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 4Description 4
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 qualied electrician
* Operated only for its designed purposes
* Used only by operators who understand its operation
* Properly maintained
2
4228-0060706-251
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.
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.
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.
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
performedonlybyaqualiedtechnician.
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 mufers, 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 qualied, 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.
34228-00
60706-251
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 specied 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
MODELVOLTAGEATS AMPERAGE
PSS60-3120/240400
PSS60-4120/208400
PSS60-17120/240200
PSS60-18277/480100
PSS90-3120/240400
PSS90-4120/208400
PSS90-17120/240400
PSS90-18277/480200
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 congurable 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 specic
needs. Contact your local WINCO dealer or the WINCO Sales
Department for a quote.
4
4228-0060706-251
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 specic
protection elements, and diagnostic reporting.
FUEL CONSUMPTION
NG LP VAPOR
(1,000 BTU/CU FT) (2,520 BTU/CU FT)
MODEL CF/HRBTU/HR#/HRGAL/
PSS60799799,00039.49.29334850,964
PSS9012301,230,00052.612.44461,149,00
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
(from ECU), ECU specic 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
MODELWATTS VOLTSAMPHZPH RPM
PSS60-356,000120/240233*6011800
PSS60-460,000120/208208**6031800
PSS60-17 60,000120/240180**6031800
PSS60-18 60,000277/48090**6031800
PSS90-380,000120/240333*6011800
PSS90-480,000120/208278**6031800
PSS90-17 80,000120/240240**6031800
PSS90-18 80,000277/480120**6031800
TANK TEMPERATURE
MODEL60 F(16 C)30 F(0 C) 0 F(-18 C)-20 F(-29 C)
PSS60500 Gal1000 Gal2000 Gal*5000 Gal*
PSS90500 Gal1000 Gal2000 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 specied 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
MODELWATTS VOLTSAMPHZPH RPM
PSS60-355,000120/240229*6011800
PSS60-458,000120/208201**6031800
PSS60-17 58,000120/240174**6031800
PSS60-18 58,000277/48087**6031800
PSS90-390,000120/240375*6011800
PSS90-490,000120/208312**6031800
PSS90-17 90,000120/240270**6031800
PSS90-18 90,000277/480135**6031800
*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 specied
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.
54228-00
60706-251
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 afx his
signature under the consignees’s memo of the loss or damage.
Contact the carrier for claim procedures.
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.
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 qualied, 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 specic requirements.
6
4228-0060706-251
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 conict with
any local, state or national codes. If in doubt, always consult
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.
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 specic 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
74228-00
60706-251
Single Regulator (L.P. Vapor only)
134
UNIT OFFTANK PSI7-11 in7-11 in
4-6 oz4-6 oz
STARTINGTANK PSI7-11 in7-11 in
4-6 oz4-6 oz
NO LOADTANK PSI 7-11 in7-11 in
4-6 oz4-6 oz
FULL LOADTANK PSI7-11 in7-11 in
4-6 oz4-6 oz
Natural Gas
234
UNIT OFFLINE PSI7-11 in7-11 in
4-6 oz 4-6 oz
STARTING LINE PSI7-11 in7-11 in
4-6 oz 4-6 oz
NO LOADLINE PSI7-11 in7-11 in
4-6 oz4-6 oz
FULL LOADLINE PSI 7-11 in7-11 in
4-6 oz4-6 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)
1234
UNIT OFFTANK PSI 10-15 lbs7-11 in7-11 in
4-6 oz4-6 oz
STARTINGTANK PSI 10-15 lbs 7-11 in7-11 in
4-6 oz4-6 oz
NO LOADTANK PSI 10-15 lbs 7-11 in 7-11 in
4-6 oz 4-6 oz
FULL LOADTANK PSI 10-15 lbs 7-11 in 7-11 in
4-6 oz4-6 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 conrm 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, rell 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, rell as specied 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.
8
4228-0060706-251
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