Winco TB4000, TB1500C, TB6000, TB2400C, TB7200 Owner's Manual

BRUSHLESS

TWO-BEARING

A

Div~sion

of

Technology

Znc

GENERATORS

INSTALLATION, OPERA TION,

and

MAINTENANCE INSTRUC-

TIONS

OWNERS MANUAL

--

-

A

Division

of

-Dy& Techno/oogy

fnc

Read and understand all instructions in the manual
before starting and operating the generator set.

USING THIS MANUAL

Congratulations on your choice of a Wnco 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 WlNCO should you need service assistance
in the future.

TABLE OF CONTENTS

INTRODUCTION

12

MONTH WARRANTY

GUIDETOPRODUCTSAFETY

BASIC INFORMATION

Specification Table
Unit Capabilities
Unpacking the unit

lNSTALLATIONlOPERATlON

Assembly
Plan The Installation
Connecting The Load
Common Problems

PROPER USE AND INSTALLATION

You must be sure your new generator set is:

*

Properly serviced before starting

*

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 HERE

No other WlNCO 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

i

PURCHASE DATE

i

1

DEALER

WINCO,

Inc.

12

Month Limited

Warranty

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 fora failure under this warranty, shall be limited to the repairof the

product. At

WINCO's option, material found to be defective in material or workmanship under normal use andservice

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 WlNCO 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: Somestates do notallowlimitation on the duration ofimplied warrantyandsomestates do notallowthe 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.

WlNCO reserves the right to change or improve its products without incurring any obligations to make such changes
or improvement on products purchased previously.

EXCLUSIONS:

WlNCO does not warrant engines, batteries, or other component parts that are warranted by their respective

manufacturers.

WlNCO does not warrant modifications or alterations which were not made by WINCO, Inc.

GUIDE TO PRODUCT SAFETY

This engine generator set has been designed and manu­factured to allow safe, reliable performance.

Poor

mainte-

L

nance, 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

2.

FIRE HAZARD-Gasolineand otherfuelsalways present
a hazard of possible explosion andlor 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.

DANGER:

DANGER indicates an imminently hazard-

ous situation which,

if

not avoided, will

result

in

death w serious injury. This
signal word is to be limited to the most
extreme situations.

WARNING:

WARNING indicates a potentially hazard-

oussituation which,

if

notavoided, could

result

in

death or serious injury.

CAUTION:

CAUTION indicatesa potentially hazardous

situation which,

if

not avoided, may re-

sult

in

minor or moderate injury. It may
also be used to alert against unsafe
practices.

NOTE:

CAUTION

is

also usedon the unitlabels and

in

this

manual to indicate a situation that

could result

in

serious damage or de-

struction of the equipmentandpossible

personalinjury.

1.

ELECTRIC SHOCK- The output voltage present in this
equipmentcan

causeafatalelectric shock. Thisequip-

ment 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 exten-

L

sion cords.
f. Be sure the unit is properly grounded to an external

ground rod driven into the earth.

3.

DEADLY EXHAUST GAS -Exhaustfumesfrom any gaso­line enginecontain 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 in-

stalling 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

in-

stallation 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. All belts,

pullies andlor drive shafts must have protec­tive guards andlor covers permanently installed by the
assembler.

d. Never remove the protective guards, cover, or recep-

tacle panels while the engine is running.

e. Use extreme caution when working on electrical com-

ponents. High output voltages from this equipment can
cause serious injury or death.

f. Always avoid hot mufflers, exhaust manifolds, and

engine parts. They all can cause severe burns in­stantly.

Page

1

TB

SERIES

BASIC INFORMATION

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 factory tests of
typical units, and is subject to, and limited by the
ambient operating temperature. The generator will
not provide full power output unless driven by a prime
mover of adequate horsepower. The prime mover
(engine or other input power source) horsepower is
also affected by temperature as well as a number of
other factors such as: fuel, altitude, and all other
conditions specified by the prime mover manufacturer.

INTRODUCTION AND DESCRIPTION

The generator is a 3600 rpm two bearing, belt driven,
brushless, revolving field design. The generator is self
excited and inherently regulated to

+I-

(plus or minus)

7%

-

no load to full rated load. It can be operated

under any load within its rating without being dam-

aged. The frequency regulation is determined by the

sensitivity of the customer supplied prime movers'
governor. It is desirable to maintain this speed to

within 3 cycles variation (61.5 Hz

-

58.5

Hz) no load to

full rated load (3690 rpm

-

3510 rprn).

Generator Specifications

MODEL WATS VOLTS AMPS HZ PH RPM

UNIT CAPABILITIES

1. Generator Coni-lections - The diagram below represents
a typical ordinary 4000 watt generator. Only 2000 watts at

120 volts (16.7 Amps) can be taken from the generator at
receptacle A and up to 2000 watts at 120 volts from
receptacle C. On an ordinary generator, CAUTION MUST
BE

EXERCISEDTO PREVENTOVERLOADING EITHER

OF THE 120 VOLT CIRCUITS (A OR C).

CONVENTIONAL DUAL VOLTAGE

120/240 VOLT SCHEMATIC

-

Neutral

A

A

--

E

120

Volts

Gro~nd~k'2$ocles

r\

TYPICAL

4000

WATT GENERATOR

The following currents (measured in amps) are produced at
120

&

240 volts for typical wattage shown.

AMPS AT

120

VOLT

240

VOLT

RECEPTACLE ID

MODEL A C

B

TB1500C 12.5 NIA NIA
TB2400C 20 NIA NIA
TB4000C 16.7 16.7 16.7
TB4000* 16.7 16.7 16.7
TB6000C

2

5 2 5 25

TB6000*

25

2

5

25

TB7200** 30 3 0 30

'Customer connections are made on the back side
of the circuit breaker

** This unit has a junction box rather than recep­tacles. Ref.

"amis the GI lead, Ref. "c" is the G3 lead

and Ref.

"b"

is GI to G3 rating

2. Starting Electric Motors - Electric motors require much
more current (amps) to start them than to run them. Some

motors, particularly low cost split-phase motors, are very

hard to start and require 5 to 7 times as much current to start

them as to run them. Capacitor motors are easier to start

and usually require 2 to 4 times as much current to start
them as to run them. Repulsion Induction motors are the
easiest to start and usually require 1-112 to 2-112 times as
much to start them as to run them.

Most fractional horsepower motors take about the same
amount of current to run them whether they are of Repul­sion-Induction (RI), Capacitor (Cap), or Split-Phase (SP)
type. The chart below shows the approximate current

required to start and run various types of sizes of 120 volt

-

60 cycle electric motors under average load conditions.

TB

SERIES

Page

2

60706-098

BASIC

INFORMATION

RUNNING STARING AMPS

HP AMPS SP CAP

RI

-

116 3.2 16T0 22 6 TO13 ST0 8
114 4.5

22TO32 9T018 7T012
113 5.2 26TO35 10T02 18T017
112 7.2 NOTMADE

14TO2911TO18

1 13.0 NOTMADE 26 TO 52 20 TO 33

The figures given above are for average load such as a
blower or fan. If the electric

motor is connected to a hard
starting load such as an air compressor, it will require
more starting current. If it is connected to a light load, or
no load such as a power saw, it will require less starting
current. The exact requirement will also vary with the
brand or design of the motor.

For 240 volt motors, the "running" current is half as much
as shown for the 120 volt motors of the same size. Some
dual voltage 1201240 volt motors are difficult to start on
240 volts when driven by enginelgenerators and can be
started more easily when connected to operate on 120
volts. This is particularly true of "capacitor start-induction
run" motors. Sometimes a 240 volt motor which cannot
be started on the 240 volt circuit of a

1201240volt generator

can be started on a 120 volt circuit and then auicklv

Generator
Model

Motor Size
(code

"G"

capacitor start)

Trying to start a larger motor or higher code (ie. J or

K)

motor may result in damage to both the generatorand the
electric motor especially

120

volt motors.

UNPACKING INSTRUCTIONS

**

NOTICE

**

When unpacking the generator, 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 a 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.

switched to the 240 volt circuit after it is started.

c his

cai

be done in applications where the motor is manually

When loss or damage is noted after delivery, segre-

controlled and is started under "no load" conditions.

gate the damaged material, and contact the carrier for
claim procedures.

A self-excited generator responds differently to severe
overloading than the power line. To illustrate, suppose

-,

that a 240 volt 10

H.P.

"capacitor start-Induction Run"

motor is connected to the generator. The engine would
not be able to supply enough power to bring the electric
motor up to operating speed. The generator would re­spond with high initial starting current, but the engine
would be very severely overloaded. The speed would
probably drop sharply and possibly stall the engine. If
allowed to operate at very low speeds, the electric motor
startwinding would burn out in a shorttime. The generator
winding might also be damaged.

On the other hand, suppose a smaller electric motor that
requires just a little more output than the generator can
produce is connected to it. It will try to run but will not reach
a high enough speed for the internal centrifugal switch to
disconnect the starting winding. The generator output,
instead of being 120 volts, may drop to 70 or 80 volts.

RUNNING THE GENERA TOR SET UN­DER EITHER OF THESE CONDITIONS

"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 claims.

1. Carefully open carton.

2. After inspecting the generator for external physical

damage, check for the owner's manual (operating

instructions, wiring diagram, parts list) inside the

carton.

2. Remove generator hold down bolts.

4. Unit can now be lifted from shipping base.

****

CAUTION

****

COULD

RESULT IN DAMAGE TO THE

Before proceeding with the installation, be sure that you

GENERATORSTATORAS WELLAS THE

have completely read and understand the assembly

MOTOR WINDING.

and installation instructions.

Because the heavy surge of current required for starting
motors is required for only an instant, the generator will

ASSEMBLY

not be damaged if it can bring the motor up to speed in a

few seconds of time. If difficulty is experienced in starting

1. An engine with adequate horsepower and a close

motors, turn all other electrical loads off and if possible

regulating (fixed speed) governor is required for

L

reduce the load on the electric motor.

satisfactory operation of any alternating current

3.

Motor Starting Ca~acitv - listed below vou will find the

generator.

motor starting ~>~al;ilit~ bf your engine ienerator set.

60706-098

Page

3

TB SERIES

INSTALLATION

These units require approximately two (2) horsepower
for every 1000 watts of generator output. Theoretically
you should be able to produce 1000 watts with

1.4

Horsepower, but this is only possible with 100%

efficiencies in both the engine and the generator.

Between engine and generator efficiencies of only

80%

to 90% and the losses through the drive system the two

horsepower requirement is more realistic.
For example, this 1,500 watt generator output will

require a 3 or 4

h.p. Engine for full output, good speed

I

voltage regulation, and satisfactory load performance.

2. When determining the prime mover I generator pulley
ratio to drive the generator at the correct operating
speed, bear in mind that the power rating of most prime
movers (usually an engine) varies with the speed-that
is, it produces more power at higher speeds, less when
slowed. The prime mover must be run fast enough to
reach the desired horsepower for good generator set
operation.

The drive belt system must be of adequate size and
must be tight enough to power the generator without
slippage. Be careful not to overtighten to the extent that
it puts excessive strain on the

bearings--doing so can
cause bearing failure and other possible damage to the
generator.

Alignment of the generator to the prime mover is
important. Misalignment of the

pullies will cause
excessive belt and pulley wear and unnecessary stress
on the prime mover.

3.

The following table shows the effect of various operating

speeds and electrical loads on a typical generator when
matched and mounted to an adequate prime mover

together with the natural "voltage drop" within the
generator itself due to load current and heating of the
windings, results in a slightly lower voltage than when

--

the generator is running idle.
The normal, slight variations in speed also directly affect

the frequency of the output current. This frequency
variation has no appreciable effect in the operation of
most loads (such as motors, lights and most small
appliances). However, timing devices and clocks will
not keep perfect time unless the engine can keep the
generator running at exactly 3600 rpm at all times.
Since this is not usually possible, minor time errors in
clocks occur.

The speed of the engine is usually adjusted so that the
generator produces proper voltage. If the adjustment is
made "cold", set the voltage a little higher than normal
since it will drop a few volts as the generator warms up.

**"

CAUTION

****

When operating continuously at full load the generator
shell becomes very warm. It will be uncomfortable to
the touch-this is normal for any high performance

inherently regulated generator.

Output voltage should be checked periodically to

insure proper operation of the generating plant and

appliances.

****

CAUTION

"**

-

Low voltage may damage any motors or appliances

connected to it. Running the generator at excessively

high speeds results in too high voltage which will also
damage electrical devices connected to it. Excessively
high speed may also cause damage to the generator
stator windings.

Although individual units and models may vary slightly,
the normal voltage and frequency of typical 60 cycle
generators described in this book are approximately as

follows when powered by a typical prime mover (engine)

run first with no load applied, then at half the generator
capacity and finally when loaded to its full capacity as
rated on the nameplate:

GENERATOR

LOAD SPEED FREQUENCY VOLTAGE
NONE 3690 RPM 61 112 HZ

129VOLTS
HALF 3600RPM 60HZ 120VOLTS
FULL 3510 RPM

58

112

HZ

115VOLTS

****

CAUTION

****

Required generator speed must be maintained at 3600

+I-

90 rpm under all load conditions.

4.All engines have a tendency to slow down when a load
is applied. The governor on the engine is designed to
hold the engine speed nearly constant. When the
electrical load connected to the generator is increased,
the engine is more heavily loaded and as a result the
speed drops slightly. This slight decrease in speed

PLAN THE INSTALLATION

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 as a guide to
finalizing your installation plans. The installation
sequence is summarized below:

Generally these two bearing generators are used on

portable equipment. For best service consider the

following

:

1 .All electrical equipment should be protected from

excessive moisture. Failure to do so will result in
deterioration of the insulation and will result in short
circuits and grounds.

2.

The generator should be installed in a sheltered area. If
the unit must be

left in the open, it should always be

protected with a weather cover such as a tarp or large

-

piece of canvas after each use to keep out water and
dust.

TB

SERIES

P

'age

4

60706-098

BASIC OPERATION

"*

CAUTION

****

Always allow the generator and prime mover to cool

-

before covering with a flammable weather covering.

****

CAUTION

*"*

The generator must be mounted with the engine to a
common rigid base to prevent stress on the engine
and generator shafts and bearings due to
vibration displacement. For permanent installations,
the engine-generator is usually mounted on a

sub­frame which can be shock mounted with special
neoprene pads on the main frame.

CONNECTING THE LOADS

1. Applying The Load - A shortwarm-up time will permit the
engine to work more efficiently when the load is applied
and will reduce the wear and extend its life.

a. Rece~tacles have been Drovided on the control Dane1

pump and other items to be powered directly into
the generator receptacles. Before

plugging in all
the tools and cord sets, recheck the rating of the
generator set. Be sure it can handle the intended load
and is compatible with the voltage, phase, and current
ratings.

f. 'Hard Wiring' this unit directly into a temporary construc-

tion site electrical system is NOT A SIMPLE DO-IT­YOURSELF JOB. For your safety all wiring must be
done by a qualified electrician and conform to the
National Electric Code and comply with all state and
local codes and regulations. Check with local authori­ties before proceeding.

****WARNING""

PERSONAL DANGER A fully isolated, double pole
double throw manual transfer switch must be installed
any time a generator is being connected to an existing
distribution system.

tocohect the loads on the models,

TBI

~OOC,

TB~~OOC,

TB4000C, TB6000C. On the models TB2400, TB4000,

**"CAUTION"*

TB6000 the connections are made on the back side of

EQUIPMENT DAMAGE - Failure to properly limit and bal-

the circuit breakers. The TB7200 has a junction box

ance the load applied to the generator will cause the

mounted on the top of the generator. The loads should

generator to produce low voltage and may damage the

be applied gradually. If a large motor is being started

engine generator set. It may also cause severe damage

or multiple motors are being started, they should be

to the loads connected to the generator at that time.

started individually and the largest should be started

Improper loading of the generator set constitutes abuse

first.

and will not be covered by warranty.

L

**"

CAUTION

****

EQUIPMENT OVERLOAD-Keep the generator load within

the generator and receptacle nameplate rating. Over-

loading may cause damage to the generator

andlor the

loads
b. Most electric tools and appliances will have the voltage

and amperage requirements on their individual name-

plates. When in doubt consult the manufacturer or a

local electrician. The nameplate amperage rating for
electric motors can be misleading. See "Starting Elec­tric Motors" in Specification Section.

c. These engine generator sets are inherently self regu-

lating based on engine speed. The engine governor
will automatically adjust itself to the load. No harm to
the generator will result if it is operated with no load
connected.

d. Proper. utilization amperage is necessary to prevent

damage to either the

receptacleslbreakers or the gen­erator. The generator is a limited source of electrical
power, therefore pay special attention to the receptacle
and generator ratings. The nameplate rating can be

obtained through a combination of receptacles or a
single receptacle as long as the receptacle amperage

rating is not exceeded. Both the 120 and

240volt output
can be utilized at the same time. See Specification
Section for proper load separation.

e. Plug your tools such as drills, saws, blowers, sump

COMMON PROBLEMS

Sometimes problems can be easily solved by checking
a few basic things. Check below before you call or take
your unit to a service center. It could save you time and
money.

Voltage too low

*Engine speed is too low.
*Generator overloaded.
*Defective stator.
*Defective rotor (field).

Circuit Breaker Trips 'Defective load.

*Defective receptacle.

Voltagetoo high

*Engine speed is too high.

Generatoroverheating *Overloaded.

*Insufficient ventilation.

Nooutputvoltage *Short in load (disconnect).

*Broken or loose wire.
*Defective receptacle.
*Defective capacitor.
*Defective diode.
*No residual magnetism in

generator.
*Defective stator.
"Defective rotor (field).

60706-098

Page

5

TB

SERIES

UNMARKED

WIRING DIAGRAMS

EXCl TATlON

WINDING

(STATOR)

LEADS EXCITATION

FIELD RECTIFIERS
COILS

(ROTOR)

CIRCUIT

BREAKERS

A.C. OUTPUT

WINDING

(STATOR)

1

EXClTATlON WINDING

CIRCUIT BREAKER

RECEPTACLES

7

*--

CAPACITOR

UNMARKED

RECTIFIERS

LEADS

COILS

(ROTOR)

EXCITATION WINDING

EXCITATION

UNMARKED

RECTIFIERS

LEADS

COILS

(ROTOR)

CIRCUIT BREAKER

wd

,

rn

A.C. OUTPUT

f

WlNDlNG

120

VOLTS

VOLTS

120

1

kr_,

BREAKER

vOrl

A

Division of

DTL

Dp Techno/ogy fnc

225

South Cordova Avenue

Le Center, Minnesota

56057