60706-188 Operators Manual PSS27LS/E & /F, PSS40LS/C & /D 2007-2009

60706-188 Operators Manual PSS27LS/E & /F, PSS40LS/C & /D 2007-2009
PACKAGE
STANDBY
SYSTEMS
PSS27LS/D
PSS40LS/C
INSTALLATION AND
OPERATIONS MANUAL
PSS40LS Engine Generator Set
SAVE THESE INSTRUCTIONS
TABLE OF CONTENTS
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____________________________________
INTRODUCTION
GUIDE TO PRODUCT SAFETY
BASIC INFORMATION
Description
DGC-2020 Engine Control Layout
Specification Table
PREPARING THE UNIT
Unpacking the unit
ENGINE GENERATOR INSTALLATION
Installation
Fuel Line Installation
Fuel Pressure Tables
LP Liquid Withdrawal
Lubrication
Coolant
Battery Installation
Battery Charger/Block Heater Wiring
AC Electrical Connections
DC Electrical Connections
INITIAL START-UP
EXERCISER CLOCK
TROUBLESHOOTING INFORMATION
LP/NG CONVERSION
VOLTAGE REGULATOR WIRING
AC WIRING - THREE PHASE
277/480 Volt
120/208 Volt
120/240 Volt
AC WIRING - SINGLE PHASE
120/240 Volt
DC SCHEMATIC - WIRING DIAGRAM
OUTLINE DRAWING
12 MONTH WARRANTY
i
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3
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5
5
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6
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7
7
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7
8
8
9
11
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12
13
14
14
15
15
16
17
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
2.
FIRE HAZARD - Natural gas and L.P. present a hazard of
possible explosion and/or fire.
a.
b.
SAVE THESE INSTRUCTION
This manual contains important instructions that
should be followed during installation and maintenance
of the generator and batteries.
3.
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.
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.
b.
c.
4.
b.
************************************************************
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.
***********************************************************
5.
b.
WARNING:
c.
WARNING indicates a potentially hazardous situation which, if
not avoided, could result in death or serious injury.
***********************************************************
d.
***********************************************************
6.
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:
a.
b.
c.
e.
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.
b.
c.
d.
e.
f.
f.
Do not allow anyone to operate the generator without
proper instruction.
Guard against electric shock.
Avoid contact with live terminals or receptacles.
Use extreme care if operating this unit in rain or snow.
Use only three-prong grounded receptacles and
extension cords.
Be sure the unit is properly grounded to an external
ground rod driven into the earth.
60706-188
g.
Page 1
Remove all grease, ice, snow or materials that create
slippery conditions around the unit.
Remove any rags or other material that could create
potential fire hazards.
Carefully wipe up any gas or oil spills before starting the
unit.
Never allow leaves or other flammable material to build
up around the engine exhaust area.
SERVICING EQUIPMENT - All service, including the
installation or replacement of service parts, should be
performed only by a qualified technician.
d.
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.
Use hearing protection equipment when working
around this equipment for long periods of time.
Keep your neighbors in mind when permanently installing this equipment.
CLEANLINESS - Keep the generator and surrounding area
clean.
a.
************************************************************
Operate only in well ventilated areas.
Never operate indoors.
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).
NOISE HAZARD - Excessive noise is not only tiring, but
continual exposure can lead to loss of hearing.
a.
ANSI SAFETY DEFINITIONS
Do not smoke or use open flame near the generator
set.
Keep a fire extinguisher nearby and know its proper use.
Fire extinguishers rated ABC by NFPA are appropriate.
Use only factory approved repair parts.
Do not work on this equipment when fatigued.
Never remove the protective guards, cover, or receptacle panels while the engine is running.
Use extreme caution when working on electrical components. High output voltages from this equipment can
cause serious injury or death.
Always avoid hot mufflers, exhaust manifolds, and
engine parts. They all can cause severe burns instantly.
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.
Always make sure unit is disabled before placing your
hands anywhere near the fan, belts, alternator or water
hoses.
7263-00
2) ENGINE/GENERATOR
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
The package standby engine generator set includes all items
necessary for a completely automatic standby power system as
standard equipment. The entire package is then tested to insure
proper operation of all components and the total system performance and reliability.
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.
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.
MODEL
PSS27LS-3
PSS27LS-4
PSS27LS-17
PSS27LS-18
PSS40LS-3
PSS40LS-4
PSS40LS-17
PSS40LS-18
VOLTAGE
120/240
120/208
120/240
277/480
120/240
120/208
120/240
277/480
RECOMMENDED
ATS AMPERAGE
200
100
100
100
200
200
200
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.
7263-00
PSS27LS- 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 27,000 watt
(27kW) 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.
PSS40LS - 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.
ENGINE CONTROL MODULE (DGC-2020)
The DGC-2020 Digital Genset Controller provides integrated
engine-genset control, protection, and metering in a single
package. Microprocessor based technology allows for exact
measurement, set point adjustment, and timing functions. Front
panel controls and indicators enable quick and simple DGC-2020
operation. Basler Electric communication software
(BESTCOMSPlus) allows units to be easily customized for each
application. A wide temperature-range liquid crystal display (LCD)
with backlighting can be viewed under a wide range of ambient
light and temperature conditions.
FEATURES
DGC-2020 Digital Genset Controllers have the following features:
• Local and Remote Generator Control
• Engine and Generator Protection
• Programmable Analog Engine Senders
• Programmable Logic
• Automatic Transfer Switch Control (Mains Failure)
• Integrated RS485
• Auto Synchronizing
FUNCTIONS
DGC-2020 Digital Genset Controllers perform the following
functions:
Page 2
60706-188
Generator Protection and Metering
Generator protection guards against over voltage, under voltage,
under frequency, and over frequency. Over current and phase
imbalance protection is available as an option at the time of
manufacture. Each generator protection function has an adjustable pickup and time delay setting. Metered generator parameters include voltage, current, real power (watts), apparent power
(VA), and power factor (PF).
Engine Protection and Metering
Engine protection features include oil pressure and coolant
temperature monitoring, over crank protection, ECU specific
protection elements, and diagnostic reporting.
Metered engine parameters include, oil pressure, coolant
temperature, battery voltage, speed, engine load, coolant level
(from ECU), ECU specific parameters, and run-time statistics.
All metering functions are displayed on the liquid crystal display.
The front panel display begins with the SUMMARY SCREEN.
Pressing the Right arrow key will open the MAIN MENU screen.
The MAIN MENU screen consists of METERING and SETTINGS
Summary Screen
Summary screen can be set to standard or scrolling. When set to
standard, only the following are displayed:
•
Generator Voltage
•
Generator Amperage
•
Generator Phase
•
Generator Frequency
•
Engine Oil Pressure
•
Engine Coolant Temperature
•
Engine Battery Voltage
ENGINE CONTROL
MODULE
DGC-2020
A - Liquid Crystal Display. The backlit, 64 by 128 pixel LCD
serves as the local information source for metering, alarms, prealarms, and protective functions. Display operation is maintained
at -20°C. An optional LCD heater maintains display operation at 40°C.
B - Not in Auto Indicator. This red LED lights when the DGC2020 is not operating in Auto mode.
C - Alarm Indicator. This red LED lights continuously during
alarm conditions and flashes during pre-alarm conditions.
D - Supplying Load Indicator. This green LED lights when the
generator current is greater than EPS threshold current.
F - Lamp Test Push-button. Pressing this button tests the DGC2020 indicators by exercising all LCD pixels and lighting all LEDs.
G - Auto Push-button and Mode Indicator. Pressing the Auto
button places the DGC-2020 in Auto mode. The green Auto mode
LED lights when Auto mode is active.
H - Off Push-button and Mode Indicator. Pressing this button
places the DGC-2020 in Off mode. The red Off mode LED lights
when the DGC-2020 is in Off mode.
I - Run Push-button and Mode Indicator. Pressing this button
places the DGC-2020 in Run mode. The green Run mode LED
lights when Run mode is active.
E - Alarm Silence Push-button. Pressing this button opens the
relay output programmed as the horn output.
60706-188
Page 3
7263-00
J - Reset Push-button. This button is pressed to cancel a
settings editing session and discard any settings changes. When
pressed, this button also resets the Breaker Management PreAlarms
K - Arrow Push-buttons. These four buttons are used to
navigate through the front panel display menus and modify
settings. The left- and right-arrow buttons are used to navigate
through the menu levels. The right arrow button is pressed to
move downward through the menu levels and the left-arrow
button is pressed to move upward. Within a level, the up-arrow
and down-arrow buttons are used to move among items within
the menu level. Pressing the down-arrow button moves to items
lower in the list. Pressing the up-arrow button moves to items
higher in the list. During a settings editing session, the up- and
down-arrow buttons are used to raise and lower the value of the
selected setting.
L - Edit Push-button. Pressing this button starts an editing
session and enables changes to the DGC-2020 settings. At the
conclusion of an editing session, the Edit push-button is pressed
again to save the setting changes.
DISPLAY OPERATION
The front panel display is used to make settings changes and
display metering values. Refer to call-outs J, K, and L in text and
illustration for information on changing settings through the front
panel and navigating through the Metering screens. When the
unit is first powered up, the clock may need to be reset. Editing
the clock provides familiarity with the edit process. All programming changes from the front panel are accessed through the edit
key to begin and exit the internal microprocessor program.
Log-in and Permissions
The microprocessor is still in the General Settings Edit mode.
Pressing ‘K’ (left) a second time exits the Edit mode and allows
full access to the View Only mode for all control settings and
current status. Any items to be changed are accessed by
pressing ‘K’ (up/down/right or left) to select, ‘L’ (Edit) to change
and ‘K’ (left) to exit.
SPECIFICATIONS
GENERATOR
MODEL
PSS27LS
PSS27LS-4
PSS27LS-17
PSS27LS-18
PSS40LS
PSS40LS-4
PSS40LS-17
PSS40LS-18
WATTS
VOLTS
AMP
HZ
PH
RPM
27,000
27,000
27,000
27,000
40,000
40,000
40,000
40,000
120/240
120/208
120/240
277/480
120/240
120/208
120/240
277/480
112.5*
94.0*
81.2*
40.6*
166.7**
138.9**
120.4**
60.2**
60
60
60
60
60
60
60
60
1
3
3
3
1
3
3
3
1800
1800
1800
1800
1800
1800
1800
1800
*Derate 11% for Natural Gas operation. Derate 3.5% per
1000 feet elevation above sea level.
**Derate 7% for LP operation. Derate 3.5% per 1000 feet
elevation above sea level.
FUEL CONSUMPTION
MODEL
PSS27LS
PSS40LS
NG (1,000 BTU/CU FT) L.P. VAPOR (2,520 BTU/CU FT)
CF/HR
BTU/HR
#/HR GAL/HR CF/HR BTU/HR
320
320,000
14.1
3.3
120
302,400
450
450,000
20.0
4.7
170
428,400
L.P. TANK SIZING
To Log-in, navigate to the SETTINGS, ENTER PASSWORD
screen and press the Edit key. Use the Up/Down arrow keys to
scroll through the characters. Use the Left/Right arrow keys to
enter more characters. The Owner operator password is OP.
Once the password has been entered, press the Edit key to Login. See the key stroke sequence listed below to access the
control and enter the edit mode. A LOGOUT selection now
appears in the list of SETTINGS. To logout, navigate to SETTINGS, LOGOUT and press the Edit key. The LOGOUT selection
is removed from the SETTINGS list.
Sequence for setting (or resetting) the system clock 1) Press ‘K’ (right key) for initial set or ‘K’ (left to back up, up /
down) to choose menu item and time/date element to be
changed.
2) Press ‘L’ (Edit) to access change mode to enter Password OP as follows:
2a -Press K (up) to select O
2b -Press K (right) to move cursor
2c -Press K (up) to select P
2d -Press L (Edit) to begin change mode
3) Press ‘K’ (up or down) to choose year
4) Press ‘L’ (Edit) to enter year
5) Press ‘K’ (down) to select month mode
6) Press ‘L’ (Edit) to access month change
7) Press ‘K’ (up or down) to choose month
8) Press ‘L’ (Edit) to enter month
7263-00
9) Repeat sequence 5 through 8 for day, minute, second and
DST (Daylight Saving Time.
To finish clock setting, process - Press ‘K’ (left).
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)
PSS27LS
100 Gal
150 Gal
500 Gal*
1500 Gal*
PSS40LS
160 Gal.
300 Gal. 1000 Gal.*
2000 Gal.*
*Recommend liquid withdrawal at these temperatures.
ENGINE SPECIFICATIONS:
Refer to engine operating and maintenance instructions
** NOTICE **
Regarding Engines - This manual covers the generator portion of
these units. See the separate engine instruction manual for
engine-related problems, detailed engine information and engine
warranty.
** CAUTION **
EQUIPMENT DAMAGE - Be sure to check the engine oil level
frequently as specified in the engine manual.
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60706-188
The engine manufacturer has established an excellent world-wide
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 10 degrees Fahrenheit above 60 degrees Fahrenheit. Units should not be operated in ambient temperature greater
than 40o 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.
General Information
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.
***** 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.
“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.
ENGINE GENERATOR SET MOUNTING
**** CAUTION ****
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.
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.
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.
The unit should be mounted to allow for ample working room
around it. A general rule to follow is five (5) feet clearance on all
sides. See NFPA Code 37 for additional clearance 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.
INSTALLATION
***************
***** WARNING ****
***************
PERSONAL INJURY - Before proceeding with the installation, be
sure the operation selector switch is in the "stop" position.
60706-188
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.
**************
***** WARNING ****
****************
FIRE HAZARD - All fuel runs should be installed by a licensed
fuel supplier.
Page 5
7263-00
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.
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. Performance of the engine is in direct
relation to the correctness of the fuel system. Shown below is a
block diagram of a typical L.P. or N.G. Installation.
Supply
Primary
Secondary
Tank
Regulator
Regulator
1
2
3
TWO (2) REGULATOR FUEL SYSTEM
INSTALLING THE FUEL LINE
** 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 12.
Supply
Primary
Generator
Tank
Regulator
Set
1
2
4
SINGLE REGULATOR FUEL SYSTEM
Reference numbers 1 through 3 in the block diagrams above are
fuel lines supplied by customer.
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.
Reference number 4 is the engine generator set.
Below is a table of the fuel pressure readings at each reference in
the system.
Fuel Pressure Table
Single Regulator (L.P. Vapor only)
2
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
Two (2) Regulator System (L.P. Vapor only)
UNIT OFF
*************
***** 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 start to hazardous
fuel leaks.
Size of pipe normally required for generators operating on
NATURAL/LP gas:
1
TANK PSI
UNIT OFF
1
TANK PSI
2
10-15 lbs
STARTING
TANK PSI
10-15 lbs
NO LOAD
TANK PSI
10-15 lbs
FULL LOAD TANK PSI
10-15 lbs
3
7-11 in
4-6 oz
7-11 in
4-6 oz
7-11 in
4-6 oz
7-11 in
4-6 oz
3
7-11 in
4-6 oz
7-11 in
4-6 oz
7-11 in
4-6 oz
7-11 in
4-6 oz
4
7-11 in
4-6oz
7-11 in
4-6 oz
7-11 in
4-6 oz
7-11 in
4-6 oz
Natural Gas
up to 25 feet*
over 25 feet*
PSS27LS
1" pipe
not recommended
PSS40LS
1" pipe
use a two regulator system
* Allow an additional 3 feet for each standard elbow.
Do not use ‘street ells’ (restrictive).
**** 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.
7263-00
Generator
Set
4
Page 6
UNIT OFF
1
LINE PSI
STARTING
LINE PSI
NO LOAD
LINE PSI
FULL LOAD
LINE PSI
2
7-11 in
4-6 oz
7-11 in
4-6 oz
7-11 in
4-6 oz
7-11 in.
4-6 oz
4
7-11 in
4-6 oz
7-11 in
4-6 oz
7-11 in
4-6 oz
7-11 in
4-6 oz
60706-188
Notice the preceding tables give two (2) different units of measuring fuel pressure. The first 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.
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
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 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
confirm 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, refill 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 filled 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, refill as specified in the engine manufacturer’s maintenance instructions. The radiator should be filled to about 1 inch
below the filler neck. For additional information on engine coolant
requirements see engine manufacturer’s maintenance instructions.
INSTALLING THE BATTERY
**** CAUTION ****
In the following battery installation procedure, check to be sure
the selector switch remains in the “stop” position. This should be
your last step before initial start-up.
A customer supplied twelve-volt battery is required to complete
the installation. Installation of the highest CCA rated battery,
within the correct BCI group, will increase cold weather starting
performance. Gel batteries should not be used with the battery
tender installed in the generator enclosure.
MINIMUM
Model
Voltage
BCI Group CCA Rating
PSS27LS
PSS40LS
12
12
24
24
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 battery 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 battery reverse the procedure, disconnect the
negative cable first and then the positive cable.
5. Be sure all connections are tight and coat the terminals and
cable end with dialectic grease.
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
* Where electrolyte contacts the skin, wash off immediately
with water.
* If electrolyte contacts the eyes, flush thoroughly and immediately with water and seek immediate medical attention.
* Spilled electrolyte is to be washed down with an acid neutralizing agent. A common practice is to use a solution of one pound
of bicarbonate of soda (baking soda) to one gallon of water. The
bicarbonate of soda solution is to be added until the evidence of
reaction, foaming, has ceased. The resulting liquid is to be
flushed with water and the area dried.
DANGER – Explosive Fire Risk
* Never smoke when near batteries
* Do not cause a flame or spark in the battery area
* Always discharge static electricity from your body before
touching batteries by first touching a grounded metal surface.
650
650
SERVICING BATTERIES
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.
60706-188
CAUTION - NEVER dispose of a battery in a fire. The battery is
capable of exploding.
Batteries used on these units may over time lose water. This is
especially true if you are using a trickle charger to maintain your
battery. When refilling the battery with water use only distilled
water. Tap water will shorten the service life of the battery.
Page 7
7263-00
Never fill the battery above the fill line. Over filling above the
upper level line may cause the electrolyte to overflow, resulting in
corrosion to the engine or nearby parts. Immediately wash off
any spilled electrolyte following the procedure above.
NOTE: Always make sure that a new battery is fully charged
before installing it on a generator set. Failure to do so can cause
damage to the engine control module in the generator set.
All connections must be clean and tight. Check the electrolyte
(fluid) in the battery periodically to be sure it is above the plates.
Never allow the battery to remain in a discharged condition.
CONNECTING THE BATTERY CHARGER &
BLOCKHEATER
A two-stage battery tender is provided on all standby generators.
This battery tender charges at a rate of 750 mA until the battery is
fully charged and then automatically switches to a 13.2 VDC float
charger. The charger has an indicator light on it, red indicates it
is charging, and green indicates it is in the storage mode (float
charge). This charger is mounted on the engine generator set
just below the engine control panel.
** NOTICE **
The trickle charger is not intended to recharge a battery which
has become completely discharged. It is designed to produce
just enough current to maintain a fully charged battery.
The battery tender receptacle is to be powered by a GFCI circuit
and installed in accordance with the United States National
Electric Code. These AC wires can be run in the same conduit as
the other AC leads from the generator. It is suggested that this
circuit be fused for 15 amps, then both the battery charger and
the block heater can be connected to the same circuit. A 120 volt
duplex receptacle is mounted on the generator along side circuit
breaker panel, the battery tender is shipped already plugged into
the receptacle.
properly installed, the normal A.T.S. Control and safety systems
will eliminate all paths for feedback.
To wire the automatic transfer switch into the existing wiring, first
determine which circuits will be on the emergency load circuit. If
the entire load is to be transferred, the transfer switch can be
wired in directly after the watt-hour meter and the service entrance, providing the service entrance ampere rating is within the
transfer switch’s rated capability.
If only specific circuits are to be powered under emergency power
failure conditions, an additional distribution panel designated
“emergency distribution panel” must be installed.
All selected emergency circuits are removed from main distribution panels and installed in the emergency distribution panel. The
A.T.S. is then installed between the main panel and the emergency distribution panel. Suggested circuits: freezer, refrigerator,
furnace, emergency lights, sump pump, emergency outlet circuits,
etc. Total running load must not exceed generator rating.
A.C. ELECTRICAL
CONNECTIONS
NOTICE - CLASS 1 WIRING METHODS ARE TO BE USED FOR
ALL FIELD WIRING CONNECTIONS TO TERMINALS OF A
CLASS 2 CIRCUIT
Note: This symbol
used.
always indicates ground where
The engine blockheater installed on this unit\ should also be
plugged in this receptacle. The block heater is thermostatically
controled and when plugged in will maintain the engine coolant
temperature between 100 and 120 degrees F.
MOUNTING THE AUTOMATIC
TRANSFER SWITCH (A.T.S.)
*************
***** WARNING *****
*************
FIRE HAZARD - All wiring must be done by a licensed electrician, and must conform to the national electrical code and comply
with all state and local codes and regulations. Check with the
local authorities before proceeding!
INSTALLATION NOTES
Because of the many different types of service, feeder, and
distribution equipment, no specific wiring instructions can be
provided. It is recommended that only copper wire be used. In
all cases it is essential that while the load is connected to the
generator, there can be absolutely no feedback from the generator to the power line or the power line to the generator. When
7263-00
A - Neutral Lugs, These neutral lugs are isolated from ground
and provided for you to connect your neutral wire from the
transfer switch to. The lugs on the 40 kW will handle wire sizes
#4 AWG to 300 MCM and should be torqued to 250 in. lbs. The
lugs on the 27 kW will accommodate #4 AWG to 300 MCM and
should be torqued to 250 in. lbs.
Page 8
60706-188
B - Generator Circuit Breaker, This circuit breaker provides
overload protection for the generator. Your power feeds from the
transfer switch will connect to the bottom lugs on the circuit
breaker. The generator power feeds have already been wired
into the upper lugs.
The table below gives you the circuit breaker size, lug wire sizes
and torque specification. (see the actual breaker for additional
information and restrictions)
kW
40
40
40
40
27
27
27
27
Voltage PH
120/240 1
120/208 3
120/240 3
277/480 3
120/240 1
120/208 3
120/240 3
277/480 3
Amp
175
150
125
60
110
90
80
40
Wire Capability
#4 AWG - 300 MCM
#4 AWG - 300 MCM
#4 AWG - 300 MCM
#14 - #1/0 AWG
#4 AWG - 300 MCM
#12 AWG -2/0 AWG
#12 AWG -2/0 AWG
#14 - #1/0 AWG
Lug Torque
250 in lbs
250 in lbs
250 in lbs
80 in lbs
250 in lbs
50 in lbs
50 in lbs
80 in lbs
All wires should be installed in rigid or flexible conduit. (Knockouts are provided in the control box).
See the manual shipped with the Automatic Transfer Switch for
connection locations in the switch. Connections in each switch
will vary depending on the type of switch and the manufacturer.
GROUNDING
A grounding lug has been provided on the engine generator set
and the generator set must be properly grounded to good earth
ground. Generally a 6 foot copper rod driven into the earth will
provide a proper earth ground.
D.C. ELECTRICAL
CONNECTIONS
Minimum Conductor Sizes between the Generator and the ATS.
Based on wire type and temperature rating. Wire has been
derated for 40o C ambient temperatures.
C/B
kW Voltage PH Amp
40 120/240 1 175
40 120/208 3 150
40 120/240 3 125
40 277/480 3 60
27 120/240 1 110
27 120/208 3 90
27 120/240 3 80
27 277/480 3 40
By code, the wire must be heavy enough to handle the full current
rating of the main line circuit-breaker (or fuse) in the entrance (or
sub-panel) protecting the contactor switch.
CU Conductor
AL Conductor
Wire Temperature Rating
900C
750C
900C
750C
3/0 AWG 2/0 AWG 250 MCM 4/0 AWG
2/0 AWG 1/0 AWG 3/0 AWG 2/0 AWG
1/0 AWG #1 AWG 3/0 AWG 2/0 AWG
#4 AWG #6 AWG #3 AWG #4 AWG
#1 AWG #2 AWG 1/0 AWG #1 AWG
#2 AWG #3 AWG 1/0 AWG #2 AWG
#3 AWG #4 AWG #1 AWG #2 AWG
#6 AWG #6 AWG #6 AWG #6 AWG
All DC connections are completed in the small box just below the
engine control cabinet. In addition there are two small fuses
mounted on the top of the engine control cabinet that protect both
the engine control and all the other DC connections. See the
display below for additional information.
For additional information on wire sizing refer to table 310-16 of
the National Electrical Code ANSI/NFPA 70.
C - Ground Lug, These ground lugs are bonded to ground and
are provided for you to connect your ground wire from the transfer
switch to. The lugs on the 40 kW will handle wire sizes #6 AWG
to 250 MCM and should be torqued to 250 in. lbs. The lugs on the
27 kW will accommodate #6 AWG to 250 MCM and should be
torqued to 250 in. lbs.
*************
***** WARNING *****
*************
A main line circuit breaker has been provided inside the generator housing. During all wiring installations make sure the breaker
is in the off position and the generator operation switch is in the
off position.
*************
***** WARNING *****
*************
EQUIPMENT DAMAGE - When installing a Three Phase 240 volt
system be sure you know which lead is the high voltage "wild" leg
(208Volt line to neutral). The generator normally carries the high
voltage on the G2 lead.
The load current carrying wires (L) and (T) must be sized to
handle the maximum load current without excessive voltage drop.
60706-188
Page 9
7263-00
generator control terminal box. Depending on the distance, 14 to
16 gauge stranded wire should be used. These wires should be
labeled S1 and S23.
CONTROL PANEL LAYOUT
A - DGC-2020 Digital Gen-Set Control. See Explanation on
page 3.
B - DC Control Circuit Fuse. The 10 amp DC Circuit Fuse
protects the 12 volt circuits and engine wiring harness against
faults in wiring or control equipment. The fuse also prevents a
discharge of the battery due to a circuit fault. (Replacement AGC10A-250V)
*************
***** WARNING *****
*************
C - DGC-2020 Fuse. This 1 amp DC fuse protects the DGC-2020
printed circuit board. (Replacement AGC-1A-250V)
*******CAUTION******
D - Emergency Stop Switch (3)- When depressed this switch
will disconnect all the 12 volt power to the DGC-2020 shutting the
engine down. The lamp in the emergency stop switch will light up
when the switch is depressed showing that the power to the panel
has been disconnected.
Be sure Engine Generator is in the "OFF" position before you
make any DC interconnections.
Never run the AC and DC wiring in the same conduit.
Zenith ATS
The terminal markings in the Zenith ATS are marked “X1” and
“X2”. The wire labeled “Start 1” is routed to start contact "X1” and
E - CUSTOMER REMOTE START CONNECTION TERMINALS The two remote start leads from the Automatic Transfer Switch
are connected to the two terminals marked 1 & 23. The wire in
terminal labeled #1 is Battery Negative and the wire in the
terminal labeled #23 is your Remote Start lead. Closing these two
leads together will signal the DGC-2020 to go into an auto-start
mode and start up the engine generator.
Depending on the distance, 14 to 16 gauge stranded wire should
be used. It is suggested that these wires be labeled S1 and S23.
The terminal blocks are designed to use terminal lugs on all
wires and the screws should be torqued to 9.6 in. lbs.
Note: Any relay closure can be used to start and stop this
generator. As long as the contact stays closed the engine
generator set will continue to run. Once the relay is opened
the unit will shut down and remain in the standby mode until
the remote start relay is closed again.
F - CUSTOMER REMOTE STOP LIGHT - This set of terminals
can be use to light a 12 volt remote light to indicate that the unit is
in emergency stop. The terminal blocks are designed to use
terminal lugs on all wires and the screws should be torqued to 9.6
in. lbs.
X1
X2
the wire labeled “Start 23” is routed to start contact “X2”
ASCO 165 UL SWITCH
Your DC connection points in the ASCO 165 ATS are
G - REMOTE DISPLAY PANEL INTERFACE TERMINALS These interface terminals are prewired to allow for the connection
of a Basler RDP-110 remote display. This display allows for the
remote annunciation of alarms at a location such as a nurses
station or a control room. This display is used to meet the remote
annunciation requirements of NFPA 110 standards.
NOTE:
This feature must be turned on at the time the manufacture.
When used with the RDP-110 two twisted pairs of 20 AWG wire
may be used for distances of up to 4000 feet. The terminal
blocks are designed to use terminal lugs on all wires and the
screws should be torqued to 9.6 in. lbs.
DC Interconnections to the Automatic Transfer Switch
Two control wires are required between the A.T.S. panel and the
7263-00
terminals “4” and “5 on the interface terminal bloc
ASCO 300 UL SWITCH
Your DC connection points in the ASCO 300 ATS are terminals
“14” and “15”. Depending on the size of the switch they are
located in different locations. See next page:
Page 10
60706-188
With the engine running smoothly check the no load voltage and
frequency on the digital display. The voltage should be 208/240/
480 AC depending on which model you have and a frequency of
59.5 To 60.5 hertz (Hz).
If you have the proper voltage at the generator the next step is to
check the voltage at the generator terminals in the Automatic
Transfer Switch. The voltage between the G1 and the G3
terminals should be the same as it was on the generator front
panel. The voltage should also be checked between the hot
terminals (G1 and G3) and the G-N to be certain of a balanced
voltage output and a solid neutral connection. The voltage
between G1 and G-N should be about 120 volts AC (277 on 480
units). The same approximate voltage should be found between
terminals G3 and G-N (120 volts AC).
On three phase panels the G2 voltage level should also be
checked. ON 240 VOLT (DELTA) SYSTEMS BE SURE YOU
KNOW WHERE THE HIGH VOLTAGE "WILD" LEG IS. IT
MUST BE IN THE SAME LOCATION ON THE LINE SIDE AS IT
IS ON THE GENERATOR SIDE. (i.e. if it's on L-3 on the line side
it must be on G-3 on the generator side.
** Notice **
INITIAL START UP
If for any reason during the check out procedure the voltage and
frequency are not correct, depress the “OFF” push-button and
correct the trouble before proceeding.
*************
***** WARNING *****
*************
After verifying that the voltage and frequency are correct, depress
the “OFF” push-button. The unit should shut off with no time
delay. You are now ready to test the automatic start function.
EQUIPMENT DAMAGE - DO NOT jump start these engine
generator sets. Starting these units on a low battery or jump
starting them will cause damage to the engine control module.
To test the Automatic Transfer Switchs follow the instruction in
the operators manual you received with your transfer switch. If
you get a fault light during the initial start up or prior to start up it
is most likely a false warning light. Simply reset the A.T.S. and
start over.
Use the following check list to verify correct installation before
starting the engine:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Engine oil. Fill as required with proper grade/qty.
Engine coolant. Fill as required with proper
mixture.
Unit mounting base properly bolted down.
Clearance for service and maintenance on all
sides.
Proper fuel line material and size.
All fuel line connections tight.
Fuel line protected and a moisture trap installed
(may be required for N.G.).
Correct LP/NG pressure 4-6 Oz. (7-11" Wc).
Battery connections clean and tight.
Battery fully charged.
All AC and DC wiring installed and properly
protected.
Once you have completed testing of the ATS, be sure you
ALWAYS leave the system in standby mode unless servicing the
unit. For standby operation, press the "AUTO" button on the front
of the engine control. The green light should light up under the
"AUTO" button.
SETTING THE EXERCISER CIRCUIT
For all ATS see the instruction manual shipped with the ATS for
instruction on setting the exercise circuit in your ATS
TROUBLESHOOTING TABLES
UNIT WILL NOT CRANK WHEN THE POWER FAILS.
After completing the above checklist, the engine-generator
set is ready for the initial start-up test.
1.
2.
PROCEDURE
Depress the “RUN” push-button on the front of the DGC. The
engine-generator will crank and start automatically. If the engine
fails to start, depress the “stop” push-button and correct the
trouble before proceeding.
60706-188
Page 11
3.
4.
5.
6.
7.
Digital Genset Controller not in "AUTO"
Transfer control switch not in "AUTOMATIC"
position.
Incorrect wiring between transfer switch and
generator.
Defective start stop relay in the transfer
switch.
Circuit breaker tripped on Digital Genset Controller.
Defective Digital Genset Controller
Loose or dirty battery terminals.
7263-00
8.
9.
10.
Defective "Run/Auto" switch on generator or
transfer switch.
Defective starter.
Defective start solenoid.
ATS PANEL WILL NOT RETRANSFER TO NORMAL
POWER
1.
ENGINE WILL NOT CRANK WITH GENERATOR
RUN PUSH-BUTTON DEPRESSED.
1.
2.
3.
4.
5.
6.
7.
8.
2.
3.
Battery dead.
DC circuit breaker for Digital Genset Controller
tripped.
Defective Digital Genset Controller.
Loose or dirty battery terminals.
Defective "Run/Auto" switch on generator.
Defective starter.
Defective start solenoid.
Locked up engine genset.
4.
NO AC OUTPUT FROM GENERATOR
1.
2.
3.
4.
5.
6.
7.
8.
ENGINE CRANKS BUT WILL NOT START
1.
2.
3.
4.
5.
6.
7.
8.
9.
Improper fuel pressure being delivered to
unit.
Fuel supply shut off.
Fuel tank empty.
Defective spark plug.
Defective engine ignition module.
Dirty air cleaner filter.
Defective fuel solenoid valve.
Low battery.
Defective fuel regulator
**** CAUTION ****
EQUIPMENT DAMAGE - Do not make any fuel adjustments or
governor adjustments until all pressure readings are in compliance with specification. See fuel pressure charts (tables 1, 2,
and 3).
The engine generator sets covered in this manual are shipped for
a specific fuel, either Liquid Propane (LP) vapor, Natural Gas
(NG) or Liquid Withdrawal Propane (LPG). If it should be
necessary to change the type of fuel used after a unit is received,
the following procedures are provided.
Engine is low on oil.
Engine has high water temperature.
Engine has overspeed.
Engine has gone into overcrank.
No output from engine alternator to engage
stop crank circuit.
NOTE: For conversion to/from liquid withdrawal LP consult the
factory. Additional parts will be required for this conversion.
NATURAL GAS TO PROPANE VAPOR
ENGINE WILL NOT COME UP TO SPEED AFTER IT
STARTS
1.
2.
3.
4.
Insufficient fuel volume getting to the unit.
a. Too small of fuel line.
b. Fuel pressure too low/high.
Fuel load block needs to be adjusted.
Governor is defective.
AC short in generator components.
ATS PANEL WILL NOT TRANSFER TO EMERGENCY
SUPPLY (GENERATOR)
1.
2.
3.
4.
5.
7263-00
No AC generator output from generator.
Broken or defective mechanical/electrical
interlocks.
Defective holding coil in the generator side
contactor.
Wiring error between generator and transfer
switch.
Defective start/stop relay
Defective diode.
Defective voltage regulator.
Defective rotor.
Defective stator.
Defective exciter rotor.
Defective exciter stator.
AC short in the output leads.
Defective field circuit breaker.
NG/ LP CONVERSION
ENGINE STARTS AND THEN STOPS AND ALARM
LIGHT COMES ON
1.
2.
3.
4.
5.
Proper normal line power not available at line
terminals in ATS panel.
Defective holding coil in line side contactor.
Broken or defective mechanical/electrical
interlocks.
Defective start/stop relay
1. Turn off fuel supply.
2. Remove the fuel line from the carburetor at the demand
regulator.
3. Remove the cap on the upright column of the regulator. This
will expose the pressure spring adjusting screw. Back off the
spring adjusting screw so there is just enough room to replace
the cover. Replace the cover.
4. Invert the regulator so it is positioned with the column
pointing down.
5. Reconnect the fuel line at the regulator.
6. Remove the 1/8 NPT plug (the one closest to fuel solenoid)
located on what is now the top of the regulator. Connect a fuel
pressure meter or a manometer where the plug has been
removed. Move the generator control switch to the run position.
As the unit starts to crank the fuel solenoid will open and you
should get a pressure reading of between 4 to 6 ounces (7 to 11
inches of water column).
7. If the pressure is correct, remove the meter and reinstall the
pipe plug.
8. Next the timing on the engine must be changed. As this unit
was shipped to operate on NG the timing advance was set at 36
degrees. For operation on LP it will be necessary for you to reset
the timing advance to 26 degrees.
Page 12
60706-188
9. You are now ready to make the final fuel mixture adjustment.
These engines were adjusted at the factory to produce about .7 to
3.4% CO. If you have the ability to test the CO, adjust the mixture
on the carburetor until you achieve the proper CO reading. If you
don't have a CO meter follow the manual adjustment procedure
later in this section.
PROPANE VAPOR TO NATURAL GAS
1. Turn off fuel supply.
2. Remove the fuel line from the carburetor at the demand
regulator.
3. Invert the regulator so the column is in the upright position.
4. Remove the cap on the upright column of the regulator. This
will expose the pressure spring adjusting screw. Turn the screw
all the way out (CCW) and then back in (CW) about 8 turns. The
plug should be approximately half way down for initial starting.
5. Reconnect the fuel line at the regulator.
6. Remove the 1/8 NPT plug (the one closest to fuel solenoid)
located on what is now the bottom of the regulator. Connect a fuel
pressure meter or a manometer where the plug has been
removed. Move the generator control switch to the "run" position.
As the unit starts to crank the fuel solenoid will open and you
should get a pressure reading of between 4 to 6 ounces (7 to 11
inches of water column).
7. If the pressure is correct, remove the meter and reinstall the
pipe plug. Next remove the 1/8 inch NPT plug on the carburetor
side of the regulator and install the pressure meter. Move the
generator switch to the run position. As soon as the solenoid
opens the pressure should rise to 2.5 to 3 oz. just as the engine
starts to crank. If it is within this range replace the cap on the
column. If not, adjust the screw down to increase and up to
decrease and retest.
8. Next the timing on the engine must be changed. As this unit
was shipped to operate on LP the timing advance was set at 26
degrees. For operation on NG it will be necessary for you to reset
the timing advance to 36 degrees.
9. You are now ready to make the final fuel mixture adjustment.
These engines were adjusted at the factory to produce a .7 to
3.4% CO. If you have the ability to test the CO, adjust the mixture
on the carburetor until you achieve the proper CO reading. If you
don't have a CO meter follow the manual adjustment procedure
later in this section.
Manual Fuel Mixture Adjustment Procedure
1. Ensure the unit is operating under an 80 to 100% load or at
the highest anticipated load.
2. Attach a frequency meter to monitor Hz.
Note: On these units the mixture adjustment is located on the
carburetor just behind the fuel inlet hose. This mixture adjustment is a partial turn, lean to rich, load block.
3. If you are adjusting from LP to NG you will have to richen the
adjustment and if you are going from NG to LP you will have to
lean out the adjustment.
4. Begin making your appropriate mixture adjustment, observing the Hz meter. If the meter begins to drop you have the mixture
set too lean or too rich. Adjust the valve in the opposite direction.
Adjustments should be made very slowly. Adjust back and forth
until the steady 60Hz reading is achieved with mixture set as lean
as possible.
VOLTAGE REGULATOR WIRING
THREE PHASE AND SINGLE PHASE
60706-188
Page 13
7263-00
THREE PHASE-LOW WYE
120/208 VOLTS
THREE PHASE AC WIRING
HIGH AND LOW WYE
THREE PHASE-HIGH WYE
277/480 VOLTS
60706-188
Page 14
7263-00
60706-188
Page 15
7263-00
SINGLE PHASE
120/240 VOLTS
THREE PHASE -DELTA
120/240 VOLTS
THREE PHASE AC WIRING - DELTA
SINGLE PHASE AC WIRING
7263-00
Page 16
60706-188
60706-188
Page 17
7263-00
DIMENSIONS ARE SUBJECT TO CHANGE. ALWAYS OBTAIN A
CERTIFIED DRAWING FOR CONSTRUCTION PURPOSES.
PSS40LS & 27LS OUTLINE DRAWING AND WIRING ENTRANCE
12 MONTH LIMITED WARRANTY
WINCO, Incorporated warrants to the original purchaser for 12 months or 1000 hours which
ever occurs first, that goods manufactured or supplied by it will be free from defects in workmanship and material, provided such goods are installed, operated and maintained in accordance
with WINCO written instructions.
WINCO’s sole liability, and Purchaser’s sole remedy for a failure under this warranty, shall be
limited to the repair of the product. At WINCO’s option, material found to be defective in material or workmanship under normal use and service will be repaired or replaced. For warranty
service, return the product within 12 months or 1000 hours which ever occurs first from the date
of purchase, transportation charges prepaid, to your nearest WINCO Authorized Service Center
or to WINCO, Inc. at Le Center Minnesota.
THERE IS NO OTHER EXPRESS WARRANTY.
To the extent permitted by law, any and all warranties, including those of merchantability and
fitness for a particular purpose, are limited to 12 months or 1000 hours which ever accurs first,
from date of purchase. In no event is WINCO liable for incidental or consequential damages.
Note: Some states do not allow limitation on the duration of implied warranty and some states
do not allow the exclusion or limitation of incidental or consequential damages, so the above
limitations may not apply in every instance. This warranty gives you specific legal rights which
may vary from state to state.
WINCO reserves the right to change or improve its products without incurring any obligations to
make such changes or improvement on products purchased previously.
EXCLUSIONS:
WINCO does not warrant Engines. Engines are covered exclusively by the warranties of their respective
manufacturers, see enclosed warranties.
WINCO does not warrant Batteries, or Other Component Parts that are warranted by their respective
manufacturers.
WINCO does not warrant modifications or alterations which were not made by WINCO, Inc.
WINCO does not warrant products which have been subjected to misuse and/or negligence or
D=LAbeen involved in an accident.
60706-188 - 7263-00
225 South Cordova
Le Center Mn 50657
507-357-6831
www.wincogen.com
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