PACKAGED STANDBY
SYSTEM
INSTALLATION AND
OPERATORS MANUAL
ULPSS12H4W/E
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1
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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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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.
CAUTION - PERSONAL DANGER
CAUTION - NEVER dispose of a battery in a fire.
The battery is capable of exploding.
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
CAUTION - 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 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 bat tery posts to be sure they are free of corrosion.
4. Always connect the battery positive cable first
and then connect the battery negative cable.
When removing the battery cables from the bat tery reverse the procedure, disconnect the nega tive cable first and then the positive cable.
5. Be sure all connections are tight and coat the
terminals and cable ends with dialectic grease.
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.
BATTERY CHARGING
Units equipped with electric start have a small flywheel charger built into the engine flywheel assembly for recharging the starting battery. This flywheel
charger generates a small AC current that passes
through a rectifier/regulator assembly on the engine
to produce a DC charging current. This circuit is not
designed to be used as a battery charging circuit to
recharge dead batteries.
**** CAUTION ****
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 im
mediately 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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EQUIPMENT DAMAGE - Always connect the positive cable first and the negative cable last. When
disconnecting, remove the negative cable first and
the positive cable last. Failure to connect and disconnect in the proper sequence can cause equipment damage.
Observe polarities: connect the positive (+) battery
terminal to the (+) cable from the engine starter;
the negative (-) battery terminal is connected to the
negative cable (ground) from the engine generator
assembly. All connections must be clean and tight.
Check the electrolyte (fluid) in the battery periodically to be sure it is above the plates. Never allow
the battery to remain in a discharged condition.
**** CAUTION ****
EQUIPMENT DAMAGE - NEVER JUMP START
these units. Doing so will destroy the engine control
module rendering the unit non-operational. Remove
and fully recharge the battery before attempting to
start.
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CONNECTING THE BATTERY CHARGER
AC ELECTRICAL
A two-stage battery tender is provided on all PSS
series generators. This battery tender charges at
a rate of 750 mA until the battery is fully charged
and then automatically switches to a 13.2 VDC float
charger. The charger has an indicator light on it,
red indicates it is charging, and green indicates it is
in the storage mode (float charge). This charger is
mounted on the generator set, located behind an acces cover on the right side of the unit.
The battery tender receptacle is to be powered by
a GFCI circuit and installed in accordane with the
United States National Electric Code. These AC
wires can be run in the same conduit as the the
other AC leads from the generator. It is suggested
that this circuit be fused for 15 amps. Terminal block
connections have been provided in the customer
connection area of the engine generator set. See
Page 10 for diagram.
** NOTICE **
The battery tender is not intended to recharge a battery which has become completely discharged. It is
designed to produce enough current to recharge a
slightly low battery, maintainging it fully charged.
CONNECTIONS
NOTICE - CLASS 1 WIRING METHODS ARE TO
BE USED FOR ALL FIELD WIRING CONNECTIONS TO TERMINALS OF A CLASS 2 CIRCUIT.
******************
***** WARNING *****
******************
A main line circuit breaker has been provided inside
the generator housing. During all wiring installation
make sure the breaker is in the off position and the
generator operators switch is in the off position.
Note: This symbol always indicates
ground where used.
GENERATOR CONNECTIONS
Minimum conductor sizes between the generator
and the ATS. Based on wire type and temperature
rating. Wire has been derated for 40° C ambient
temperatures.
WIRE TEMPERATURE RATING
MOUNTING THE AUTOMATIC
TRANSFER SWITCH (ATS)
******************
***** WARNING *****
******************
EQUIPMENT DAMAGE - Protect the switch from
construction grit and metal chips to prevent malfunction or shortened life of the switch. Contactors
returned for warranty consideration with foreign
materials inside of them will not be warranted.
Before installing the ATS you must first ensure that
the transfer switch is large enough to handle your
complete distribution panel. If you are installing a
100 amp transfer switch the main line circuit breaker
must not be larger than 100 amps. If you have a
125, 150, 200 amp or larger system and want to use
a 100 amp transfer switch, you will not be able to
transfer the complete electrical system. In this case
it will be necessary to install a secondary emergency
distribution panel. NOTE: THE MAXIMUM OUTPUT OF THE GENERATOR IS 50 AMPS AT 240
VOLTS.
CU Connector AL Connector
75° C # 6 AWG # 4 AWG
90° C # 8 AWG # 6 AWG
To gain acces to the customer connections remove
the end door panel opposite the muffler. All AC and
DC connections to the ATS, 120 Volt power connec
tion for battery charger, and battery installation are
made behind this panel. After removing the door
remove the cover over the customer connection box,
using a 7/16 inch open end wrench. See pages 20
and 21 for generator set and pad layout.
Two (2) hot leads, one (1) neutral and (1) ground
lead are required between the generator and the
ATS or distribution panel. The two power leads from
the generator are marked G1 and G3. Next install
two leads, one neutral and one ground lead from the
generator set to the ATS or distribution panel.
In addition to the power leads install a three wire 120
volt, 15 amp circuit from your distribution panel to
the generator. This circuit wll be used to power the
battery charger, optional block heater and optional
battery heater.
-
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The last four wires you will install are the DC control
leads (14 or 16 gauge) for the start circuit in the ATS.
These connections will be discussed later in more
detail.
WINCO UL ATS (ASCO 165)
See the ASCO installation manual for additional
details on proper wiring of the Automatic Transfer Switch.
The standby generator terminals in the ATS are
marked “ALTERNATE L2 & L6”. The “hot” leads
G1 and G3 from the generator are connected to the
terminals L2 & L6.
The normal line power terminals in the ATS are
marked “PREFERRED - L1 & L5”. The “hot” line
power leads are L1 and L3 from your normal power
supply are connected to terminals L1 and L5.
The load terminals in the ATS are marked “LOAD
- L3 & L7”. The leads to the load distribution panel
are connected to terminals L3 & L7.
******************
***** WARNING *****
******************
A service disconnect must be installed in front of the
ATS panel as the ATS is not service enterance rated.
This will alow you to test the generator under load.
Should you ever have to work on the switch, you will
be able to disconnect the power and work on the
switch cold without having the power company pull
your meter.
To wire the automatic transfer switch into the existing wiring, first determine which circuits will be on
the emergency load circuit. If the entire load is to
be transferred, the transfer switch can be wired in
directly after the watt-hour meter and the service
enterance, providing the service enterance ampere
rating is within the transfer switch’s rated capability.
If only specific circuits are to be powered under
emergency power failure conditions, and additional
distribution panel designated “emergency distribution
panel” must be installed.
The neutral leads from all three locations are connected to the isolated terminal lugs on the sidewall
of the cabinet. This terminal block is labeled “NEUTRAL” and the terminal lugs are mounted on red
isolation standoffs.
The ground leads from all locations are connected to
the grounded terminal lugs also located on the side
wall. This set of terminals is labeled “GROUND”.
INSTALLATION NOTES
The load current carrying wires (L) and (T) must be
sized to handle the maximum load current without
excessive voltage drop. By code, the wire must be
heavy enough to handle the full current rating of the
main line circuit breaker (or fuse) in the enterance
(or sub-panel) protecting the contactor switch.
All wires should be installed in rigid or flexible conduit. Because of the many different types of service,
feeder, and distribution equipment, no specific wiring
instructions can be provided. It is, however, recommended that copper wire be used. In all cases it is
essential that while the load is connected to the generator, there can be absolutely no feedback from the
generator to the power line or the power line to the
generator. When properly installed, the normal ATS
control and safety systems will eliminate all paths for
feedback. Check with your local electrical inspector
on applicable local, state and federal codes.
All selected emergency circuits are removed from
main distribution panels and reinstalled in the emergency distribution panel. Suggested circuits: freezer, refrigerator, furnace, emergency lights, sump
pump, emergency outlet circuits, etc. Total running
load must not exceed generator rating.
DC ELECTRICAL
INTERCONNECTION
**** CAUTION ****
Never run the AC and DC wiring in the same conduit.
ASCO 165 UL SWITCH
Your DC connection points in the ASCO 165 UL ATS
are on the terminal block in the upper right hand
corner of the ATS panel. The terminal block (TB7) is
numbered 1 through 9. These terminals will accept
# 22 - # 14 AWG stranded wire. It is recommended
that you use # 16 AWG for distances up to 200 feet.
You need to run four (4) wires from the generator
set to the transfer switch. See table and illustration
on the next page.
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WIRE # PURPOSE RECOMMEND
# 5 Battery Positive Black
# 1 Battery Negative White
# 24 Fuel Solenoid Red
# 22 Start Orange
COLOR
These wire colors are a recommendation only. The
wires terminate on TB7 as follows:
WIRE # COLOR TB7 TERMINAL
# 5 Black # 3
# 1 White # 2
# 24 Red # 4
# 22 Orange # 7
Jumpers will need to be installed as follows:
WIRE # COLOR TB7 TERMINAL
# 5 Black # 3 & # 5
# 5 Black # 5 & # 8
INITIAL START UP
******************
***** WARNING *****
******************
DO NOT jump start these generator sets. Starting
these units on a low battery by jump starting them
will cause damage to the engine control module.
Use the following checklist to verify correct installaion before starting the engine:
� Engine oil. Check level & fill as required with
proper grade/quantity. Refer to engine owners
manual for proper levels and types.
� Unit mounting base properly bolted down.
� Clearance for service and maintenance on all
sides.
� Proper fuel line material and size.
� All fuel line connections tight.
� Fuel line protected and a moisture trap in
stalled (may be required for NG).
� LP/NG pressure OK. 4-6 oz. (7-11 in. WC).
� Battery connections clean and tight.
� Battery fully charged.
� All AC and DC wiring installed and properly
protected.
The following is an optional way to interconnect the
Generator and the Transfer Switch. the wires terminate on TB7 terminal as follows:
WIRE # COLOR TB7 TERMINAL
# 1 White # 2
# 24 Red # 4
# 22 Orange # 7
The following leads are wire-nutted together:
WIRE # COLOR FROM
# 5 Black Generator
# 5 Black TB7 # 3
# 5 Black TB7 # 5
#5 Black TB7 # 8
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After completing the above checklist, the generator
set is ready for the initial start-up test.
START UP PROCEDURE
Engine Generator Set only
Move the left hand toggle switch from OFF to the
ON position. The alarm light should go out. Next
move the right hand toggle witch from the AUTO to
the RUN position. You should hear the fuel solenoid
engage at this time. Next lift the toggle switch to the
START position and hold. The engine starter should
engage and the engine will start. As soon as the engine starts release the toggle switch and it will return
to the run position. If the engine does not start after
15 seconds release the switch and let the starter rest
for 15 seconds and re-attempt to start. If the unit still
will not start, consult the troubleshooting guide in the
back of this manual.
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With the engine running smoothly, check the no load
voltage and frequency at wire # 1 and # 4 (L2 and
L6 in the ASCO ATS) on the generator terminal block
in the ATS. The voltage should be 240 volts plus or
minus nominal. The frequency should be between
61.5 to 62 hertz (Hz). The voltage should also be
checked between the hot terminals (L2 and L6) and
the neutral to be certain of a balanced voltage output
and a solid neutral connection. The voltage should
be about on half of the line to line voltage.
the Automatic Transfer Switch.
******************
***** WARNING *****
******************
PERSONAL INJURY HAZARD - Install front cover
in transfer switch before operation. An electrical system fault could cause a flash and severe personal
injury.
2. Turn on the preferred source (utility) circuit
breaker. The utility source acceptable light should
now come on as well as the transfer switch on utility
light. If these lights fail to come on recheck your
incoming power to insure you have 240 volts nominal. If not, troubleshoot your utility source before
continuing.
3. Turn on the altenate source (generator) curcuit
breaker.
** NOTICE **
If for any reason during the check out procedures
the voltage and frequency are not correct, move the
toggle switch to the “STOP” position and correct the
trouble before proceeding.
After verifying the voltage and frequency are correct, move the right hand toggle switch to the AUTO
position. The unit should shut off with no time delay.
The right hand toggle switch must be left in the
AUTO position for proper operation of the generator. If you leave it in the RUN position the fuel
solenoid will remain open and it will not shutdown
properly after the next exercise period.
Transfer Switch & Engine Generator
This procedure checks the electrical operation of
the automatic transfer switch. If the actual operation
does not follow this procedure, consult the troublshooting section in the transfer switch manual.
1. Move the left hand toggle switch from the OFF
position to the ON position. The alarm light should
go out. The unit is now ready to be operated from
There are two ways to test your transfer switch
operation: WITHOUT a load transfer or WITH a
load transfer.
WITHOUT load transfer (normal exercise)
1. Press and release the
The generator set should start immediately. About
15 seconds the generator (alternate source) accept
able light comes on and stays on.
Push to Test button.
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2. The generator set runs for 20 minutes. The
Transfer Switch does not transfer the load to the
generator set. The Transfer Switch on utility (pre-
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ferred source) light stays on.
3. To bypass the time delay or cancel the test,
press and release the Push to Test button again.
4. The generator set stops and the Generator
acceptacle light goes off.
In order to set and test the exercise circuit the
left hand toggle switch on the generator control
panel must be in the ON position.
SETTING THE EXERCISER CIRCUIT
WITH Load Transfer
1. Press and hold the
the generator (alternate source) acceptable light
comes on and stays on. Then release the button.
This will start up your generator set.
This light indicates that the generator is running and
the output voltage and frequency are within acceptable limits. Under normal conditions this light should
come on in 5 to 10 seconds. If the light does not
come on and stay on a malfunction has occurred.
Either the unit didn’t start or the voltage or frequency
is incorrect. Correct the problem before continuing.
2. About 15 seconds after the generator (alter
nate source) acceptable light comes on, the automatic transfer switch should transfer the load from
the utility to the generator. At that time the Transfer
Switch on generator light should come on.
3. The generator will stay connected to the load
for about 5 minutes at which time the transfer switch
will transfer the load back to the utility. At the time it
transfers back to utility the Transfer Switch on Utility
light should come on and the Transfer Switch on
generator light should go out. To bypass this five
minute time delay you can press and release the
Push to Test button again at any time.
4. After the load retransfers to the utility, the generator will continue to run for about 1 minute (without
a load) and then shut down. The generator acceptable light will go off indicating the generator set has
shut down.
This completes the functional test of the transfer
switch and the generator set. If you want to leave
the generator in the automatic start mode you can
leave the left hand toggle switch on the generator in
the ON position. If you have additional work to do
or don’t want to leave the engine generator set in
the automatic position start mode move the toggle
switch to the OFF position. In the OFF postion the
alarm light will come on and the generator set will
not start or run.
Push to Test button until
-
GENERATOR EXERCISER CIRCUIT
The automatic generator exerciser is configured to
automatically exercise the generator for 20 minutes
once every 14 days.
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Press and release the Automatic Generator Exer-
ciser button. After about 8 seconds the exerciser
light flashes 14 times to indicate that the exerciser
circuit has been set. The number of flashes indicates the number of days until the next exercise
period. This 20 minute period will occur at approximately the same time of the day the button was
pressed.
DISABLING THE EXERCISER CIRCUIT
Press and hold the Automatic Generator Exerciser
button until the light goes off, the light flashes then
goes off.
ENABLING THE EXERCISER CIRCUIT
Press and hold the Automatic Generator Exerciser
button until the light goes off, the light flashes then
goes off. After about 8 seconds the exerciser light
flashes fourteen times to indicate that the exerciser
circuit has be re-enabled.
******************
***** WARNING *****
******************
WITH A TOTAL POWER FAILURE (UTILITY
POWER FAILS AND THE GENERATOR FAILS TO
START AND RUN) THE EXERCISER MUST BE
RESET AFTER THE POWER IS RESTORED.
CLEARING AN “ERROR” CODE
An error codes occurs on the ASCO control board if
the generator set fails to start or there is some other
malfunction. BOTH Transfer Switch lights will be
blinking together. The Automatic Generator Exerciser light will be blinking a number of times then
pause. This number gives the error code reason
from page 8 of the ASCO 165 owner’s manual. To
clear this code press and release the Push to Test
button once. Then troubleshoot the problem according to the ASCO 165 owner’s manual.
This completes your installation and unit testing.
ALWAYS leave the system in automatic mode unless
servicing the unit. For automatic operation, the left
hand toggle switch on the generator control panel
must be left in the “ON” position.
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PREVENTIVE
MAINTENANCE
Reasonable care in preventive maintenance will
insure high reliability and a long life for the generator
set and Automatic Transfer Switch.
*****************
***** WARNING *****
*****************
When performing any type of maintenance on this
equipment make sure the selector switch on the
generator set is in the off position. If you are working in the Automatic Transfer Switch, confirm with a
reliable meter that all power has been disconnected.
AUTOMATIC TRANSFER SWITCH
Clean and inspect the switch once a year. de-energize all power sources, both line and generator set,
then brush and vacuum away any excessive dust
or dirty accumulation. You can at this time with the
contactor de-energized remove the contactor covers
and check the contacts. Make sure contacts are
clean and not burned or pitted.
ENGINE GENERATOR SET
Service the engine in accordance with the engine
manufacturers manual provided with your new
equipment. Routinely remove debris and dirt from
around the inside generator enclosure. Insure that
the air intakes are free from leaves and other debris
at all times.
Clean and inspect battery terminals a least twice a
year. Check the battery water level at least twice a
year also.
Other than keeping the generator set clean and
free of debris there is no other routine or preventative maintenance required, as long as the generator
is run biweekly to keep it dry and in good working
order.
COLD WEATHER OPERATION
Extreme cold weather operation requires special
considerations. Higher CCA batteries are required
for cold weather starting, 650 CCA or larger are recommended. In addition you should consider installing an oil heater kit and a battery warmer for reliable
starting during cold weather.
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TROUBLESHOOTING
ENGINE CRANKS BUT WILL NOT START
TABLES
********************
****** WARNING ******
********************
NEVER JUMP START THESE UNITS.
JUMP STARTING THESE UNITS WITH
LOW OR BAD BATTERIES WILL CAUSE
PERMANENT DAMAGE TO THE ENGINE
CONTROL MODULE.
UNIT WILL NOT CRANK WHEN THE POWER
FAILS.
1. Right generator control toggle switch not in
“AUTO” position.
2. Low or dead battery, must hold 12 volts during
cranking.
3. Incorrect wiring between transfer switch and
generator.
4. Loose or dirty battery terminals
5. Defective “ON/OFF” switch.
6. Defective starter.
7. Defective start solenoid.
8. Defective start/stop control in the transfer
switch.
9. ATS panel in fault from previous run cycle.
10. Blown 3/4 amp fuse on generator control
panel.
11. Blown 10 amp fuse on generator control
panel.
12. Defective starter/fuel solenoid relay(s).
1. Improper fuel pressure being delivered to unit.
2. Fuel supply shut off.
3. Fuel supply empty.
4. Defective spark plug.
5. Defective engine ignition module.
6. Dirty air cleaner filter.
7. Defective fuel solenoid valve.
8. Low voltage from battery to fuel solenoid, must
hold 12 volts during cranking.
9. Oil in the bottom of air cleaner from crankcase
breather.
10. Defective starter/fuel solenoid relay(s).
ENGINE STARTS AND THEN STOPS AND FAULT
LIGHT COMES ON.
1. Engine is low on oil.
2. No AC output from generator to engage stop
crank circuit.
ENGINE WILL NOT COME UP TO SPEED AFTER
IT STARTS
1. Insufficient fuel volume getting to the unit.
a. Fuel line too small.
b. Low fuel pressure.
2. AC short circuit.
3. Wiring to the ATS panel crossed or shorted.
4. Unit is overloaded. Check load amperage.
ATS PANEL WILL NOT TRANSFER TO EMERGENCY SUPPLY (GENERATOR).
1. No AC generator output from generator.
2. See Automatic Transfer Switch Manual.
ENGINE WILL NOT CRANK USING THE AUTO/
RUN/START SWITCH IN GENERATOR.
1. Low or dead battery, must hold 12 volts during
cranking.
2. Blown 3/4 amp fuse on generator control
panel.
3. Blown 10 amp fuse on generator control panel.
4. Loose or dirty battery terminals.
5. Defective “AUTO/RUN/START” switch.
6. Defective starter.
7. Defective start solenoid.
8. Locked up engine generator set.
9. Defective starter/fuel solenoid relay(s).
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ATS PANEL WILL NOT PULL IN ON NORMAL
POWER.
See Automatic Transfer Switch Manual
NO AC OUTPUT FROM GENERATOR
1. Diodes on rotor blown.
2. Defective capacitor(s).
3. Defective rotor.
4. Defective stator.
5. AC short in the output leads.
6. Unit has lost its residual voltage.
7. Rotor loose on engine crankshaft.
8. Low engine speed, must be 3600 RPM.
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AC AND DC GENERATOR SCHEMATIC
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WINCO UL ATS
Complete installation instructions for WINCO UL Automatic Transfer Switches
are contained in the operators manual with each switch. Read the complete
instructions before installing.
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CUSTOMER CONNECTION POINT
All control wires (18-14 AWG) must be torqued to 19 in. lbs.
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ENGINE GENERATOR SET
LAYOUT ULPSS12H4W/E
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PAD LAYOUT
ENGINE GENERATOR SET
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12 MONTH LIMITED WARRANTY
WINCO, Incorporated warrants to the original purchaser for 12 months or 1000 hours
which ever occurs first, 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 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 12 months or 1000 hours which
ever occurs first from the date of purchase, transportation charges prepaid, to your nearest WINCO Authorized Service Center or to WINCO, Inc. at LeCenter 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 or 1000 hours which ever
occurs first, from date of purchase. In no event is WINCO liable for incidental or consequential damages.
Note: Some states do not allow limitation on the duration of implied warranty and some
states do not allow the 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.
WINCO reserves the right to change or improve it products without incurring any obligations to make such changes or improvements on products purchased previously.
EXCLUSIONS:
WINCO does not warrant Engines. Engines are covered exclusively by the warranties
of their respective manufacturers, see enclosed warranties.
WINCO does not warrant Batteries, or Other Component Parts that are warranted by
their respective manufacturers.
WINCO does not warrant modifications or alterations which were not made by WINCO
Inc.
WINCO does not warrant products which have been subjected to misuse and/or negligence or have been involved in an accident.
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DATE
HOURS
MAINTENANCE LOG
ITEM WORK PERFORMED
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225 S. CORDOVA AVE.
LECENTER, MN 56057
507-357-6821
SERVICE DEPT.
507-357-6831
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