Winco ULPSS8B4WE User Manual
PACKAGED STANDBY
SYSTEM
INSTALLATION AND
OPERATORS MANUAL
ULPSS8B4W/E
11045-00 60706-210
1
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
ENGINE GENERATOR INSTALLATION
Installation 5
Fuel Installation 6
Vapor Fuel Pressure Tables 7
Fuel Conversions 8
Lubrication 8
Battery Installation 8
Connecting Battery Charger 9
TRANSFER SWITCH INSTALLATION
AC Electrical Connections 11
DC Electrical Connections 12
PREVENTIVE MAINTENANCE 15
TROUBLESHOOTING INFORMATION 16
WIRING DIAGRAMS
AC & DC Generator Schematics 17
UL ATS Wiring Diagram 18
GENERATOR SET OUTLINE 19
GENERATOR SET PAD LAYOUT 20
GENERATOR WINDING DATA 21
12 MONTH WARRANTY 22
MAINTENANCE LOG 23
MODEL__________________________________
SERIAL NUMBER_________________________
PURCHASE DATE_________________________
DEALER_________________________________
DEALER PHONE # ________________________
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60706-210
SAFETY INFORMATION
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.
***********************************************************
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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3
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
engine-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
ULPSS8B4W 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 Briggs &
Stratton Vanguard, 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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60706-210
SPECIFICATIONS
GENERATOR
MODEL WATTS* VOLTS AMPS HZ PH RPM
PSS8 8000 120/240 33.0 60 1 3600
* Derate 10% for Natural Gas operation. Derate to
6000 watts when operating on Natural Gas pressure
of 4-6 inches water column. Derate 3.5% per 1000
feet elevation above sea level.
“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.
**** CAUTION ****
FUEL CONSUMPTION
NATURAL GAS
1000 BTU/CU FT
CF/HR 132 63
BTU/HR 132,000 158,760*
GAL/HR N/A 1.6
LBS/HR* N/A 6.7
* Based on full load operation.
LP VAPOR
2520 BTU/CU FT
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) 150 GALLON
0° F (18° C) 250 GALLON
-20° F (-29° C) 500 GALLON
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.
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.
11045-00 60706-210
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
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***** 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.
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.
5
ENGINE GENERATOR SET MOUNTING
WARNING - Personal Injury
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.
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.
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.
These units are normally tested on Natural Gas and
will have a tag hanging on the fuel hose indicating
on what fuel your unit was factory tested. If you are
running on LP or have to change fuel types at any
time see information on page 8 on LP/NG CONVERSION.
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.
Line Size
Unit location will determine the size of fuel line that
is required to supply the engine with a constant fuel
pressure and volume. Refer to the tables below for
fuel line size, fuel consumption and recommended
tank size. For distances of 50 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. A secondary regulator is installed to
further reduce the fuel pressure to the required four
(4) to six (6) oz. operating pressure. This second-
ary 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 duel stage
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)
stage 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 secondary
regulator. (Consult you 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.
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). These fuel pressures are
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******************
***** 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.
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NATURAL GAS or LP VAPOR PIPE SIZE
Size of pipe nomally required for generators operating on NATURAL GAS or LP VAPOR.
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).
**** CAUTION ****
Reference numbers 1 through 3 in the diagrams
above are system parts supplied by the customer.
Be careful when sealing gas joints. Excessive sealing compound can be drawn into the solenoid, regulator or carburetor causing an engine malfunction.
FUEL PRESSURE
LP & NG VAPOR FUEL Correct fuel pressure can-
not 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 or NG
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.
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 Regulator (LP Vapor only)
REF # 1 3 4
UNIT OFF TANK PSI 7-11 IN
4-6 OZ
STARTING TANK PSI 7-11 IN
4-6 OZ
NO LOAD TANK PSI 7-11 IN
4-6 OZ
FULL
LOAD
TANK 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
TANK
PSI
TANK
PSI
TANK
PSI
TANK
PSI
10-15
LBS
10-15
LBS
10-15
LBS
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
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Natural Gas
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
LP/NG FUEL CONVERSION
7-11 IN
4-6 OZ
7-11 IN
4-6 OZ
7-11 IN
4-6 OZ
7-11 IN
4-6 OZ
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
ULPSS8B4W 12 26 500
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.
These generator sets are factory tested on Natural
Gas and will require no modifications for normal
operation on Natural Gas. The carburation system
has been preset and anti-tamper plugs have been
installed in the carburator as required by the EPA.
If you are operating on LP fuel you will have to
make the following modifications: On the left side of
the engine, above the starter there is a small twowire white connector lying loose. The wires will be
labeled 1 and 21. This connector has to be plugged
into the mating two-wire white connector coming out
of the carburator area on the left side of the unit.
This connection will engage an orifice in the carburator allowing the unit to operate on Liquid Propane
vapor fuel. NO other adjustments are required.
If you are reinstalling a unit that has been operating
on Liquid Propane vapor and you now want to operate it on Natural Gas all that you will need to do is
unplug this connector.
LUBRICATON
Before starting the engine, check and fill the crankcase with the proper weight/grade oil, as recommended by the engine manufacturer’s maintenance
instructions. The necessity of using the correct oil,
and keeping the crankcase full cannot be over emphasized. DO NOT OVERFILL THE ENGINE, Use
the dipstick.
INSTALLING THE BATTERY
**** CAUTION ****
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.
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 engine 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 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.
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.
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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.
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