TB2400/E
TB4800/A
TB7200/C
TWO BEARING
GENERATORS
TB7200
INSTALLATION AND
OPERATORS
MANUAL
WINCO INC. • 225 S. CORDOVA AVE. • LE CENTER, MN 56057 • 507-357-6821
SERVICE DEPT. 507-357-6831
wincogen.com
TABLE OF CONTENTS
TESTING POLICY 2
SPECIFICATIONS 3
TB2400/E
TB4800/A
TB7200/C
INTRODUCTION 3
SAFETY 4
IMPORTANT SAFETY INSTRUCTIONS
ANSI SAFETY DEFINITIONS
CALIFORNIA PROPOSITION 65
UNIT CAPABILITIES 5
GENERATOR CONNECTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions that should be followed
during installation and maintenance of the generator. Read and
understand all instructions in the manual before starting and operating
the generator.
USING THIS MANUAL
Congratulations on your choice of a WINCO generator. You have
selected a high-quality, precision-engineered generator designed and
tested to give you years of satisfactory service.
To get the best performance from your new generator, it is important
that you carefully read and follow the operating instructions in this
manual.
STARTING ELECTRIC MOTORS 5
PREPARING THE UNIT 6
UNPACKING
CONNECTING THE LOADS 6
APPLYING THE LOAD
UNIT INSTALLATION 7
PLAN THE INSTALLATION
MOUNTING
TROUBLESHOOTING 8
WIRING SCHEMATICS 9
TB2400
TB4800
TB7200
12 MONTH LIMITED WARRANTY 12
Should you experience a problem please follow the “Troubleshooting
Tables” near the end of this manual. The warranty listed in the 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 your 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 NAME ___________________________________________
DEALER PHONE # ________________________________________
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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 generator is based on engineering tests of typical units,
and is subject to, and limited by, the temperature, altitude, fuel, and
other conditions specied by the manufacturer of applicable engines.
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SPECIFICATIONS
INTRODUCTION
TB2400/E
Watts 2,400
Volts 120
Amps 20
Receptacles (1) NEMA 5-20 Duplex
Moisture Protection IP 23
Generator End
Manufacturer Mecc Alte
Model S15W-85
Capacitor 16 µF
Capacitor Part Number 16346-802
TB4800/A
Watts 4,800
Volts 120/240
Amps 40/20
Receptacles (1) NEMA 5-20 Duplex
(1) NEMA L14-30R
Moisture Protection IP 23
Generator End
Manufacturer Mecc Alte
Model S16W-130/2
Capacitor 25 µF
Capacitor Part Number 16346-612
These generators are a 3600 RPM two-bearing, belt-driven, brushless,
rotating eld design. The generators are self excited and inherently
regulated to +/- (plus or minus) 5% - no load to full rated load. It can be
operated under any load within its rating without being damaged. The
frequency regulation is determined by the sensitivity of the customer
supplied prime mover’s 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 RPM)
TB7200/C
Watts 7,200
Volts 120/240
Amps 60/30
Receptacles (1) NEMA L14-30R
Moisture Protection IP 23
Generator End
Manufacturer Mecc Alte
Model S20W-110/2
Capacitor 35 µF
Capacitor Part Number 16346-312
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SAFETY
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important information that should be understood
and followed before the installation, operation and maintenance of the
generator. Failure to follow the safety instructions in this manual could
result in serious injury or death. Keep this manual available for future
reference.
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.
4. 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 materials that could create a
potential re hazard.
C. Carefully clean up any gas or oil spills before starting the unit.
5.SERVICING EQUIPMENT -
All service, including the installation or replacement of service parts,
should be performed only by a qualied technician.
A. Use only factory approved repair parts.
B. Do not work on this equipment fatigued.
C. Use extreme caution when working on electrical components.
High output voltages from this equipment can cause serious
injury or death.
D. Installing a generator is not a “do-it-yourself” project. Consult
a qualied, licensed electrician or contractor. The installation
must comply with all national, state, and local codes.
CAUTION:
CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may 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.
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 plugs and extension cords.
F. Be sure the unit is properly grounded to an external ground rod
driven into the earth.
2. FIRE HAZARD -
A. Keep a re extinguisher nearby and know its proper use. Fire
extinguishers rated ABC by NFPA are appropriate.
CALIFORNIA PROPOSITION 65
WARNING: This product contains crude oil, gasoline,
diesel fuel and other petroleum products, Antifreeze to
which can expose you to chemicals including toluene
and benzene, Ethylene glycol (ingested) which are
known to the State of California to cause cancer, birth defects or other
reproductive harm and developmental issues.
For more information go to www.P65Warning.ca.gov.
3. NOISE HAZARD -
Excessive noise is not only tiring, but continual exposure can lead to
loss of hearing.
A. Use hearing protection when working around this
equipment for long periods of time.
B. Keep your neighbors in mind when permanently installing this
equipment.
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UNIT CAPABILITIES
STARTING ELECTRIC MOTORS
GENERATOR CONNECTIONS
The TB2400 is designed for 120 Volt alternating current (AC) and has
circuit breaker protected receptacles. Generator full output can be
drawn from the 120 Volt GFCI NEMA 5-20 receptacles, mounted on the
end of the generator.
The TB4800 and TB7200 generators are designed for 120/240 Volt
alternating current (AC) and have circuit breaker protected receptacles.
All three generators can be spun in either direction.
FULL POWER 120 VOLT ONLY
TheTB4800 and TB7200 generators can be converted to full power 120
Volt only. Replacement of the circuit breaker and receptacle is required.
The TB4800, has a 40 Amp 1-Pole circuit breaker. On the TB7200, a 60
Amp 1-pole circuit breaker and a 3-wire 60 Amp twist-lock receptacle is
recommended for full power applications. See wiring schematic below:
240 Volt
Electric motors require much more current (Amps) to start than to run.
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 than to
run them. Capacitor motors are easier to start and usually require 2
to 4 times as much current to start them than to run them. Repulsion
Induction motors are the easiest to start and require 1 1/2 to 2 1/2
times as much current to start them than to run them.
Most fractional horsepower motors take about the same amount
of current to run them whether they are Repulsion Induction (RI),
Capacitor (C), or Split-Phase (SP) type. The chart below shows the
approximate current required to start and run various types and sizes of
120 Volt, 60 cycle electric motors under average conditions.
HP AMPS
RUNNING
SP CAP RI
1/6 3.2 16 TO 22 6 TO 13 5 TO 8
1/4 4.5 22 TO 32 9 TO 8 7 TO 12
1/3 5.2 26 TO 35 10 TO 21 8 TO 17
1/2 7.2 NOT MADE 14 TO 29 11 TO 18
1 13.0 NOT MADE 26 TO 52 20 TO 33
STARTING
AMPS
120 Volt
Check the appliance or tool nameplates for the current and voltage to
ensure compatibility. Although a circuit breaker is provided, damage
due to overloading constitutes abuse and will not be warranted. Refer
to the generator nameplate for unit’s capabilities.
TB4800 - Only 2,400 Watts at 120 Volt (20 Amps) can be taken from
the generator at receptacle A and up to 2,400 Watts at 120 Volts from
receptacle C.
TB7200 - Only 3,600 Watts at 120 Volt (30 Amps) can be taken from
the generator at receptacle A and up to 3,600 Watts at 120 Volts from
receptacle C.
The following diagram represents both the TB4800 and TB7200
generators.
The gures 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.
Self- exciting generators respond to severe overloading differently
that utility power. When over loaded, the engine is not able to supply
enough power to bring electric motor up to operating speed. The
generator responds with high initial starting current, but the engine
speed drops sharply. The overload may stall the engine. If allowed to
operate at very low speeds, the electric motor starting winding will burn
out in a short time. The generator winding may also be damaged.
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PREPARING THE UNIT
CONNECTING THE LOADS
UNPACKING
CAUTION: EQUIPMENT DAMAGE
When you unpack your new generator, be sure to remove all of the
information sheets and manual from the carton.
1. As you receive your unit, it is critical to check it for any damage. If
any damage is noted, it is always easiest to refuse the shipment and
let WINCO take care of the freight claim. If you sign for the unit, the
transfer of the ownership requires that you le the freight claim
2. Before proceeding with the preparations of your new generator
for operation, take a couple of minutes to ensure the unit you have
received is the correct model and review the specication pages in this
manual to ensure that this unit meets your job requirements.
APPLYING THE LOAD
A short warm-up time will permit the engine to work more efciently
when the load is applied and will reduce the wear and extend its life.
CAUTION: EQUIPMENT DAMAGE:
Keep the generator load within the generator and receptacle nameplate
ratings. Overloading may cause damage to the generator and/or loads.
Most electric tools and appliances will have the voltage and amperage
requirements on their individual nameplates. When in doubt, consult
the manufacturer or a local electrician. The nameplate’s amperage
rating for electric motors can be misleading. See “Starting Electric
Motors” in specication section.
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 combination of receptacles
or a single receptacle as long as the receptacle amperage rating is not
exceeded. Both the 120 and 240 Volt output can be utilized at the same
time. See specication section for proper load separation. Overloading
a specic receptacle or winding group can result in damage to the
equipment.
Plug your tools such as drills, saws, blowers, sump pump, and other
items to be powered directly into the generator receptacles. Before
plugging in all of the tools and cord sets, recheck the rating of the
generator. Be sure it can handle the intended load and is compatible
with voltage, phase, and current ratings.
‘Hard Wiring’ this unit directly into a temporary construction site
electrical system is NOT A SIMPLE DO-IT-YOURSELF JOB. For
your safety, all wiring must be done by a qualied electrician and
conform to the National Electric Code and all state and local codes and
regulations. Check with local authorities before proceeding.
WARNING: PERSONAL DANGER
A fully isolated, double pole throw manual transfer switch must be
installed any time a generator is being connected to an existing
distribution system.
CAUTION: EQUIPMENT DAMAGE
Failure to properly limit and balance the load applied to the generator
will cause the generator to produce low voltage and may damage the
generator. It may also cause severe damage to the loads connected to
the generator at that time. Improper loading of the generator constitutes
abuse and will not be covered by warranty.
CAUTION: EQUIPMENT DAMAGE
Low voltage may damage any motors or appliances connected to it.
Running the generator at excessively high speeds result in high voltage
which will also damage electrical devices connected to it. Excessively
high speed may also cause damage to the generator armature
windings.
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UNIT 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 nalizing your installation plans. The installation sequence is
summarized below.
The drive belt system must be of adequate size and must be tight
enough to power the generator without slippage. Be careful not to
over-tighten 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 pulleys will cause excessive belt and pulley wear
and unnecessary stress on the prime mover.
PLAN THE INSTALLATION
Generally, 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 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.
CAUTION: EQUIPMENT DAMAGE
Always allow the generator and prime mover to cool before covering
with a ammable weather covering.
MOUNTING
CAUTION: EQUIPMENT DAMAGE
The generator must be mounted with the engine to a common rigid
base to prevent stress on the engine and generator shafts and
bearings do to vibration displacement. For permanent installations,
the engine-generator is usually mounted on a sub-frame which can be
shock mounted with neoprene pads on the main frame.
Before proceeding with installation, be sure that you have completely
read and understood the assembly and installation instructions.
The following table shows the effect if carious operating speeds and
electrical loads on a typical generator when matched and mounted to
an adequate prime mover.
LOAD VS. OUTPUT
Generator
Load
None 3690 61.5 129V
Half 3600 60.0 120V
Full 3510 58.5 115V
*Note: Required generator speed must be at 3600 +/- 90 RPM under all
load conditions.
Although individual units and models may vary slightly, the normal
voltage and frequency of typical 60 cycle engine-driven generators
described in this manual are approximately as follows when powered
by a typical prime mover (engine) run rst with no load applied, then at
half capacity as rated on the nameplate.
All engines have a tendency to slow down when a load is applied.
The governor on the engine is designed to hold 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 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.
Speed
(RPM)
FREQUENCY
(Hz)
Voltage
An engine with adequate horsepower and a close regulated (xed
speed) governor is required for satisfactory operation of this generator.
About 1.4 horsepower is required to produce 1,000 Watts of generator
output power assuming 100% efciency of both the engine and the
generator. However, due to engine and generator efciencies of 80
to 90%, the loss of power due to engine driving accessories such as
cooling fans, battery charging alternators, etc., friction losses and
slippage in the drive pulleys and belts, the general conservative rule
of thumb allowing approximately two (2) horsepower for every 1,000
Watts of generator output is much more realistic. For example, the
7,200 Watt generator output will require a 14.4 horsepower engine
for full output, good speed/voltage regulation, and satisfactory load
performance. When determining the prime mover/generator pulley
ratio to drive the generator at the correct operating speed, bear in mind
the power rating of most prime movers (usually an engine) varies with
speed. It produces more power at higher speeds, less when slowed.
The prime mover must be fast enough to reach desired horsepower for
good generator operation.
The normal slight variations on 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 at exactly 3600 RPM at
all times. Since this is not usually possible, minor time errors in clock
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.
NOTE: 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 ensure proper operation of
the generator and appliances.
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TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSE(S)
Low voltage 1. Generator operating below correct RPM
2. Generator overloaded
3. Defective stator
4. Defective rotor
Output voltage too high Engine speed too high
Generator overheating 1. Generator overloaded
2. Poor ventilation
No output voltage 1. Short in load
2. Broken or loose wire
3. Defective receptacles
4. Defective capacitor
5. Defective diodes
6. No residual magnetism in generator
7. Defective stator
8. Defective rotor
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WIRING SCHEMATICS
GND
GND
G1
G1
G1
N
N
TB2400
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TB4800
2
N
N
N
G1
G1
G1
G2
G2G2
GND GND
GND
GND
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2
G1
G1
G2
G2
N
N
GND
GND GND
TB7200
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12 MONTH LIMITED WARRANTY
WINCO 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 and applicable codes.
WINCO’s sole liability, and Purchaser’s sole remedy for a failure under this warranty, shall be limited to the repair of the product. At WINCO’s
option, material found to be defective in material or workmanship under normal use and service will be repaired or replaced. For warranty service,
return the product within the warranty period, to your nearest WINCO Authorized Service Center or to WINCO in Le Center Minnesota.
Duration Consumer, Commercial and Rental
Parts & Labor: 12 Months
EXCLUSIONS:
• Normal maintenance consumables or labor.
• This warranty does not cover travel time, mileage or labor for removal or re-installation of WINCO product from its application.
• Normal wear and tear.
• Costs of rental equipment.
• WINCO does not warrant engines. Engines are covered exclusively by the warranties of their respective manufacturers.
• WINCO does not warrant component parts that are warranted by their respective manufacturers.
• WINCO does not warrant modications or alterations which were not made by WINCO.
• WINCO does not warrant products which have been subjected to misuse and/or negligence or have been involved in an accident.
Proof of proper maintenance must be furnished upon request.
THERE ARE NO EXPRESS WARRANTIES OTHER THAN THOSE DESCRIBED HEREIN. THERE ARE NO OTHER WARRANTIES,
EXPRESSED OR IMPLIED, OR OTHERWISE CREATED, INCLUDING BUT NOT LIMITED TO WARRANTIES OF MERCHANTABILITY, OR
WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE.
WINCO is liable for the repair or replacement of the product only and is not liable for incidental or consequential damages as permitted by your
state. This warranty gives you specic legal rights which may vary from state to state.
WINCO INC. • 225 S. CORDOVA AVE. • LE CENTER, MN 56057 • 507-357-6821
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