Winco ULPSS90D User Manual

PACKAGE
PSS60/D STANDBY SYSTEMS
PSS90/D
DSE7310
INSTALLATION AND
OPERATORS MANUAL
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 2 GUIDE TO PRODUCT SAFETY 3 BASIC INFORMATION 4 Description 4
DSE 7310 Engine Control 5
Specication Table 5
PREPARING THE UNIT Unpacking the unit 6
ENGINE GENERATOR INSTALLATION Installation 6
Fuel Line Installation 7 Fuel Pressure Tables 7 LP Liquid Withdrawal 8 Lubrication 8 Coolant 8 Battery Installation 9 Battery Charger/Block Heater Wiring 9 AC Electrical Connections 10 DC Electrical Connections 11 ENGINE CONTROL PANEL LAYOUT 13 DSE 7310 CONTROLLER 13 INITIAL START-UP 14 START-UP PROCEDURE 14
EXERCISER CLOCK 15 TROUBLESHOOTING INFORMATION 15 CHANGING THE FUEL TYPE 16 GENERATOR END SPECIFICATION 16 ENGINE SPECIFICATIONS 17
ENGINE MAINTENANCE SCHEDULE 18
VOLTAGE REGULATOR WIRING 19 AC WIRING - THREE PHASE
277/480 Volt 20 120/208 Volt 20 120/240 Volt 21
AC WIRING - SINGLE PHASE
120/240 Volt 21
DC SCHEMATIC - WIRING DIAGRAM 22 OUTLINE DRAWING 23 12 MONTH WARRANTY 24
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 qualied electrician
* Operated only for its designed purposes * Used only by operators who understand its operation * Properly maintained
2
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 re. 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
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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.
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WARNING:
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
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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.
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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.
2. FIRE HAZARD - Natural gas and L.P. present a hazard of
possible explosion and/or re.
a. Do not smoke or use open ame near the generator
set.
b. Keep a re extinguisher nearby and know its proper use.
Fire extinguishers rated ABC by NFPA are appropriate.
3. DEADLY EXHAUST GAS - Exhaust fumes from any gaso- line 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 oors).
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 re hazards.
c. Carefully wipe up any gas or oil spills before starting the unit.
d. Never allow leaves or other ammable material to build
up around the engine exhaust area.
6. SERVICING EQUIPMENT - All service, including the installation or replacement of service parts, should be
performedonlybyaqualied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 mufers, 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 qualied, 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 specied 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
PSS60- The engine generator set consists of a GM 5.7L, V-8
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 electronic governor within .5 cycles variation,
from no load to rated load. The 60,000 watt (60kW) generator is a single bearing, direct drive, rotating eld design. The generator is connected to the engine ywheel via exible 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 Deep Sea (DSE) engine control mounted in the
engine generator enclosure.
PSS90 - The engine generator set consists of a GM 5.7L, Turbocharged/Aftercooled V-8 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
90,000 watt (90kW) generator is a single bearing, direct drive, rotating eld design. The generator is connected to the engine ywheel via exible 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 Deep Sea (DSE)
engine control 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. An 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
PSS60-3 120/240 400
PSS60-4 120/208 400
PSS60-17 120/240 200
PSS60-18 277/480 100
PSS90-3 120/240 400
PSS90-4 120/208 400
PSS90-17 120/240 400
PSS90-18 277/480 200
ENGINE CONTROL MODULE (DSE 7310 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 congurable 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)
Additional optional A.T.S. sizes are available to meet specic
needs. Contact your local WINCO dealer or the WINCO Sales Department for a quote.
4
FUNCTIONS
DSE 7310 Series Control Modules perform the following protection and metering functions:
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 specic
protection elements, and diagnostic reporting.
FUEL CONSUMPTION
NG LP VAPOR
(1,000 BTU/CU FT) (2,520 BTU/CU FT)
MODEL CF/HRBTU/HR #/HR GAL/
PSS60 799 799,000 39.4 9.29 334 850,964
PSS90 1230 1,230,000 52.6 12.4 446 1,149,00
CF/HRBTU/HR
HR
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)
Metered engine parameters include, oil pressure, coolant temperature, battery voltage, speed, engine load, coolant level
(from ECU), ECU specic parameters, and run-time statistics.
** NOTICE **
These units will automatically transfer if a power outage occurs while running in an exercise mode.
SPECIFICATIONS LP RATING
MODEL WATTS VOLTS AMP HZ PH RPM
PSS60-3 56,000 120/240 233* 60 1 1800
PSS60-4 60,000 120/208 208** 60 3 1800
PSS60-17 60,000 120/240 180** 60 3 1800
PSS60-18 60,000 277/480 90** 60 3 1800
PSS90-3 80,000 120/240 333* 60 1 1800
PSS90-4 80,000 120/208 278** 60 3 1800
PSS90-17 80,000 120/240 240** 60 3 1800
PSS90-18 80,000 277/480 120** 60 3 1800
TANK TEMPERATURE
MODEL 60 F(16 C) 30 F(0 C) 0 F(-18 C) -20 F(-29 C)
PSS60 500 Gal 1000 Gal 2000 Gal* 5000 Gal*
PSS90 500 Gal 1000 Gal 2000 Gal* 5000 Gal*
*Recommend liquid withdrawal at these temperatures.
ENGINE SPECIFICATIONS:
** 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. Refer to engine operating and maintenance
instructions
** CAUTION **
EQUIPMENT DAMAGE - Be sure to check the engine oil level
frequently as specied 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. Go to the WINCO web site for a list of engine dealers. (http://www.wincogen.com/
Engine_Support/ )
NG RATING
MODEL WATTS VOLTS AMP HZ PH RPM
PSS60-3 55,000 120/240 229* 60 1 1800
PSS60-4 58,000 120/208 201** 60 3 1800
PSS60-17 58,000 120/240 174** 60 3 1800
PSS60-18 58,000 277/480 87** 60 3 1800
PSS90-3 90,000 120/240 375* 60 1 1800
PSS90-4 90,000 120/208 312** 60 3 1800
PSS90-17 90,000 120/240 270** 60 3 1800
PSS90-18 90,000 277/480 135** 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.
The rated power of each engine-generator is limited by the
temperature, altitude and all other ambient conditions specied
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 104o F.
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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 afx his
signature under the consignees’s memo of the loss or damage. Contact the carrier for claim procedures.
INSTALLATION
**************** ***** WARNING ***** ****************
PERSONAL INJURY - Before proceeding with the installation, be sure the operation selector switch is in the “stop” position.
General Information
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 le a claim.
**** CAUTION ****
EQUIPMENT DAMAGE - These units are shipped with oil, and
a 50/50 mix of coolant. Be sure to check all uid 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 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.
Note:Roofaccesspanelshavebeenprovidetocheck/ll
the engine oil and the coolant. Side panels are equipped with door latches for their removal. All the door latches are keyed with a common key.
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 qualied, licensed electrician or contractor to
install and wire the transfer switch. The installation must always comply with all national, state, and local codes.
***** 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 ow.
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 nalizing 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.
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 specic requirements.
6
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 conict with
any local, state or national codes. If in doubt, always consult
your local re 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 demand
regulator must be four to six ounces per square inch or 7 to 11 inches W.C. (Water column) on 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.
**************** ***** WARNING ***** ****************
PERSONAL DANGER - Do not use galvanized pipe in fuel line
runs. The galvanized coating can become eroded and ake off,
causing possible obstructions in the regulator or fuel valve. The results could range from inoperative engine start to hazardous fuel leaks.
Size of pipe normally required for generators operating on NG/ LP:
UP TO 25 FEET*
PSS60 1.25” pipe NOT
PSS90 1.25” pipe NOT
* Allow an additional 3 feet for each standard elbow.
Do not use ‘street ells’ (restrictive).
** USE THE TWO REGULATOR SYSTEM SHOWN BELOW.
OVER 25 FEET
RECOMMENDED**
RECOMMENDED**
**** CAUTION ****
EQUIPMENT DAMAGE - Be careful when sealing gas line joints. Excessive sealing compound can be drawn into the solenoid, regulator or carburetor causing an engine malfunction.
INSTALLING THE FUEL LINE
** NOTICE **
The engine generator sets are properly adjusted before they
leave the factory for a specic 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 eld see information on page 16.
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.
FUEL PRESSURE (vapor system)
Correct fuel pressure cannot be stressed enough. The most common cause for inoperative systems is an inadequate or incorrect fuel pressure. Power and performance of the engine is in direct relation to the correctness of the fuel system. Shown below is a diagram of a typical L.P. or N.G. installation. Reference numbers 1 through 3 in the diagrams below are system parts supplied by customer. Reference number 4 is the engine generator set. Below is a table of the fuel pressure reading at each reference in the system.
Fuel Pressure Table
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Single Regulator (L.P. Vapor only)
1 3 4
UNIT OFF TANK PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
STARTING TANK PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
NO LOAD TANK PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
FULL LOAD TANK PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
Natural Gas
2 3 4
UNIT OFF LINE PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
STARTING LINE PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
NO LOAD LINE PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
FULL LOAD LINE PSI 7-11 in 7-11 in
4-6 oz 4-6 oz
Notice the preceding tables give two (2) different units of measuring fuel pressure. The rst is with a pressure gauge
calibrated in ounces per square inch. The second and most accurate is the use of a simple water manometer. A manometer is calibrated in inches of water column.
Remember that whichever fuel delivery system or type of vapor fuel used, the fuel pressure at the demand regulator installed on the engine generator must be between 4 and 6 oz. (7-11 inches
of water column). Any lower pressure and the unit will starve for fuel under load. Any higher and the unit may ‘ood’ when
attempting to start.
Two (2) Regulator System (L.P. Vapor only)
1 2 3 4
UNIT OFF TANK PSI 10-15 lbs 7-11 in 7-11 in
4-6 oz 4-6 oz
STARTING TANK PSI 10-15 lbs 7-11 in 7-11 in
4-6 oz 4-6 oz
NO LOAD TANK PSI 10-15 lbs 7-11 in 7-11 in
4-6 oz 4-6 oz
FULL LOAD TANK PSI 10-15 lbs 7-11 in 7-11 in
4-6 oz 4-6 oz
LP LIQUID WITHDRAWAL SYSTEMS
When installing a unit equipped the LP liquid withdrawal a primary regulator is not required on the supply tank. The supply line is connected to a liquid withdrawal valve on the supply tank and runs directly to the fuellock strainer mounted on the engine generator set. Normally a 3/8 to 1/2 inch copper line is acceptable for this type of fuel installation. You must be sure that the valve you have connected to on the supply tank is in fact a liquid supply valve and has a drop tube inside the tank that is pulling fuel from the bottom of the supply tank. Before
starting the unit you must conrm that you have a good liquid
supply at the unit. Engine generator sets equipped for liquid withdrawal will not run properly when supplied with high pressure vapor fuel.
LUBRICATION
Before starting the engine, check the oil level in the crankcase.
If it is low, rell to the full mark with the proper weight/grade of
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. Failure to use
the proper oil and keep the crankcase properly lled will cause
excessive engine wear and shorten its useful life.
COOLANT
Before starting the engine, check the coolant level in radiator.
If it is low, rell as specied in the engine manufacturer’s maintenance instructions. The radiator should be lled to about 1 inch below the ller neck. For additional information on engine
coolant requirements see engine manufacturer’s maintenance instructions.
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