Winco ULPSS12H4WE User Manual
PACKAGED STANDBY
SYSTEM
INSTALLATION AND
OPERATORS MANUAL
ULPSS12H4W/E
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SAVE THESE INSTRUCTIONS
PROPER USE AND
This manual contains important instructions that
should be followed during installation and maintenance of the generator and battery. Read and
understand all instructions in the manual before
starting and operating the generator set.
USING THE 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 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 “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.
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.
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.
TABLE OF CONTENTS
INTRODUCTION 2
GUIDE TO PRODUCT SAFETY 3
BASIC INFORMATION
Description 4
Specifications 5
PREPARING THE UNIT
Unpacking the Unit 5
GENERATOR SET INSTALLATION
Installation 5
Fuel Installation 6,7
Fuel Conversions 6
Vapor Fuel Pressure Tables
Battery Installation 8
Connecting Battery Charger 11
TRANSFER SWITCH INSTALLATION
AC Electrical Connections 11
DC Electrical Connections 12
INITIAL START UP 13
PREVENTIVE MAINTENANCE 16
TROUBLESHOOTING INFORMATION 17
WIRING DIAGRAMS
AC & DC Generator Schematics 18
UL ATS Wiring Diagram 19
GENERATOR SET OUTLINE 20
GENERATOR SET PAD LAYOUT 21
12 MONTH WARRANTY 22
MAINTENANCE LOG 23
MODEL__________________________________
SERIAL NUMBER_________________________
PURCHASE DATE_________________________
DEALER_________________________________
DEALER PHONE # ________________________
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SAFETY INFORMATION
This 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.
***********************************************************
2. FIRE HAZARD Natural gas and L.P. 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 gen erator 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.
f. Follow local codes for closeness to combust ible material.
3. DEADLY EXHAUST GAS Exhaust fumes from
any gasoline engine contain carbon monoxide, an invisible, oderless and deadly gas that must be mixed
with fresh air.
***********************************************************
WARNING:
WARNING inducates 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.
1. ELECTRICAL SHOCK The output voltage present in this equipment can cause 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-pronged grounded receptacles
and extension cords.
f. Be sure the unit is properly grounded to an
external gound rod driven into the earth.
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, floors).
4. 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 permanent ly installing 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 materials that could
create a potential fire hazard.
c. Carefully clean up any gas or oil spills before
starting the unit.
6. SERVICING EQUIPMENT All service, including the installation or replacement of service parts,
should be preformed 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, covers, or
receptacle panels while the engine is running.
d. Use exteme caution when working on electri cal components. High output voltage from this
equipment can cause serious injury or death.
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e. Always avoid hot mufflers, exhaust manifolds,
and engine parts. They can cause severe
burns instantly.
f. Installing a generator set is not a “Do-it-your self” project. Consult a qualified, licensed elec trician or contractor. The installation must com ply with all national, state, and local codes.
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 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.
These packaged standby systems consist ot two
major components:
1) AUTOMATIC TRANSFER SWITCH
A wall mounted ASCO 165 Automatic Transfer
Switch (ATS) designed for inside installation. The
transfer switch is UL1008 approved. A fourteen day
electronic exerciser circuit is installed in the ATS
as standard equipment. The ATS also contains the
power failure sensing circuitry necessary to start and
stop the engine generator set. The transfer switch is
also equipped standard with a 3 second start delay,
and a 15 second transfer delay to allow the engine
to warm up before transferring the load to the generator. When the line power is restored the ATS has
a 5 minute retransfer delay to allow the incoming utility to stabilize before transferring back to line power
and then an additional 1 minute engine cool down
delay before the engine shuts down. Read and
understand the ATS owners manual before installing,
servicing or operating the transfer switch.
INTRODUCTION AND
DESCRIPTION
The package standby system includes all times
necessary for a completely automatic standby power
system as standard equipment.
DESCRIPTION
The package standby system is designed to automatically provide standby power to unattended
loads during electrical outages. Upon an interruption
of normal electrical service the packaged standby
system electrical control circuits will automatically
start the engine. The generator will produce electrical power and the Automatic Transfer Switch (ATS)
will automatically transfer the electrical loads to the
generator set. Upon restoration of normal electrical service the emergency transfer switch will sense
return of the normal commercial power. The Automatic Transfer Switch will retransfer the load back to
the normal commercial power source. The engine
control circuits will begin a cool-down cycle, after
which the fuel supply will be shut off and the engine
ignition system disabled.
UL Automatic Transfer Switch Sizes
UNIT LINE SIDE GENERATOR
CONTACTOR SIDE CONTACTOR
ULPSS12H4W 100 AMPS 100 AMPS
200 AMPS 200 AMPS
Both the 100 amp and the 200 amp UL Switches are
available in single phase only.
2) ENGINE / GENERATOR
The engine generator set consists of a Honda, twin
cylinder, four cycle air cooled engine. The engine is
factory equipped to run on LP or NG fuel. The engine operates at 3600 rpm and frequency regulation
is maintained by the engine governor within 4 cycles
variation (62.5 Hz - 58.5 Hz) from no load to rated
load. The generator is a brushless, single bearing,
direct drive, rotating field design. The generator is
connnected to the engine’s tapered (quill) crankshaft
extension. The engine generator is mounted in a
drip-proof enclosure for outside installation. Connection boxes and terminal blocks are provided for
all customer connections (both AC output and DC
control). A customer supplied 12 volt 500 CCA (BCI
group 26) battery is required to complete the installation.
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** NOTICE **
This unit will automatically transfer if a power outage
occurs while running in an exercise mode.
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SPECIFICATIONS
**** CAUTION ****
GENERATOR
MODEL WATTS* VOLTS AMPS HZ PH RPM
PSS12 12000 120/240
* Derate 16% for Natural Gas operation. Derate to
7192 watts when operating on Natural Gas pressure
of 4-6 inches water column. Derate 3.5% per 1000
feet elevation above sea level.
50.0 60 1 3600
FUEL CONSUMPTION
NATURAL GAS
1000 BTU/CU FT
CF/HR 190 76.6
BTU/HR 190,000 194,000
GAL/HR N/A 2.1
LBS/HR* N/A 9.0
* Based on full load operation.
LP VAPOR
2520 BTU/CU FT
ENGINE SPECIFICATIONS
Refer to engine operating and maintenance 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 make note of the loss
or damage on the freight bill, or affix his signature
under the consignor’s memo of the loss or damage.
Contact the carrier for claim procedures.
These units are shipped with oil. Be sure to check
oil 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 and trans fer switch for external physical damage, check
for the following items packed inside the carton.
a. Owner’s manual.
b. Engine manufacturer’s instruction manual.
3. Remove main frame hold down bolts. (4)
4. Unit can now be lifted from shipping pallet.
INSTALLATION
General Information
******************
***** WARNING *****
******************
Before proceeding with the installation be sure the
operation selector switch is in the stop position.
These engine generator sets are designed to be
mounted on a concrete pad outdoors only. As an
option a prefab pad may be used as long as proper
attention is paid to site preparation to insure the unit
will not move after installation. The transfer switch is
mounted next to your electrical entrance or distribution panel inside or outside 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.
When loss or damage is noted after delivery, segregate the damaged material, and contact the carrier
for claim procedures. Be sure to retain the packaging material for carrier inspection.
“Concealed Damage” is understood to mean damage to the contents of a package which is not evident at the time of delivery by the carrier, but wheich
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 F.O.B. factory, and only the
consignee can legally file a claim. Please note, most
carriers have a time limit for filing concealed damage
claims.
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Before beginning the installation process check the
rating of the generator set and its transfer switch
rating. Be certain they can handle the intended
load and are compatible with the enterance 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 finializing
your installation plans.
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ENGINE GENERATOR SET MOUNTING
WARNING - Personal Injury
The enclosures on these units can become very
hot adjacent to the exhaust areas. Special care
must be taken when installing these units to
insure that the risk of contact by people is minimized.
The unit’s main frame should be bolted to a four to
six inch thick cement pad. The engine-generator is
mounted on a sub-frame which is isolated with special shock mounts on the main frame. This allows
the engine-generator to vibrate without affecting the
control panel on the main frame. (See page 20).
Do not install any shock mounts between the base
frame and the concrete pad. Engine vibration will be
transmitted to the control panel causing erroneous
start/stop cycles and premature control failure.
These units should be mounted a minimum of
24” from a structure. This will allow for ample
room to maintain and work on the generator set.
Units must be installed in accordance with all local,
state, and national codes. Consult your local agency
having jurisdiction for specific requirements.
These fuel pressures are critical; failure to provide
the proper pressure can cause many problems ranging from a unit that will not start to causing damage
to the fuel system.
These units are normally tested on Natural Gas and
will have a fuel line connected to the NG port on the
fuel outlet tee. If you are going to operate on LP you
will need to move the fuel line from the NG port to
the LP port on the fuel outlet tee. These two ports
have different orifice inserts installed in them, which
provide proper operation with no further adjustments.
When moving the fuel line from one port to the other
be sure not to kink or bend the line. Use a large
sweeping curve as possible and never shorten the
fuel line. For proper operation the fuel line must stay
the same length as it was shipped.
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 and information provided be interpreted to conflict with any local, state
or national codes. If in doubt, always consult your
local fire marshal, gas supplier or building inspector.
******************
***** WARNING *****
******************
FIRE HAZARD - All fuel runs should be installed
by a licensed fuel supplier.
To connect the fuel line to the generator set you will
connect your incoming fuel line to the 3/4 inch NPT
fitting located on the left side of the engine-generator set. This fitting is shipped with a plastic plug
installed to insure the fuel system stays clean.
For all vapor fuel systems the delivery pressure of
the fuel to the fuel solenoid on the unit must be four
to six ounces psi (per square inch) or 7 to 11 inches
W.C. (water column).
INSTALLING THE FUEL LINE
** NOTICE **
The engine generator sets are properly adjusted
before they leave the factory. A tag is attached to
the unit that specifies the fuel, natural gas (NG) or
propane vapor (LP) that the unit was set up and
tested on.
NATURAL GAS or LP VAPOR PIPE SIZE
Size of pipe nomally required for generators operating on NATURAL GAS or LP VAPOR.
Unit location will determine the size of fuel line that
is required to supply the engine with a constant fuel
pressure and volume.
LIQUID PROPANE VAPOR (LP)
Refer to the tables below for fuel line size and recommended tank size. For distances of 100 feet or
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.
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A low pressure regulator is installed to further reduce
the fuel pressure to the required four (4) to six (6) oz.
operating pressure. This low pressure 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.
This is also true for the single low pressure regulators, it should also be a minimum of 10 feet from the
unit. 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 the two (2) regulator system is used on LP, a fuel line size of 1/2 to 5/8
inch is generally adequate for distances up to 300
feet from the primary to the low pressure regulator. (Consult you local fuel supplier for your exact
requirements). The appropriate line size from the
table below is then installed from the low pressure
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 to hazardous fuel
leaks.
**** CAUTION ****
Be careful when sealing gas joints. Excessive sealing compound can be drawn into the solenoid, regu-
lator or carburetor causing an engine malfunction.
FUEL PRESSURE
FEET SIZE OF PIPE
up to 25 FT* 3/4 “ Pipe
25 - 100 FT* 1” Pipe
over 100 FT* Use a two regulator
system.
* Allow an additional 3 feet for each standard
elbow. Do not use ‘street ells’ (restrictive).
NATURAL GAS (NG)
The primary regulator (fuel meter) on the building
should deliver the correct volume and pressure to
the generator set. This regulator must be sized to
deliver the required BTU’s to the generator set and
all other appliances in the building. If the primary
regulator (fuel meter) is a high pressure regulator then a low pressure regulator must be
installed to bring the pressure down to 4-6 oz.
(7-11 inches water column) of pressure. This low
pressure 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 regu-
lator on the unit and the pressure regulator in the
fuel line will interfere with each other. This regulator must be sized to accomidate the demand of the
generator set and any other appliance connected to
it. See table below for the correct size of pipe to be
installed.
LP & NG VAPOR FUEL 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 diagram of a typical LP vapor fuel
installation. Notice the following tables give two
(2) different units of measuring fuel pressure. The
first and most accurate is the use of a simple water
manometer. A manometer is calibrated in inches of
water column. The second is with a pressure gauge
calibrated in ounces per square inch.
FEET SIZE OF PIPE
up to 25 FT* 3/4 “ Pipe
25 - 100 FT* 1” Pipe
over 100 FT* Consult Factory
* Allow an additional 3 feet for each standard
elbow. Do not use ‘street ells’ (restrictive).
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Shown below is a diagram of a natural gas (NG)
installation.
Reference numbers 2 through 4 in the diagram
above are system parts supplied by the customer.
Reference number 4 is on the generator.
Below are tables of the fuel pressure readings at
each reference in the system.
FUEL PRESSURE TABLES
Single Low Pressure Regulator (LP Vapor only)
Natural Gas
REF # 2 3 4
UNIT OFF 2 PSI 7-11 IN
4-6 OZ
STARTING 2 PSI 7-11 IN
4-6 OZ
NO LOAD 2 PSI 7-11 IN
4-6 OZ
FULL
LOAD
2 PSI 7-11 IN
4-6 OZ
7-11 IN
4-6 OZ
7-11 IN
4-6 OZ
7-11 IN
4-6 OZ
7-11 IN
4-6 OZ
LP TANK SIZING
Required LP tank size for LP Vapor withdrawal
operating at various outside temperatures given in
degrees Fahrenheit (Celsius).
TANK TEMPERATURE TANK SIZE
60° F (16° C) 150 GALLON
32° F (0° C) 250 GALLON
0° F (18° C) 500 GALLON
-20° F (-29° C) 1000 GALLON
REF # 1 3 4
UNIT OFF LINE PSI 7-11 IN
4-6 OZ
STARTING LINE PSI 7-11 IN
4-6 OZ
NO LOAD LINE PSI 7-11 IN
4-6 OZ
FULL
LOAD
LINE PSI 7-11 IN
4-6 OZ
7-11 IN
4-6 OZ
7-11 IN
4-6 OZ
7-11 IN
4-6 OZ
7-11 IN
4-6 OZ
Two (2) Regulator System (LP Vapor only)
REF # 1 2 3 4
UNIT
OFF
START-
ING
NO
LOAD
FULL
LOAD
LINE PSI 10-15
LBS
LINE PSI 10-15
LBS
LINE PSI 10-15
LBS
LINE PSI 10-15
LBS
7-11 IN
4-6 OZ
7-11 IN
4-6 OZ
7-11 IN
4-6 OZ
7-11 IN
4-6 OZ
7-11 IN
4-6 OZ
7-11 IN
4-6 OZ
7-11 IN
4-6 OZ
7-11 IN
4-6 OZ
LP/NG FUEL CONVERSION
The ULPSS12H4W/E generator sets have been
tested on NATURAL GAS prior to shipment. If you
are going to use them on LP vapor, follow the procedures in FUEL INSTALLATION. See Page 6.
INSTALLING THE BATTERY
**** CAUTION ****
In the following battery installation procedure, check
to be sure the selector switch remains in the “off”
position. This should be your last step before initial
start-up.
A customer supplied twelve-volt battery is required to
complete the installation. Installation of the highest CCA rated battery, within the correct BCI group
(size), will increase cold weather starting performance. Gel batteries should not be used with the
battery tender installed in the generator enclosure.
Model Voltage BCI Group MINIMUM
CCA Rating
ULPSS12H4W 12 26 500
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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.
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