Winco ULPSS40E User Manual
PSS30/B
PACKAGE
STANDBY
SYSTEMS
INSTALLA TION AND
OPERATIONS MANUAL
PSS40/E
SAVE THESE INSTRUCTIONS
This manual contains important instructions that
should be followed during installation and maintenance
of the generator and batteries.
Read and understand all instructions in the manual
before starting and operating the generator set.
USING THIS MANUAL
Congratulations on your choice of a Winco generator set.
You have selected a high-quality, precision-engineered
generator set designed and tested to give you years of
satisfactory standby service.
To get the best performance from your new engine generator set, it is important that you carefully read and follow the
operating instructions in this manual.
Should you experience a problem please follow the “Things
To Check” near the end of this manual. The warranty listed
in this manual describes what you can expect from WINCO
should you need service assistance in the future.
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.
MODEL_____________________________________
SERIAL NUMBER____________________________
TABLE OF CONTENTS
INTRODUCTION i
GUIDE TO PRODUCT SAFETY 1
BASIC INFORMATION 2
Description 2
DGC-2020 Engine Control Layout 3
Specification Table 4
PREPARING THE UNIT 5
Unpacking the unit 5
ENGINE GENERATOR INSTALLATION 5
Installation 6
Fuel Line Installation 6
Fuel Pressure Tables 6
LP Liquid Withdrawal 7
Lubrication 7
Coolant 7
Battery Installation 7
Battery Charger/Block Heater Wiring 8
AC Electrical Connections 8
DC Electrical Connections 9
INITIAL START-UP 11
EXERCISER CLOCK 11
TROUBLESHOOTING INFORMATION 12
CHANGING THE FUEL TYPE 12
VOLTAGE REGULATOR WIRING 13
AC WIRING - THREE PHASE
277/480 Volt 14
120/208 Volt 14
120/240 Volt 15
AC WIRING - SINGLE PHASE
120/240 Volt 15
DC SCHEMATIC - WIRING DIAGRAM 16
OUTLINE DRAWING 17
12 MONTH WARRANTY 18
PURCHASE DATE____________________________
DEALER____________________________________
PROPER USE AND 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
Page i
IMPORTANT SAFETY
INSTRUCTIONS
SAVE THESE INSTRUCTION
This manual contains important instructions that
should be followed during installation and maintenance
of the generator and batteries.
Read and understand all instructions in the manual
before starting and operating the generator set.
This engine 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.
************************************************************
************************************************************
WARNING:
WARNING indicates a potentially hazardous situation which, if
not avoided, could result in death or serious injury.
************************************************************
2. FIRE HAZARD - Natural gas and L.P. present a hazard of
possible explosion and/or fire.
a. Do not smoke or use open flame near the generator
set.
b. Keep a fire extinguisher nearby and know its proper use.
Fire extinguishers rated ABC by NFPA are appropriate.
3. DEADLY EXHAUST GAS - Exhaust fumes from any gasoline engine contain carbon monoxide, an invisible, odorless
and deadly gas that must be mixed with fresh air.
a. Operate only in well ventilated areas.
b. Never operate indoors.
c. Never operate the unit in such a way as to allow exhaust
gases to seep back into closed rooms (i.e. through
windows, walls or floors).
4. NOISE HAZARD - Excessive noise is not only tiring, but
continual exposure can lead to loss of hearing.
a. Use hearing protection equipment when working
around this equipment for long periods of time.
b. Keep your neighbors in mind when permanently install-
ing this equipment.
5. CLEANLINESS - Keep the generator and surrounding area
clean.
a. Remove all grease, ice, snow or materials that create
slippery conditions around the unit.
b. Remove any rags or other material that could create
potential fire hazards.
c. Carefully wipe up any gas or oil spills before starting the
unit.
d. Never allow leaves or other flammable material to build
up around the engine exhaust area.
************************************************************
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. ELECTRIC SHOCK - The output voltage present in this
equipment can cause a fatal electric shock. This equipment
must be operated by a responsible person.
a. Do not allow anyone to operate the generator without
proper instruction.
b. Guard against electric shock.
c. Avoid contact with live terminals or receptacles.
d. Use extreme care if operating this unit in rain or snow.
e. Use only three-prong grounded receptacles and
extension cords.
f. Be sure the unit is properly grounded to an external
ground rod driven into the earth.
6. SERVICING EQUIPMENT - All service, including the
installation or replacement of service parts, should be
performed only by a qualified technician.
a. Use only factory approved repair parts.
b. Do not work on this equipment when fatigued.
c. Never remove the protective guards, cover, or recep-
tacle panels while the engine is running.
d. Use extreme caution when working on electrical compo-
nents. High output voltages from this equipment can
cause serious injury or death.
e. Always avoid hot mufflers, exhaust manifolds, and
engine parts. They all can cause severe burns instantly.
f. Installing a generator set is not a “do-it-yourself” project.
Consult a qualified, licensed electrician or contractor.
The installation must comply with all national, state, and
local codes.
g. Always make sure unit is disabled before placing your
hands anywhere near the fan, belts, alternator or water
hoses.
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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 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.
INTRODUCTION AND
DESCRIPTION
With the addition of an Automatic Transfer Switch this packaged
standby system includes all items necessary for a completely
automatic standby power system.
DESCRIPTION
This package power system is designed to automatically provide
standby power to unattended loads during electrical outages.
Upon an interruption of normal electrical service this package
power system's electrical control circuits will automatically start
the engine. The generator will produce electrical power and the
Automatic Transfer Switch (A.T.S.) will automatically transfer the
electrical loads to the engine-generator set. Upon restoration of
normal electrical service the A.T.S. will sense return of the normal
commercial power and retransfer the load back to normal
commercial power source. The engine control circuits shut off the
run signal to the engine generator set.
2) ENGINE/GENERATOR
PSS30- The engine generator set consists of a GM 3.0L, I-4
Industrial, four cylinder, liquid cooled engine equipped to run on
L.P./N.G. fuel. The engine operates at 1800 rpm and frequency
regulation is maintained by the electronic governor within .5
cycles variation, from no load to rated load. The 30,000 watt
(30kW) generator is a single bearing, direct drive, rotating field
design. The generator is connected to the engine flywheel via
flexible drive disks. The engine generator is mounted in a
weather proof enclosure for outside installation. Connection
boxes are provided to all customer connections (both AC output
and DC control). A customer supplied 12 Volt, 650 CCA (BCI
group 24) battery is required to complete the installation. Engine
operation is controlled by a Digital Genset Controller (DGC)
mounted in the engine generator enclosure.
PSS40 - The engine generator set consists of a GM 4.3L ,V-6
Industrial, liquid cooled engine equipped to run on L.P./N.G.
fuel. The engine operates at 1800 rpm and frequency regulation
is maintained by the engine governor within .5 cycles variation, no
load to rated load. The 40,000 watt (40kW) generator is a single
bearing, direct drive, rotating field design. The generator is
connected to the engine flywheel via flexible drive disks. The
engine generator is mounted in a weather proof enclosure for
outside installation. Connection boxes are provided to all
customer connections (both AC output and DC control). A
customer supplied 12 Volt, 650 CCA (BCI group 24) battery is
required to complete the installation. Engine operation is controlled by a Digital Genset Controller (DGC) mounted in the
engine generator enclosure.
** NOTICE **
These units will automatically transfer if a power outage occurs
while running in an exercise mode.
These package power systems consist of two major components:
1) AUTOMATIC TRANSFER SWITCH (UL LISTED)
The Automatic Transfer Switches (A.T.S.) is a wall mount switch
designed for inside installation. A electronic exerciser circuit is
installed in the A.T.S. as standard equipment. The A.T.S. also
contains the power failure sensing circuitry necessary to send a
start/stop signal to the engine generator set. The following is a list
of recommended A.T.S. sizes for each model. Outside switches
as well as additional sizes are available, consult your sales rep
for additional information.
RECOMMENDED
MODEL VOLTAGE ATS AMPERAGE
PSS30-3 120/240 200
PSS30-4 120/208 100
PSS30-17 120/240 100
PSS30-18 277/480 100
PSS40-3 120/240 200
PSS40-4 120/208 200
PSS40-17 120/240 200
PSS40-18 277/480 100
Additional optional A.T.S. sizes are available to meet specific
needs. Contact your local WINCO dealer or the WINCO Sales
Department for a quote.
ENGINE CONTROL MODULE (DGC-2020)
The DGC-2020 Digital Genset Controller provides integrated
engine-genset control, protection, and metering in a single
package. Microprocessor based technology allows for exact
measurement, set point adjustment, and timing functions. Front
panel controls and indicators enable quick and simple DGC-2020
operation. Basler Electric communication software
(BESTCOMSPlus) allows units to be easily customized for each
application. A wide temperature-range liquid crystal display (LCD)
with backlighting can be viewed under a wide range of ambient
light and temperature conditions.
FEATURES
DGC-2020 Digital Genset Controllers have the following features:
• Local and Remote Generator Control
• Engine and Generator Protection
• Programmable Analog Engine Senders
• Programmable Logic
• Automatic Transfer Switch Control (Mains Failure)
• Integrated RS485
• Auto Synchronizing
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FUNCTIONS
DGC-2020 Digital Genset Controllers perform the following
functions:
Generator Protection and Metering
Generator protection guards against over voltage, under voltage,
under frequency, and over frequency. Over current and phase
imbalance protection is available as an option at the time of
manufacture. Each generator protection function has an adjustable pickup and time delay setting. Metered generator parameters include voltage, current, real power (watts), apparent power
(VA), and power factor (PF).
Engine Protection and Metering
Engine protection features include oil pressure and coolant
temperature monitoring, over crank protection, ECU specific
protection elements, and diagnostic reporting.
Metered engine parameters include, oil pressure, coolant
ENGINE CONTROL
MODULE
DGC-2020
temperature, battery voltage, speed, engine load, coolant level
(from ECU), ECU specific parameters, and run-time statistics.
All metering functions are displayed on the liquid crystal display.
The front panel display begins with the SUMMARY SCREEN.
Pressing the Right arrow key will open the MAIN MENU screen.
The MAIN MENU screen consists of METERING and SETTINGS
Summary Screen
Summary screen can be set to standard or scrolling. When set to
standard, only the following are displayed:
• Generator Voltage
• Generator Amperage
• Generator Phase
• Generator Frequency
• Engine Oil Pressure
• Engine Coolant Temperature
• Engine Battery Voltage
A - Liquid Crystal Display. The backlit, 64 by 128 pixel LCD
serves as the local information source for metering, alarms, prealarms, and protective functions. Display operation is maintained
at -20°C. An optional LCD heater maintains display operation at 40°C.
B - Not in Auto Indicator. This red LED lights when the DGC2020 is not operating in Auto mode.
C - Alarm Indicator. This red LED lights continuously during
alarm conditions and flashes during pre-alarm conditions.
D - Supplying Load Indicator. This green LED lights when the
generator current is greater than EPS threshold current.
E - Alarm Silence Push-button. Pressing this button opens the
relay output programmed as the horn output.
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F - Lamp Test Push-button. Pressing this button tests the DGC2020 indicators by exercising all LCD pixels and lighting all LEDs.
G - Auto Push-button and Mode Indicator. Pressing the Auto
button places the DGC-2020 in Auto mode. The green Auto mode
LED lights when Auto mode is active.
H - Off Push-button and Mode Indicator. Pressing this button
places the DGC-2020 in Off mode. The red Off mode LED lights
when the DGC-2020 is in Off mode.
I - Run Push-button and Mode Indicator. Pressing this button
places the DGC-2020 in Run mode. The green Run mode LED
lights when Run mode is active.
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J - Reset Push-button. This button is pressed to cancel a
settings editing session and discard any settings changes. When
pressed, this button also resets the Breaker Management PreAlarms
K - Arrow Push-buttons. These four buttons are used to
navigate through the front panel display menus and modify
settings. The left- and right-arrow buttons are used to navigate
through the menu levels. The right-arrow button is pressed to
move downward through the menu levels and the left-arrow
button is pressed to move upward. Within a level, the up-arrow
and down-arrow buttons are used to move among items within
the menu level. Pressing the down-arrow button moves to items
lower in the list. Pressing the up-arrow button moves to items
higher in the list. During a settings editing session, the up- and
down-arrow buttons are used to raise and lower the value of the
selected setting.
L - Edit Push-button. Pressing this button starts an editing
session and enables changes to the DGC-2020 settings. At the
conclusion of an editing session, the Edit push-button is pressed
again to save the setting changes.
DISPLAY OPERATION
The front panel display is used to make settings changes and
display metering values. Refer to call-outs J, K, and L in text and
illustration for information on changing settings through the front
panel and navigating through the Metering screens. When the
unit is first powered up, the clock may need to be reset. Editing
the clock provides familiarity with the edit process. All programming changes from the front panel are accessed through the edit
key to begin and exit the internal microprocessor program.
Log-in and Permissions
To Log-in, navigate to the SETTINGS, ENTER PASSWORD
screen and press the Edit key. Use the Up/Down arrow keys to
scroll through the characters. Use the Left/Right arrow keys to
enter more characters. The Owner operator password is OP.
Once the password has been entered, press the Edit key to Login. See the key stroke sequence listed below to access the
control and enter the edit mode. A LOGOUT selection now
appears in the list of SETTINGS. To logout, navigate to SETTINGS, LOGOUT and press the Edit key. The LOGOUT selection
is removed from the SETTINGS list.
9) Repeat sequence 5 through 8 for day, minute, second and
DST (Daylight Saving Time.
To finish clock setting, process - Press ‘K’ (left).
The microprocessor is still in the General Settings Edit mode.
Pressing ‘K’ (left) a second time exits the Edit mode and allows
full access to the View Only mode for all control settings and
current status. Any items to be changed are accessed by
pressing ‘K’ (up/down/right or left) to select, ‘L’ (Edit) to change
and ‘K’ (left) to exit.
SPECIFICATIONS
GENERATOR
MODEL WATTS VOLTS AMP HZ PH RPM
PSS30-3 30,000 120/240 125.0* 60 1 1800
PSS30-4 30,000 120/208 104.2** 60 3 1800
PSS30-17 30,000 120/240 90.3** 60 3 1800
PSS30-18 30,000 277/480 45.1** 60 3 1800
PSS40-3 40,000 120/240 166.7* 60 1 1800
PSS40-4 40,000 120/208 138.9** 60 3 1800
PSS40-17 40,000 120/240 120.4** 60 3 1800
PSS40-18 40,000 277/480 60.2** 60 3 1800
*Unity Power Factor - Derate 3.5% per 1000 feet elevation above
sea level.
**Power Factor .8 - Derate 3.5% per 1000 feet elevation above
sea level.
FUEL CONSUMPTION
NG (1,000 BTU/CU FT) L.P. VAPOR (2,520 BTU/CU FT)
MODEL CF/HR BTU/HR #/HR GAL/HR CF/HR BTU/HR
PSS30 432 432,000 20.4 4.9 172 442.049
PSS40 499 498,907 25.0 5.9 210 541.012
L.P. TANK SIZING
Minimum required L.P. Tank size for L.P. Vapor withdrawal
operating at various outside temperatures given in degrees
Fahrenheit (Celsius)
TANK TEMPERATURE
MODEL 60 F(16 C) 30 F(0 C) 0 F(-18 C) -20 F(-29 C)
PSS30 160 Gal 300 Gal 1000 Gal* 2000 Gal*
PSS40 250 Gal. 500 Gal. 1000 Gal.* 2000 Gal.*
*Recommend liquid withdrawal at these temperatures.
Sequence for setting (or resetting) the system clock -
1) Press ‘K’ (right key) for initial set or ‘K’ (left to back up, up /
down) to choose menu item and time/date element to be
changed.
2) Press ‘L’ (Edit) to access change mode to enter Password OP as follows:
2a -Press 'K' (up) to select O
2b -Press 'K '(right) to move cursor
2c -Press 'K' (up) to select P
2d -Press 'L' (Edit) to begin change mode
3) Press ‘K’ (up or down) to choose year
4) Press ‘L’ (Edit) to enter year
5) Press ‘K’ (down) to select month mode
6) Press ‘L’ (Edit) to access month change
7) Press ‘K’ (up or down) to choose month
8) Press ‘L’ (Edit) to enter month
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ENGINE SPECIFICATIONS:
Refer to engine operating and maintenance instructions
** NOTICE **
Regarding Engines - This manual covers the generator portion of
these units. See the separate engine instruction manual for
engine-related problems, detailed engine information and engine
warranty.
** CAUTION **
EQUIPMENT DAMAGE - Be sure to check the engine oil level
frequently as specified in the engine manual.
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