Winco ULPSS40G User Manual
PSS30/D
PSS40/G
DSE7310
PACKAGE
STANDBY
SYSTEMS
INSTALLATION AND
OPERATIONS MANUAL
PSS30-3/C
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____________________________
PURCHASE DATE____________________________
DEALER____________________________________
TABLE OF CONTENTS
INTRODUCTION i
GUIDE TO PRODUCT SAFETY 1
BASIC INFORMATION 2
Description 2
DSE 7310 Engine Control 2
Specification Table 3
PREPARING THE UNIT
Unpacking the unit 3
ENGINE GENERATOR INSTALLATION
Installation 4
Fuel Line Installation 4
Fuel Pressure Tables 5
LP Liquid Withdrawal 5
Lubrication 5
Coolant 5
Battery Installation 6
Battery Charger/Block Heater Wiring 6
AC Electrical Connections 7
DC Electrical Connections 8
ENGINE CONTROL PANEL LAYOUT 9
DSE 7310 CONTROLLER 10
INITIAL START-UP 11
START-UP PROCEDURE 11
EXERCISER CLOCK 12
TROUBLESHOOTING INFORMATION 12
CHANGING THE FUEL TYPE 13
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
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 (DSE 7X10 Series)
The DSE 7310 Series control modules provide integrated engine
and generator set 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 operation.
Fully configurable via PC software, allows units to be easily
customized for each application. Includes selected front panel
programming for on site changes. A wide temperature-range
liquid crystal display (132 x 64) with backlighting can be viewed
under a wide range of ambient light and temperature conditions.
FEATURES
DSE 7310 Control Modules have the following features:
¨ Local and Remote Generator Control
¨ Engine and Generator Protection
¨ CAN Bus compatible
¨ Programmable Logic
¨ Five-key Menu Navigation
¨ Engine Exercise Mode
¨ Automatic Transfer Switch Control (Mains Failure)
¨ User Selectable RS232 & RS485 (Remote Operation)
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FUNCTIONS
DSE 7X10 Series Control Modules perform the following protection and metering functions:
ENGINE SPECIFICATIONS:
Refer to engine operating and maintenance instructions
Generator Protection and Metering
Generator protection includes over voltage, under voltage, under
frequency, over frequency and overload protection. Each generator protection function has an adjustable pickup and time delay
setting. Metered generator parameters include voltage, current,
real power (watts), 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
temperature, battery voltage, speed, engine load, coolant level
(from ECU), ECU specific parameters, and run-time statistics.
** NOTICE **
These units will automatically transfer if a power outage occurs
while running in an exercise mode.
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
** 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.
The engine manufacturer has established an excellent worldwide
engine service organization; engine service is available from a
nearby authorized dealer or distributor; check the Yellow Pages
of the telephone directory under “engines,” or ask the dealer from
whom you purchased the power plant.
The rated power of each engine-generator is limited by the
temperature, altitude and all other ambient conditions specified
by the engine manufacturer. Engine power will decrease 3-1/2%
for each 1000 ft. above sea level, and will decrease an additional
1% for each 10o Fahrenheit above 60o Fahrenheit. Units should
not be operated in ambient temperature greater than 40
o
C.
UNPACKING 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 consignees’s memo of the loss or damage. Contact
the carrier for claim procedures.
When loss or damage is noted after delivery, segregate the
damaged material, and contact the carrier for claim procedures.
“Concealed Damage” is understood to mean damage to the
contents of a package which is not in evidence at the time of
delivery by the carrier, but which is discovered later. The carrier
or carriers are responsible for merchandise lost or damaged in
transit. The title to goods rests with the consignee when generators are shipped FOB factory, and only the consignee can legally
file a claim.
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.
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**** CAUTION ****
EQUIPMENT DAMAGE - These units are shipped with oil, and a
50/50 mix of coolant. Be sure to check all fluid levels before
operating. See engine manufacturer’s instruction manual for
recommended oil requirements before initial starting.
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UNPACKING:
1. Carefully remove the carton.
2. After inspecting the engine-generator for external physical
damage, check for the following items packed inside the
carton:
a. Owner’s manual and wiring diagram.
b. Engine manufacturer’s instruction manual.
3. Remove main frame hold down bolts, (6).
4. Unit can now be lifted from shipping rails.
INSTALLATION
****************
***** WARNING *****
****************
PERSONAL INJURY - Before proceeding with the installation, be
sure the operation selector switch is in the "stop" position.
General Information
Note: Roof access panels have been provide to check/fill the
engine oil and the coolant. Side panels may be removed by
removing the thumb screws on the bottom under side of
each panel
These engine generator sets are for outdoor installation. These
units must be bolted solidly to a concrete pad. The transfer
switch is mounted next to your distribution panel inside the
building. Consult a qualified, licensed electrician or contractor to
install and wire the transfer switch. The installation must always
comply with all national, state, and local codes.
These units should be mounted to allow for ample working room
around it. Units must be installed in accordance with all local,
state and national codes. Consult your local agency having
jurisdiction for specific requirements.
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 or information provided be interpreted to conflict with
any local, state or national codes. If in doubt, always consult your
local fire marshal or gas supplier.
****************
***** WARNING *****
****************
FIRE HAZARD - All fuel runs should be installed by a licensed
fuel supplier.
Connect the fuel supply to the inlet of the fuel solenoid (see table
for recommended line size). The pressure at the secondary
demand regulator must be four to six ounces psi (per square
inch) or 7 to 11 inches W.C. (Water column) for vapor withdrawal
units. On units equipped with liquid withdrawal fuel systems full
tank pressure is plumbed to the fuellock strainer mounted on the
generator rails. The fuel converter mounted on the unit will
handle both vaporization of the fuel and pressure reduction.
INSTALLING THE FUEL LINE
***** CAUTION *****
EQUIPMENT DAMAGE - These units must be mounted on a
solid concrete pad to prevent air from exiting under the unit.
Allowing air to exit under the unit may cause the unit to overheat
from lack of proper air flow.
Before beginning the installation process recheck the rating of the
generator set and its transfer switch rating. Be certain they can
handle the intended load and are compatible with the entrance
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
finalizing your installation plans. For full service switching the
A.T.S. must have a fusible disconnect (circuit breaker) installed
before the switch to protect the contacts.
ENGINE GENERATOR SET MOUNTING
The unit’s main frame should be bolted solidly to a 4 to 6 inch
thick cement pad. The engine-generator is mounted on a subframe which is attached with special shock mounts to the main
frame. This allows the engine-generator free movement without
affecting the control panel which is mounted on the main frame.
Do not shock mount the main frame. Engine vibration will be
transmitted to the control panel causing erroneous start/stop
cycles and premature control failure.
** NOTICE **
The engine generator sets are properly adjusted before they
leave the factory for a specific fuel, either NG (natural gas), LP
(liquid propane vapor) or LPG (liquid withdrawal propane). This
fuel type is noted in your model number. If it becomes necessary
to change the fuel type in the field see information on page 13.
Line Size (vapor system)
Unit location will determine the size of fuel line that is required to
supply the engine with a constant fuel pressure. Refer to the
tables below for fuel line size, fuel consumption and recommended tank size. For distances of 25 feet and 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. A secondary regulator is
installed to further reduce the fuel pressure to the required six (6)
oz operating pressure. This secondary 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 regulator on the unit and the pressure
regulator in the fuel line will interfere with each other. When this
two (2) stage regulator system is used, a fuel line size of 3/4 to 1
inch is generally adequate for distances up to 300 feet from the
primary to the secondary regulator. (Consult your local fuel
supplier for your exact requirements). The appropriate line size
from the table below is then installed from the secondary regulator to the generator set.
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