Winco RP55 User Manual
OWNERS MANUAL
INSTALLATION AND OPERATION MANUAL
60706-200
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
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
DGC-2020 ENGINE CONTROL 4
FRONT PANEL DESCRIPTION 6
RECEPTACLE AND BREAKERS 7
FULL POWER CONNECTIONS 8
OPERATIONS
SELECTING THE CORRECT
VOLTAGE 8
START-UP CHECKLIST 9
ELECTRIC STARTING 9
REMOTE STARTING 9
CONNECTING THE LOADS 10
UNIT STORAGE 11
50 CYCLE OPERATION 11
MAINTENANCE 11
PREVENTIVE MAINTENANCE 11
WIRING DIAGRAMS
DC ELECTRICAL SCHEMATIC 12
SHORE POWER 13
GENERATOR WIRING 14
SELECTOR SWITCH WIRING 15
CIRCUIT BREAKER WIRING 16
RECEPTACLE PANEL 17
WARRANTY 18
COPY YOUR MODEL AND SERIAL NUMBER
BELOW FOR FUTURE REFERENCE.
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___________________________________
Page i
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.
************************************************************
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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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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.
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.
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 standby 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.
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).
7190-00
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
ENGINE SPECIFICATIONS
GENERATOR SPECIFICATIONS
RP55
KILOWATT 45 kW
KILOVOLT-AMPS (.8 PF)56 kVA
AMPERAGE 277/480 VOLT 3 PHASE 68 AMPS*
120/240 VOLT 3 PHASE 135 AMPS*
120/208 VOLT 3 PHASE 150 AMPS*
120/240 VOLT 1 PHASE 188 AMPS**
*Based on .8 power factor
**Single Phase is limited by the circuit breaker to 150
Amps on the full power terminal block - The additional
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%
RP80
KILOWATT 65 kW
KILOVOLT-AMPS (.8 PF)80 kVA
AMPERAGE 277/480 VOLT 3 PHASE 98 AMPS*
120/240 VOLT 3 PHASE 195 AMPS*
120/208 VOLT 3 PHASE 225 AMPS*
120/240 VOLT 1 PHASE 233 AMPS**
*Based on .8 power factor
**Single Phase is limited by the circuit breaker to 225
Amps on the full power terminal block - The additional
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%
See Iveco Operation and Maintenance Manual for complete engine specifications.
TRAILER/HOUSING
RP55/RP80
Capacity 7000 lb.
Fuel Capacity 110 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.
GENERATOR RESISTANCE
RP55 RP80
Generator Make Stamford Stamford
Generator Model UCI224E UCI224F
Generator Winding #311 #311
Voltage Regulator SX460 SX460
Main Stator 0.05 ohms 0.033 ohms
Main Rotor 0.69 ohms 0.83 ohms
Exciter Stator 20 ohms 20 ohms
Exciter Rotor 0.156 ohms 0.156 ohms
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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
RP55 12 12.8
RP80 12 12.8
FUEL REQUIREMENTS
See your engine operator's manual for complete type and
fuel grade information.
WARNING -NO BIODIESEL
7190-00
Filling the Fuel Tank
Standard Trailer - The standard trailer is equipped with a
single 110 gallon fuel tank. Use caution when filling the
tank so as not to overflow the tank into the trailer.
WARNING PERSONAL DANGER
Never refuel a running engine. Always stop the engine
and allow to cool before refueling.
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.
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.
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 Iveco engine manual for the proper type and mixture
of water, antifreeze and supplemental coolant additives.
WARNING: EQUIPMENT DAMAGE
Failure to properly follow Iveco 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 ENGINE CONTROL SWITCH IN
THE ‘OFF’ POSITION PRIOR TO CONNECTING THE
BATTERY CABLE(S) MAY RESULT IN DAMAGE TO
THE ECM. (SOLID STATE ENGINE CONTROL MODULE).
CAUTION – PERSONAL DANGER
NEVER dispose of a battery in a fire. The battery is capable of
exploding.
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:
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
RP55 12 24 650
RP80 12 24 650
7190-00
* 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.
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60706-200
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.
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.
ENGINE CONTROL
MODULE
DGC-2020
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).
DESCRIPTION AND IDENTIFICATION
1. ENGINE CONTROL MODULE (DGC-
2020)
The DGC-2020 Digital Genset Controller 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 DGC-2020 operation. Basler Electric communication software (BESTCOMSPlus) allows
units to be easily customized for each application. A wide
temperature-range liquid crystal display (LCD) with backlighting can be viewed under a wide range of ambient light
and temperature conditions.
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FEATURES
DGC-2020 Digital Genset Controllers have the following
features:
• Local and Remote Generator Control
• Engine and Generator Protection
• Programmable Analog Engine Senders
• ECU Communications via SAE J1939
• Programmable Logic
• Automatic Transfer Switch Control (Mains Failure)
• Integrated RS485
• Auto Synchronizing
FUNCTIONS
DGC-2020 Digital Genset Controllers perform the following
functions:
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
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