make sure that the area under the equipment is kept
clear.
A. Be certain rigging is designed to lift unit safely.
B. Never attempt to lift the equipment unless you are
certain the lifting device has sufficient capacity.
C. Never allow the equipment to swing while suspended.
D. Be certain the supporting structure is adequate to
handle the load.
8. TOWING THE EQUIPMENT - When towing this equipment always use a vehicle large enough for safe operation.
A. Never tow without the safety chains secured.
B. Always use the proper size hitch ball on the vehicle.
C. Never attempt to tow with a vehicle that does not have
side mirrors installed.
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SPECIFICATIONS
GENERATOR SPECIFICATIONS
RP25
KILOWATT 20 kW
KILOVOLT-AMPS (.8 PF)25 kVA
AMPERAGE 277/480 VOLT 3 PHASE 30 AMPS*
120/240 VOLT 3 PHASE 60 AMPS*
120/208 VOLT 3 PHASE 69 AMPS*
120/240 VOLT 1 PHASE 70 AMPS**
*Based on .8 power factor
**Single Phase is limited by the circuit breaker to 150
Amps on the full power terminal block - The
addtional amperage is available through receptacles.
Derate 3% per 1000 feet (305 meters) between 300 feet
(90 meters) and 7,500 feet (2,286 meters) above sea
level. Contact the factory for rating data for operation in
altitudes above 7,500 feet (2,286 meters).
For prime power application (24/7) derate all output rating
by 10%
GENERATOR RESISTANCE
RP25
Generator Make Stamford
Generator Model PI144F
Generator Winding #311
Voltage Regulator AS480
Main Stator 0.265 ohms
Main Rotor 0.708 ohms
Exciter Stator 20.3 ohms
Exciter Rotor 0.201 ohms
ENGINE SPECIFICATIONS
TRAILER/HOUSING
RP25
Capacity 3500 lb.
Fuel Capacity 55 Gallons
Axles Single
Hitch Height Adjustable
Tires P225/75R-15
Tire Pressure 35 psi
Sound Attenuated ULTRA QUIET
Housing Housing Standard
PREPARATION
NOTE: This booklet covers the entire unit, EXCEPT
THE ENGINE. See the engine manufacturer’s operator
manual for specific maintenance and care information regarding the engine. Read ALL instructions in the manuals
provided before attempting to operate the generator set.
UNPACKING
When receiving the unit, be sure to inspect it carefully
for freight loss or damage. Check the nameplate to be
sure it is what you ordered (proper kW, voltage, fuel,
etc.). If you have questions, contact your local authorized
dealer. If you see evidence of loss or damage at the time
of delivery, have the driver sign and describe the loss or
damage in the “memo of loss or damage” section on the
freight bill. Then contact the carrier to get instructions on
filing a claim.
When loss or damage is discovered after the equipment
is delivered, but not seen at the time of delivery, it is referred to as “concealed damage.” Separate any damaged
material and contact the carrier for proper procedures to
file a “concealed damage” claim.
RP25/B
Make Isuzu
Model 4LE1
Fuel Consumption Full Load 1.9 gal/hr
1/2 Load .9 gal/hr
Starting System 12 Volt DC
Fuel Diesel
Oil API CF - CH4
SAE 10W30
8.69 Liters
Oil & Filter Replacement 250 HRS
Coolant 50/50 Mix
2.75 Gallons
Battery 12 Volt (Group 24) 650 CCA*
*Battery is not included.
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OIL REQUIREMENTS
This engine was filled at the factory. Before starting
check the oil level and ensure it is full. If not, refill to the
proper level. See engine manual for proper grade of oil.
OIL QUANTITY US Qt. Liters
RP25 9 8.7
FUEL REQUIREMENTS
See your engine operator's manual for complete type and
fuel grade information.
WARNING -NO BIODIESEL
Filling the Fuel Tank
Standard Trailer - The standard trailer is equipped with
a single 45 gallon fuel tank. Use caution when filling the
tank so as not to overflow the tank into the trailer.
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WARNING PERSONAL DANGER
Never refuel a running engine. Always stop the engine
and allow to cool before refueling.
CAUTION – PERSONAL DANGER
NEVER dispose of a battery in a fire. The battery is capable of
exploding.
Never allow the fuel tank to run completely empty, as air
may enter the fuel system making it necessary to bleed
the engine when restarting.
COOLANT REQUIREMENTS
The cooling system of this engine has been filled at the
factory with a 50% water and 50% ethylene-glycol antifreeze and the proper amount of supplemental coolant
additives. This mixture provides engine protection to -37
degrees F.
When replenishing coolant or changing coolant refer to
your Isuzu engine manual for the proper type and mixture
of water, antifreeze and supplemental coolant additives.
WARNING: EQUIPMENT DAMAGE
Failure to properly follow Isuzu requirements for antifreeze and supplemental coolant additives can lead to
permanent damage to your engine cylinder liner walls.
BATTERY CONNECTION INSTRUCTIONS
WARNING! EQUIPMENT DAMAGE
FAILURE TO PUT THE GENERATOR CONTROL
POWER SWITCH IN THE ‘OFF’ POSITION PRIOR TO
CONNECTING THE BATTERY CABLES) MAY RESULT
IN DAMAGE TO THE ECM (SOLID STATE ENGINE
CONTROL MODULE).
INSTALLING THE BATTERY
A customer supplied twelve-volt battery is required to
complete the installation. Installation of the highest CCA
rated battery, within the correct BCI group, will increase
cold weather starting performance. Gel batteries should
not be used with the battery tender installed in the generator enclosure.
MINIMUM
Model Voltage BCI Group CCA Rating
RP25 12 24 650
Installation and servicing of batteries must be performed
or supervised only by personnel knowledgeable of batteries and the required precautions. Keep unauthorized
personnel away from batteries.
DO NOT open or mutilate the battery. Released electrolyte is
known to be harmful to the skin and eyes and to be very toxic.
These engine generator sets are all NEGATIVE ground.
Be very careful not to connect the battery in reverse
polarity, as this may short circuit the battery charging
system on the engine.
CAUTION – A battery presents a risk of electrical shock and
high short circuit current. The following precautions must be
observed when working with batteries:
1. Remove watches, rings and other metal objects.
2. Use tools with insulated handles.
3. Check both the battery cable ends and the battery
posts to be sure they are free of corrosion.
3. Always connect the battery positive cable first and
then connect the battery negative cable. When
removing the battery cables from the battery reverse
the procedure, disconnect the negative cable first and
then the positive cable.
4. Be sure all connections are tight and coat the terminals and cable end with dialectic grease.
WARNING – The electrolyte is a diluted sulfuric acid that is
harmful to the skin and eyes. It is electrically conductive and
corrosive. The following precautions must always be taken:
* Always wear full eye protection and protective
clothing.
* Where electrolyte contacts the skin, wash off
immediately with water.
* If electrolyte contacts the eyes, flush thoroughly and
immediately with water and seek immediate medical
attention.
* Spilled electrolyte is to be washed down with an acid
neutralizing agent. A common practice is to use a
solution of one pound of bicarbonate of soda (baking
soda) to one gallon of water. The bicarbonate of soda
solution is to be added until the evidence of reaction,
foaming, has ceased. The resulting liquid is to be
flushed with water and the area dried.
DANGER – Explosive Fire Risk
* Never smoke when near batteries
* Do not cause a flame or spark in the battery area
* Always discharge static electricity from your body
before touching batteries by first touching a grounded
metal surface.
When installing or replacing batteries, use the proper
group/size starting battery. The battery should be a
Maintenance Free lead acid design. Deep cycle batteries
will not work for this application.
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SERVICING BATTERIES
Batteries used on these units may over time lose water.
This is especially true if you are using a trickle charger
to maintain your battery. When refilling the battery with
water use only distilled water. Tap water will shorten the
service life of the battery.
Never fill the battery above the fill line. Over filling above
the upper level line may cause the electrolyte to overflow,
resulting in corrosion to the engine or nearby parts. Immediately wash off any spilled electrolyte following the
procedure above..
CAUTION - NEVER ATTEMPT TO JUMP START THIS
ENGINE. If the battery should accidentally become
discharged disconnect the battery cables and recharge
the battery before attempting to start the unit. Boost/jump
starting this unit improperly will result in PERMANENT
DAMAGE TO THE ENGINE CONTROL MODULE (ECM).
crystal display (LCD) with backlighting can be viewed
under a wide range of ambient light and temperature
conditions.
FEATURES
DSE Generator Controllers have the following features:
• Five-key Menu Navigation
• Engine and Generator Protection
• Programmable Analog Engine Senders
• ECU Communications
• Programmable Logic
• Automatic Transfer Switch Control (Mains Failure)
• User Selectable RS232 & RS485 communications
• Multiple configurable inputs & outputs
• Event Log 250 events
• UL/CSA Listed
FUNCTIONS
DSE-7310 Generator Controllers perform the following
functions:
DESCRIPTION AND IDENTIFICATION
1. ENGINE CONTROL MODULE (DSE7310)
The DSE-7310 Automatic Start Control Module provides
integrated engine-genset control, protection, and metering in a single package. Microprocessor based technology allows for exact measurement, set point adjustment,
and timing functions. Front panel controls and indicators
enable quick and simple DSE-7310 operation. Deep Sea
communication software allows units to be easily customized for each application. A wide temperature-range liquid
ENGINE
A
CONTROL
MODULE
DSE-7310
H
Generator Protection and Metering
Generator protection guards against over voltage, under
voltage, under frequency, and over frequency. Over current and phase imbalance protection is available as an
option at the time of manufacture. Each generator protection function has an adjustable pickup and time delay
setting. Metered generator parameters include voltage,
current, real power (watts), apparent power (VA), and
power factor (PF).
K
J
G
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