DR30I4 thru DR350I4 with DSE Controller, Installation & Operation Manual 2012

DR30I4 thru DR350I4 with DSE Controller, Installation & Operation Manual 2012
DIESEL
GENERA
TO R
AT
SY
STEMS
YS
DR30 - DR350
With DSE7310
DEEP SEA
Engine Control
INSTALLATION AND
OPERATIONS MANUAL
DR45I4 Shown for Comparison
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 Winpower 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
WINPOWER should you need service assistance in the
future.
COPY YOUR MODEL AND SERIAL NUMBER
HERE
No other WINPOWER 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____________________________
'M" Spec.
__________________________________
PURCHASE DATE____________________________
TABLE OF CONTENTS
INTRODUCTION
GUIDE TO PRODUCT SAFETY
BASIC INFORMATION
Description
DSE7X10 Engine Control Layout
DSE7X10 Display Operations
RECEIVING THE GENERATOR
Unpacking the unit
Lifting the unit
ENGINE GENERATOR INSTALLATION
Installation
Engine Generator Set Mounting
Fuel Installation
Lubrication
Coolant
Battery Installation
Battery Charger/Block Heater Wiring
Mounting The Transfer Switch
AC ELECTRICAL CONNECTIONS
DC ELECTRICAL CONNECTIONS
INITIAL START-UP
EXERCISER CLOCK
TROUBLESHOOTING INFORMATION
APPENDIX DIRECTORY
Appendixes
12 MONTH WARRANTY
i
1
2
2
3
4
5
2
5
6
7
7
7
7
7
8
8
9
10
12
13
13
14
15-24
25
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
DEALER____________________________________
Page i
IMPORTANT SAFETY
INSTRUCTIONS
2.
FIRE HAZARD - Deisel fuel presents a hazard of possible
explosion and/or fire.
a.
SAVE THESE INSTRUCTION
b.
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 diesel
engine contain carbon monoxide, an invisible, odorless
and deadly gas that must be mixed with fresh air.
a.
b.
c.
4.
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.
b.
************************************************************
Use hearing protection equipment when working
around this equipment for long periods of time.
Keep your neighbors in mind when permanently installing this equipment.
DANGER:
5.
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.
***********************************************************
CLEANLINESS - Keep the generator and surrounding area
clean.
a.
b.
************************************************************
WARNING:
c.
WARNING indicates a potentially hazardous situation which, if
not avoided, could result in death or serious injury.
***********************************************************
d.
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 fuel or oil spills before starting the
unit.
Never allow leaves or other flammable material to build
up around the engine exhaust area.
***********************************************************
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.
************************************************************
SERVICING EQUIPMENT - All service, including the
installation or replacement of service parts, should be
performed only by a qualified technician.
NOTE:
a.
b.
c.
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.
d.
1.
e.
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.
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.
60708-160
f.
g.
Page 1
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 in
stantly.
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.
2170-00
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
PRODUCT DESCRIPTION:
This engine-generator set is designed for unattended remote start
operation. It can be operated as part of a fully automatic standby
power system or independently as a local start unit in a prime power
system. The engine-generator set is fully tested at the factory prior
to shipment to insure proper operation of each individual component as well as the total system's performance and reliability.
The engine generator set consists of a multi-cylinder, liquid cooled
engine nominally operating at 1800 rpm. The generator frequency
regulation is maintained by the engine governor to within +/- 1.5 hertz
(cps), from no load to rated load for standard mechanical governors
and to within +/- .5 hertz or better for units equipped with an electronic
governor. The generator is a single bearing, direct drive, rotating
field design. The generator is connected to the engine flywheel via
flexible drive disks. The Generator Set is skid mounted with
isolation mounts between the engine and base on all units.
Unit Orientation Note: All references used in this manual for unit
familiarization, access and component locations on the Generator
Set are oriented from a TOP (plan) VIEW with engine at the FRONT
and generator to the REAR.
WINPOWER uses a common junction box for all customer control
and power connections (both AC output and DC control). The
common electrical junction box is always on the left side at the
generator end of the machine.
A customer supplied 12 (or 24) Volt battery is required to complete
the installation. See appendix 1, to identify the voltage, size and CCA
(Cold Cranking Amp) requirements for your specific unit.
The engine is controlled and Generator Set operation is monitored
for safe operation by a programmable microprocessor based
Electronic Engine Control Module (ECM) with an LCD digital display.
The Generator Set ECM control is mounted on a vertical pedestal
on the right side of the generator. The ECM is programmed with a
cycle cranking sequence - 3 cycles of 15 seconds on / 15 seconds
off, and a 5 minute cool down delay. The cool down delay can be
changed in the field from 0 to 30 minutes by your dealer. Other
features, timing cycles, set points and signal output capabilities are
possible. Consult factory for procedure and passwords.
** NOTICE **
These units will automatically transfer if a power outage occurs
while running in an exercise mode.
MODEL NUMBER STRUCTURE:
The WINPOWER alpha-numerical numbering system consists of
a base model designation, followed by an options section, separated by a dash mark. The base component of the model numbering system identifies an engine type, engine starting method, fuel
type, kilowatt rating, engine manufacturer, and number of generator poles. Following the separation dash mark is the voltage connection and optional installed equipment. Options include features like weather enclosures (housing), base mounted fuel tank
sizes, and trailer options.
Please note that some features or packages, such as NFPA
level I & II, do not have an indication place in this numbering
system. They are issued and built with an M-Spec (i.e. M-10372)
number which can be found on the WINPOWER data tag. When
the M-Spec is present, supplemental inserts will accompany this
standard manual providing information about the special
equipment and features installed. The standard model numbering key that can be used along with the data tag information and/
or M-spec supplements to determine the generator sets ratings
and specifications
MODEL NUMBERING SYSTEM
BUILD YOUR GENSET REQUIREMENT FROM
THE BOTTOM OF THE PAGE TO THE TOP
G R N 20 I 4 - A H M T
TESTING POLICY:
TRAILER OPTION IF PRESENT UNIT IS MOUNTED ON A
TRAILER WITH FUEL TANK FUEL. TANK SIZES SHOWN BY
PREVOUIS LETTER (SMALL AND MEDUIM FUEL TANKS ONLY)
FUEL TANK SIZE
S = SMALL
L = LARGE
SEE CURRENT PRICE SHEET
TO DETERMINE CAPACITY
M = MEDUIM
* = NONE
HOUSING TYPE
H = WEATHER HOUSING (WEATHER-PAK)
* = NO HOUSING
A = SOUND ATTENUATED/WEATHER PROTECTIVE (SOUND-PAK)
VOLTAGE
X = SWITCHABLE
A = SINGLE PHASE 120/240
J = THREE PHASE 120/240
D = THREE PHASE 120/208
L = THREE PHASE 277/480
BASE UNIT - OPTIONS SEPARATOR
NUMBER OF POLES ON THE GENERATOR
4 POLES STANDARD
ENGINE MANUFACTURE
V = VOLVO
I = ISUZU (10 & 20 kW)
D = DEUTZ
I = IVECO (ALL OTHERS)
KILOWATTS
G = GM
N = NG ENGINES
GENERATOR OUTPUT IN KILOWATTS WITH STANDBY
GASEOUS FUEL TYPE
N = NATURAL GAS
P = LIQUID PROPANE VAPOR
L = L/P LIQUID WITHDRAWL
NOT USED WITH DIESEL FUEL
STARTING METHOD
R - REMOTE STARTING
FUEL TYPE
D = DIESEL
G = GASEOUS
SPECIFICATIONS
GENERATOR SET:
Every WINPOWER Generator Set has its own unique identity data
plate. This data plate identifies the complete unit model number,
the system serial number and has links to the individual components that form the generator set in our factory records. Several of
the major components also have their own individual identity plates
providing additional information to document build data for warranty and replacement parts.
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 125 degrees Fahrenheit.
GENERATOR:
WINPOWER Generators Sets use totally brushless, AVR (AutoVoltage Regulator) controlled broad-range generator ends. The
generator converts rotational mechanical energy into electrical
energy. Standard WINPOWER units are equipped with generators manufactured by Stamford/Newage. Each generator ‘end’
has its own data tag. The unique serial number is stamped on
the data plate and into the upper section of the mounting adapter
of the generator frame. The data label is affixed to the main
frame of the generator on the lower left side, similar to the
sample shown.
Typical Winpower Nameplate
Be sure to have the main WINPOWER unit data plate information
recorded inside the front cover of this manual for future reference
and for identification whenever requesting field or factory technical
assistance. Sample data plate is shown for reference. Primary
fields needed for assistance are complete model number, serial
number and especially the M-Spec number. The M-Spec number
(if provided) is recorded in the ‘TYPE NO.’ block on the Lower Right
of the plate. See the appendixs in the back of this manual for
individual units specifications and wiring diagram references.
ENGINE CONTROL PANEL LAYOUT
ENGINE:
Each engine has a nameplate on it that gives the specific engine
model number, build specification and the serial number for the
engine. See the technical data pages in the back of this manual
for individual engine specifications, fuel consumptions and
wiring diagram references.
This manual covers specific operation of the combined engine
generator set. Refer to engine operating and maintenance
instructions for specific instruction on the care and maintenance
of the engine. Oil and fuel requirements along with maintenance schedules and engine warranty information are provided
by the individual engine manufactures.
** CAUTION **
EQUIPMENT DAMAGE - Be sure to check the engine oil level
frequently as specified in the engine manual.
The engine manufacturer has established an excellent worldwide engine service organization; engine service is available
from a nearby authorized dealer or distributor; check the Yellow
Pages of the telephone directory under “engines,” or ask the
dealer from whom you purchased the power plant.
A. USB PROGRAMMING PORT - USB port for computer
interface. Used for programming the DSE7310 controller.
A
J
B. GENERATOR CONTROL POWER - Battery disconnect
switch for engine control. Used during long term storage to
prevent battery discharge
C. DSE7310 CONTROLLER - See controller explanation
below.
D.
will
the
ate
1
2
H
Emergency Stop Switch - When depressed this switch
disconnect all the 12 volt power to the DSE7X10 shutting
engine down. The display on the controller will annunci“Emergency Stop”.
3
4
B
G
E. AC INTERFACE CONNECTOR - This connector is used to
interface with the AC generator end. It provides the controller
with the voltage, amperage and frequency reading for the
display.
F. DC INTERFACE CONNECTOR - This connector provides
all the interface connections for the engine. Including the DC
power supply to operate the DSE7X10 controller. Engine
CAN connections are also made through this connector
providing the controller with the engine operational reading.
G. VOLTAGE ADJUSTMENT - This rheostat is used to fine
tune the AC output voltage after changing the voltage selector
switch.
H. 10 AMP FUSE This fuse supplies the DSE7X10 controller
12 Volt DC for all controller switching functions. (Replacement AGC-10A-250V)
C
D
F
E
C. MANUAL - This mode allows manual control of the generator functions. Once in the MANUAL mode the module will allow
you to start the unit using the START button. The unit will continue to run until either the STOP/RESET or AUTO button is
pressed. If the unit receives a remote start signal during manual
operation, the generator will remain running even after the remote
start signal has been lost. You must use the STOP/RESET or
AUTO button to stop the unit once you have started it in manual
mode.
**** CAUTION ****
J. 3 AMP FUSE -This fuse supplies the 12 volt DC to power
the DSE7X10 controller circuitry on the board. (Replacement
AGC-3A-250V)
K, L, M. 2 AMP FUSE- These fuses are in the AC input line
from the generator. These are the feeds that provide the AC
voltage reading on the display. If one of these is blown the
controller will not show the proper voltage on one leg and
may shutdown for low voltage. (Replacement AGC-2A-250V)
IF THE POWER FAILS WHILE RUNNING IN THE MANUAL
MODE THE TRANSFER SWITCH WILL TRANSFER THE LOAD
TO THE GENERATOR. TO PREVENT THIS THE MAINLINE
CIRCUIT BREAKER ON THE GENERATOR MUST BE OPENED.
D. AUTO – This button places the module into its AUTOMATIC
mode. This module will monitor the remote start input for a relay
closure. When the remote start signal is received it will time out
the start delay (5 Seconds) and then start the engine generator
set. When the remote start signal is lost (relay opened up) the
module will shut the engine generator set down after the cool
down timer has time out. The module will return to the auto start
mode and await the next start signal.
N. CUSTOMER DC INTERCONNECTIONS - See page 10 for
additional details.
A. MENU NAVIGATION BUTTONS – Left and Right buttons
select different grouping (i.e. Engine reading, Generator
reading, etc.) Up and down buttons scroll through the
different reading for each group.
E. LAMP TEST/HORN RESET - This button silences the audible
alarm if it is sounding and illuminates all of the LEDs as a lamp
test feature. When configured and fitted to a compatible engine
ECU, pressing this button in STOP/RESET mode after pressing
the START button (to power the ECU) will cancel any “passive)
alarms on the engine ECU.
B. STOP/RESET – This button places the module into its
STOP/RESET mode. This will clear an alarm conditions for
which the triggering criteria have been removed. If the
engine is running and this button is pushed the module will
shut off the fuel solenoid and the engine will come to a stop.
If a remote start signal is received while this switch is
activated, the unit will not start.
F. START – This button is active only in the MANUAL or STOP/
RESET mode. Pressing this button in the MANUAL mode will
start the engine locally for testing. The engine will continue to run
until either the STOP/RESET or the AUTO button is pressed.
Pressing this button with the control in the STOP/RESET mode
will turn on the CAN engine ECU (when correctly configured and
fitted to a compatible engine ECU)
DSE 7X10 Series CONTROLLER
G.
2170
Page 4
CLOSE GEN-SET – NOT USED IN THIS APPLICATION
60708-160
H.
OPEN GEN-SET – NOT USED IN THIS APPLICATION
***** CAUTION ****
J.
USER CONFIGURABLE INDICATORS –
1. Remote Start.
2. Low Fuel
3. Generator Available
4. Emergency Stop
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.
NOTE: STOP/RESET, MANUAL mode and AUTO mode buttons
all have indicator lamps next to them to tell you what mode you
are in. Pressing buttons out of sequence will cause the engine
not to function properly.. See button operation sequencing
above.
.
RECEIVING THE GENERATOR
The generator set will generally be shipped by a commercial ‘common freight carrier’. Large and bulky units are often shipped on a
dedicated or specially contracted ‘Flat-Bed’ truck. The means of
shipment is determined in consultation between the WINPOWER
Sales and Shipping staff and the customer. Routing is determined
by the bulk, size, and a means available to unload the generator at
the receiving end. WINPOWER recommends units that are shipped
by common carrier be delivered to a commercial dock to allow the
Generator Set to be unloaded in a safe, efficient manner and to
minimize handling damage to the unit.
UNPACKING:
(Not recommended until the unit is on-site)
1. Carefully remove the crate.
2. After inspecting the engine-generator for external physical
damage, locate and check the following items packed with
the unit.
a.
b.
c.
d.
Owner’s operators manual.
Engine manufacturer’s instruction manual.
Battery hold-down brackets & hardware.
Unit components or accessory items shipped loose
for on-site installation.
e. Optional accessories (i.e. remote annunciator)
3. Remove main frame hold down bolts.
4. Unit can now be lifted from shipping rails.
Locate the packing slip on the side of the crate or request it from
the truck driver. When receiving the unit take special care in examining the unit for damage during shipment. Avoid signing for the
equipment until a full visual assessment and inventory have been
made. Verify that you have received the right equipment and the
proper amount by matching up the equipment to the packing list.
Larger units may ship with the fuel tank and muffler removed.
Verify that those components are undamaged and removed from
the truck prior to their release.
The keys for doors of the enclosed generators sets are typically
attached to lifting eye on the base of the machine. These keys are
matched to all the doors on the generator set housing.
UNPACKING INSTRUCTIONS:
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
consignee’s memo of the loss or damage. Contact the carrier for
claim procedures.
LIFTING THE GENERATOR SET
NOTICE - Personal Injury
To prevent injury to persons or equipment, observe the following guidelines when lifting the generator:
Due to the different designs, configurations, options, weights, site
conditions, and available material handling equipment, specific
lifting instructions are not provided for each individual generator
set model. General guidelines provided are applicable to the entire standby generator line. It is the responsibility of the installing
party to follow the lifting equipment’s operators manual to prevent
injury to personnel and damage to the generator. Smaller Generator Sets may not require use of overhead lifting equipment and
may be placed on the pad with basic material handling equipment, i.e. a forklift.
CAUTION: - Do not attempt to lift the generator set by the means
of the lifting eyes on the engine or generator end.
When loss or damage is noted after delivery, segregate the damaged material, and contact the carrier for claim procedures.
These lifting points are only for use during the manufacturing process and are designed for lifting of the individual Generator Set
component.
“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.
WINPOWER has designed all of its Generators Sets to be lifted at
the corners with an appropriate lifting rig. The lifting points are
located on the side rails of the generator base or on the optional
base mounted fuel tank of a Diesel Generator Set.
60708-160
Page 5
2170-00
The generator set can be lifted with properly rated chains or cables
along with the use of spreader bars. The spreader bars should be
long enough so that the lift cables or chains do not come into
contact with the generator set. Use of commercially available lifting fixtures may also be used. Always be sure that the equipment
is properly rated for the weight of the generator. Failure to do so
can cause damage to the generator, injury to personnel or even
death.
The generator set and fuel tank may or may not be shipped as a
complete unit. If the fuel tank is shipped separate from the generator, place the tank on the cement pad first, and then place the
generator on top of the fuel tank.
***************
***** WARNING ****
***************
NEVER - attempt to lift the fuel tank while filled with fuel. Sloshing of the fuel can cause a shift in the balance of the fuel tank,
making for a DANGEROUS, unbalanced lifting load. If the generator was shipped on the fuel tank, use the lifting points located on the fuel tank to move the entire Generator Set into
place. DO NOT place fuel in the tank prior to lifting.
Depending on generator set size and configuration, the exhaust
system may ‘ship loose’ with the generator set for installation on
site. The muffler and its attaching brackets must be mounted on
top of the generator housing prior to operating the engine
generator set.
2170
INSTALLATION
***************
***** WARNING ****
***************
PERSONAL INJURY - Before proceeding with the installation,
be sure the DSE7X10 is in the "stop" position. Before proceeding with the installation, be sure the Generator MLCB
(Main Line Circuit Breaker) is in the ‘OFF’ position and the unit
starting battery is disconnected.
GENERAL INFORMATION
These engine/generator sets are generally supplied as weather
enclosed packages for quick installation on an outdoor concrete
pad. They are also available as open skid mounted units for indoor
installation in a building or protective enclosure supplied by the
installer. The factory weather enclosures are available as standard
or acoustical housing intended for outdoor installation only. Factory
weather enclosed units are not intended to be used indoors and
no support is available to assist in re-engineering finished packaged units.
All versions must be bolted to a solid base for proper operation. A
properly designed concrete pad is necessary for stationary operation. A substantial DOT certified trailer is required for mobile
applications. Consult a qualified, licensed electrician or contractor
to install and wire this Generator Set. The installation must comply
with all national, state, and local codes.
Page 6
60708-160
Before beginning the installation process, recheck the voltage,
phase and amperage rating of the Generator Set and ATS (Automatic Transfer Switch). 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.
** NOTICE **
For full service switching of the entire load, the ATS must be ‘SE’
(Service Entrance) rated or must have a properly rated fusible
disconnect installed before the ATS to protect the contacts.
.
ENGINE GENERATOR SET MOUNTING
The unit’s main frame must 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.
The unit should be mounted to allow for ample working room
around it. A general rule to follow is five (5) feet of clearance on
all sides. (Code NFPA 37)
FIRE DANGER - Connecting rigid fuel line (i.e. steel or copper
line) directly to the inlet fuel filter or fuel pump may cause the
fuel line to crack during operation creating a serious fire
hazard.
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 the 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 ****
FUEL INSTALLATION
The fuel supply should be as close to the engine as possible. This
will reduce the installation cost of fuel runs and minimize line
losses. The diesel fuel supply should be no more than 3 feet below
the fuel inlet on the pump. If your fuel supply is lower than three feet
you may have to install an additional lift pump to bring the fuel up to
the mechanical fuel pump on the engine.
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 fuel supplier.
INSTALLING THE FUEL LINE
Engine generator sets are properly adjusted before they leave the
factory. Connecting a fuel supply with adequate supply volume is
critical to reliable operation. Diesel units with optional base mounted
fuel tanks are pre-plumbed to the mechanical fuel pump on the
engine.
Open skid mounted Diesel units are often supplied with capped
inlet and return lines. The use of a suitable customer supplied
flexible fuel line is essential between the engine and fuel supply to
provide a vibration break between your fuel supply and the engine.
60708-160
***************
***** WARNING ****
***************
In the following battery installation procedure, check to be
sure the DSE7X10 is 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; 24 volt systems require 2 batteries. 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.
See the specification listing in appendix 1 for the correct battery
size and minimum CCA rating for the different models.
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.
When installing or replacing batteries, use the proper group/size
starting battery. The battery should be a Maintenance Free lead
acid design. Deep cycle batteries will not work for this application.
CAUTION – PERSONAL DANGER
CAUTION - NEVER dispose of a battery in a fire. The battery is
capable of exploding.
CAUTION -DO NOT open or mutilate the battery. Released
electrolyte is known to be harmful to the skin and eyes and to be
very toxic.
Page 7
2170-00
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.
3. 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.
4. Be sure all connections are tight and coat the terminals and
cable ends 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.
CONNECTING THE BATTERY CHARGER &
BLOCKHEATER
A three-stage battery charger is provided standard for all 12 volt
standby systems. The standard charger is a Automatic Battery
Charger & Maintainer. This Charger has three rates of charging.
During the first stage, know as BULK Charging, the charging
current is limited to 2 Amps at a voltage of up to 14.5 volts. The
green LED will blink during this stage. During stage two, know
as ABSORPTION Charging, the charging voltage is held at 14.5
volts and the charging rate gradually reduces the amount of
current (amps) flowing to the battery. The green LED will also
blink during this stage. Stage three is called MAINTENANCE
Charging. During this stage the voltage will drop to 13.3 volts
and the charge rate will drop to as low at .1 amps. This keeps
your batteries in a fully charged condition without over charging
them. During this stage the green LED is constantly lit.
This charger is mounted on the back side of the generator
cabinet and plugged into the receptacle mounted in the AC
connection cabinet.
All 24 volt battery chargers and option 12 volt chargers will have
a cord on them that you can plug into the receptacle on the side
of the connection box or depending on size they may require
hard wiring in the terminal block in the bottom left of the connection box.
** 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. It is suggested that this circuit be fused for 20 30 amps, depending on blockheater requirements. 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 the side circuit breaker panel, for a 20 amp
circuit and terminal blocks are provided for heavier circuits.
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
SERVICING BATTERIES
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.
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.
The engine blockheater installed on this unit should also be
plugged in this receptacle. The block heater is thermostatically
controlled 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!
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.
2170
Page 8
60708-160
INSTALLATION NOTES
CUSTOMER CONNECTION BOX FOR
BOTH AC & DC CONNECTION
10 kW THROUGH 125 kW
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 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
CUSTOMER CONNECTION BOX FOR
BOTH AC & DC CONNECTION
150 kW THROUGH 350 kW
NOTICE - CLASS 1 WIRING METHODS ARE TO BE USED FOR
ALL FIELD WIRING CONNECTIONS TO TERMINALS OF A
CLASS 2 CIRCUIT
Note: This symbol
shown.
always indicates ground where
All wiring must be completed in accordance with the Nation
Electric Code as well as any state or local codes.
You must pay particular attention to wire size requirement for the
amperage of service you are dealing with. Appendix "2" provides you guidance on wire sizing based on both wire type and
amperage. Wire amperage's have been derated for 40o C
ambient temperatures operation.
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 generator.
The 1200 amp terminal block lugs on the 300 to 600 kW will
handle wire sizes #3/0 to 600 MCM and should be torqued to 28
ft. lbs.
The 1000 amp terminal block lugs on the 130 kW to 250 kW will
handle wire sizes #3/0 to 500 MCM and should be torqued to 28
ft. lbs. (Rated for 900 AMP for AL)
The 400 amp terminal block lugs on the 65 & 90 kW will handle
wire sizes #1 AWG to 400 MCM and should be torqued to 300 in.
lbs.
60708-160
Page 9
2170-00
The 225 amp terminal block lugs on the 20 kW to 45 kW will
accommodate #4 AWG to 300 MCM and should be torqued to
250 in. lbs.
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.
Please refer to the circuit breaker installed on your unit for
breaker lug capacities and proper torque specifications.
To select the proper conductor size between the Generator and
the ATS, first look your model up in Table 1 of Appendix "A" for
your generator amperage. Then refer to Appendix "2" for guidance on wire sizing based on both wire type and amperage.
Wire amperages have been derated for 40o C ambient temperatures operation.
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 65 kW and larger will handle
wire sizes #6 AWG to 300 MCM and should be torqued to 21 ft.
lbs. The lugs on the 20 &45 kW will accommodate #10 AWG to
2/0 AWG and should be torqued to 200 in. lbs.
D - 120 VOLT GFCI CIRCUIT TERMINAL BLOCK - These terminals are rated for 85 amps and will handle wire sizes #4 AWG to
#18 AWG. They should be torqued to 16 in. lbs. This circuit must
be fed from a fused circuit in the distribution panel and provides
power for the blockheater and the battery charger.
*************
***** 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.
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 8 foot copper rod driven into the earth will
provide a proper earth ground.
D.C. ELECTRICAL
CONNECTIONS
All DC connections are completed on the terminal strip just
below the engine control. All DC connection must be run in
separate conduit. You can not mix AC and DC leads in the
same conduit.
CONNECTION BOX TERMINALS
Wire size requirements for each of the connections may vary
but terminal lugs should be used for all connections. Torque
E - 120 VOLT/20 AMP DUPLEX RECEPTACLE, This convenience
receptacle is used on the small units to plug in both the small
float charger as well as the blockheater. On some the units with
the larger block heater you will have to wire directly into the
terminal block.
F - This lug is provided on the neutral terminal block to allow you
to run a neutral to ground lead if you are using the generator in a
stand alone application. This would be an application where
there is not distribution panel and no other ground to neutral
bond in the wiring system. If a grounding wire is attached here
remove the floating neutral label in the panel. This will not be
used when you are wiring a generator and transfer switch into
an existing power system.
*************
***** 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.
spec for terminal lugs is 9 in. lbs.
A - Customer Remote Start CONNECTIONS 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 DSE 7X10 to go into an autostart 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.
2170
Page 10
60708-160
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.
ASCO 165 UL SWITCH
Your DC connection points in the ASCO 165 ATS are
terminals “4” and “5 on the interface terminal block.
B - ESTOP- & ESTOP+. Remote Emergency Stop terminals.
These two terminals are shipped with a jumper installed. If your
application requires the installation of a Remote Emergency
Stop switch, remove the jumper and wire your switch to these
terminals. This unit will not start and run without either the
jumper installed or a remote N/C switch installed..
C. - Battery Charger Failure. Battery charger failure relay input
from remote battery charger to DSE7310 controller.
D - Remote Display Panel Interface Terminals. These interface
terminals are prewired to allow for the connection of a 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 can used to meet the remote annunciation requirements of NFPA 110 standards. (This feature meets the annunciation requirements in applications requiring NFPA110 level
one protection.)
DC Interconnections to the
Automatic Transfer Switch
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.
Two control wires are required between the A.T.S. panel and the
generator control terminal box. Depending on the distance, 14
to 16 gauge stranded wire should be used. These wires should
be labeled S1 (ground) and S23 (start).
*************
***** WARNING *****
*************
Be sure Engine Generator is in the "OFF" position before you
make any DC interconnections.
*******CAUTION******
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
the wire labeled “Start 23” is routed to start contact “X2”
X1
60708-160
X2
Page 11
2170-00
INITIAL START UP
*************
***** WARNING *****
*************
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.
Use the following check list to verify correct installation before
starting the engine:
1.
2.
3.
4.
5.
6.
7.
8.
9.
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.
Battery connections clean and tight.
Battery fully charged.
All AC and DC wiring installed and properly
protected.
The AC output readings displayed on the DSE7X10 are collected
through the AC interface harness wired in the generator control
box. An shutdowns related to the AC output are not a function of
the engine ECU but are based on information collected in the
DSE7X10 via this AC harness.
4. During manual operation the load will not normally be applied
to the generator. But caution must be used, if the line power
should fail or be turn off to the transfer switch during manual
operation the load may be applied to the generator.
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).
After completing the above checklist, the engine-generator set is
ready for the initial start-up test.
STARTING PROCEDURE
MANUAL MODE
****************
***** WARNING *****
****************
EQUIPMENT DAMAGE - BEFORE ATTEMPTING TO START
THIS UNIT COMPLETE YOUR PRESTART CHECKLIST AND
INSURE THE GENERATOR MAINLINE CIRCUIT BREAKER IS
IN THE PROPER POSITION PRIOR TO STARTING. STARTING
THIS UNIT WITHOUT IT PROPERLY CONNECTED CAN
CAUSE SERIOUS PERSONAL INJURY OR EQUIPMENT
DAMAGE.
1. Depress the manual mode button on the control panel. The
small LED light next to it should come on.
2. Press the start button- The DSE7X10 will send a start signal
to the ECU on the engine. The engine ECU will then energize
the fuel solenoid and start the cranking cycle (10 seconds on
and 10 seconds off).
NOTE: There is no start delay in this mode of operation.
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 **
If for any reason during the check out procedure the voltage and
frequency are not correct, depress the STOP/RESET button and
correct the trouble before proceeding.
5. Stopping – There are two ways to stop the unit when it is in
the manual mode. Pressing the STOP/RESET button will stop
the unit immediately. Pressing the AUTO mode button will stop
the unit but only after the cool down timers have timed out and
there is no remote start signal being sent to the unit.
AUTO MODE
If the engine fails to start during this cranking period the starter
motor is disengaged and goes into a rest mode after which a
second attempt is made to start the engine. Should this
sequence continue through 3 cranking cycles the start sequence
will be stopped and the display will show ‘FAILED TO START’.
2170
All engine functions are controlled by the ECU on the engine.
The ECU on the engine will send information signals to the
DSE7X10 via the CAN connections to indicate oil pressure,
water temperature, etc for the display on the engine control.
All shutdown functions are also controlled by the ECU on the
engine what you see displayed on the DSE7X10 display is what
is happening inside the ECU on the engine.
To activate the automatic start mode you will just need to
depress the AUTO button, the LED indicator beside the button
confirms that the unit is in automatic start mode.
Page 12
60708-160
To test the automatic start Transfer Switches follow the instruction in the operator’s 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
ATS and start over.
ENGINE STARTS AND THEN STOPS AND ALARM LIGHT
COMES ON
1.
2.
3.
4.
5.
6.
7.
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 next the
AUTO button.
ENGINE WILL NOT COME UP TO SPEED AFTER IT
STARTS
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.
1.
TROUBLESHOOTING TABLES
Note: Before doing any troubleshooting, check the digital
display on the DSE7X10. Normally it will tell why the unit has
failed. This will shorten your troubleshooting time and in
many cases prevent the replacement of parts that may not be
defective.
2.
3.
3.
4.
5.
6.
7.
8.
9.
10.
Digital Genset Controller not in "AUTO"
Transfer control switch not in "AUTOMATIC"
position.
Incorrect wiring between transfer switch and
generator.
Defective control relay in the transfer
switch.
Fuse (s) blown in the Digital Genset Controller.
Defective Digital Genset Controller
Loose or dirty battery terminals.
Defective starter.
Defective start solenoid.
Dead Battery
1.
2.
3.
3.
4.
5.
6.
7.
8.
No AC generator output from generator.
Defective ATS control board. See applicable
transfer switch manual .
Circuit breaker between generator and transfer
switch is either open or defective.
ATS PANEL WILL NOT RETRANSFER TO NORMAL
POWER
1.
2.
Proper normal line power not available at line
terminals in ATS panel.
Defective ATS control board. See applicable
transfer switch manual .
NO AC OUTPUT FROM GENERATOR
1.
2.
3.
4.
5.
6.
7.
8.
9.
ENGINE WILL NOT CRANK WITH GENERATOR
RUN PUSH-BUTTON DEPRESSED.
1.
2.
Insufficient fuel volume getting to the unit.
a. Too small of fuel line.
b. Fuel racks not opened properly
Governor is defective.
AC short in generator components.
ATS PANEL WILL NOT TRANSFER TO EMERGENCY
SUPPLY (GENERATOR)
UNIT WILL NOT CRANK WHEN THE POWER FAILS.
1.
2.
Engine is low on oil.
Engine has high water temperature.
Engine has overspeed.
Engine has gone into overcrank.
No output from AC generator.
Loss of speed signal.
Loss of run signal.
Battery dead.
Blown DC fuses on the 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.
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.
Wiring error
ENGINE CRANKS BUT WILL NOT START
1.
2.
3.
4.
5.
6.
60708-160
Improper fuel delivery to the unit.
Fuel supply shut off.
Fuel tank empty.
Air in the injection system.
Engine fuel rack has not opened.
Defective CANBus on the engine
Page 13
2170-00
APPENDIX
UNIT SPECIFICATIONS
ENGINE MODEL NUMBER
BATTERY REQUIREMENTS
FULL LOAD FUEL REQUIREMENTS
WIRE SIZING TABLE
WIRING DIAGRAM CROSS REFERENCE
BY MODEL NUMBER
GENERATOR AC CONNECTION DIAGRAM
120/240 VOLT SINGLE PHASE
120/240 VOLT THREE PHASE
120/208 VOLT THREE PHASE
277/480 VOLT THREE PHASE
VOLTAGE REGULATOR CONNECTION
GENERATOR CONTROL PANEL WIRING
ENGINE SCHEMATIC
GENERATOR CROSS REFERENCE
WARRANTY STATEMENT
PAGE 15
PAGE 15
PAGE 15
PAGE 15
PAGE 16
PAGE 17
PAGE 18
PAGE 18
PAGE 19
PAGE 19
PAGE 14
PAGE 20
PAGE 21 & 22
PAGE 24
PAGE 25
VOLTAGE REGULATOR WIRING
THREE PHASE AND SINGLE PHASE
2170
Page 14
60708-160
APPENDIX 1
MODEL
SPECIFICATIONS TABLES
WATTS
VOLTS
PF
AMP
HZ PH
ENGINE
ENGINE
DR30I4-A
DR30I4-D
DR30I4-J
DR30I4-L
30,000
30,000
30,000
30,000
120/240
120/208
120/240
277/480
1.0
0.8
0.8
0.8
125
104
90
45
60
60
60
60
1
3
3
3
ISUZU
ISUZU
ISUZU
ISUZU
12 VOLTS
12 VOLTS
12 VOLTS
12 VOLTS
24/650
24/650
24/650
24/650
3.1 GAL
3.1 GAL
3.1 GAL
3.1 GAL
DR45I4-A
DR45I4-D
DR45I4-J
DR45I4-L
45,000
45,000
45,000
45,000
120/240
120/208
120/240
277/480
1.0
0.8
0.8
0.8
187
156
135
68
60
60
60
60
1
3
3
3
IVECO NEF45 SM1
IVECO NEF45 SM1
IVECO NEF45 SM1
IVECO NEF45 SM1
12 VOLTS
12 VOLTS
12 VOLTS
12 VOLTS
24/650
24/650
24/650
24/350
4.1 GAL
4.1 GAL
4.1 GAL
4.1 GAL
DR65I4-A
DR65I4-D
DR65I4-J
DR65I4-L
65,000
65,000
65,000
65,000
120/240
120/208
120/240
277/480
1.0
0.8
0.8
0.8
270
225
195
97
60
60
60
60
1
3
3
3
IVECO NEF45 SM2
IVECO NEF45 SM2
IVECO NEF45 SM2
IVECO NEF45 SM2
12 VOLTS
12 VOLTS
12 VOLTS
12 VOLTS
24/650
24/650
24/650
24/650
4.6 GAL
4.6 GAL
4.6 GAL
4.6 GAL
DR90I4-A
DR90I4-D
DR90I4-J
DR90I4-L
90,000
90,000
90,000
90,000
120/240
120/208
120/240
277/480
1.0
0.8
0.8
0.8
375
312
270
135
60
60
60
60
1
3
3
3
IVECO NEF45 TM2
IVECO NEF45 TM2
IVECO NEF45 TM2
IVECO NEF45 TM2
12 VOLTS
12 VOLTS
12 VOLTS
12 VOLTS
31/900
31/900
31/900
31/900
6.9 GAL
6.9 GAL
6.9 GAL
6.9 GAL
DR100I4-A
DR100I4-D
DR100I4-J
DR100i4-L
100,000
105,000
105,000
110,000
120/240
120/208
120/240
277/480
1.0
0.8
0.8
0.8
416
364
315
172
60
60
60
60
1
3
3
3
IVECO NEF67 TM1
IVECO NEF67 TM1
IVECO NEF67 TM1
IVECO NEF67 TM1
12 VOLTS
12 VOLTS
12 VOLTS
12 VOLTS
31/900
31/900
31/900
31/900
7.7 GAL
7.7 GAL
7.7 GAL
7.7 GAL
DR130I4-A
DR130I4-D
DR130I4-J
DR130I4-L
130,000
130,000
130,000
130,000
120/240
120/208
120/240
277/480
1.0
0.8
0.8
0.8
541
451
390
195
60
60
60
60
1
3
3
3
IVECO NEF67 TM1
IVECO NEF67 TM1
IVECO NEF67 TM1
IVECO NEF67 TM1
12 VOLTS
12 VOLTS
12 VOLTS
12 VOLTS
31/900
31/900
31/900
31/900
8.9 GAL
8.9 GAL
8.9 GAL
8.9 GAL
DR175I4-A
DR175I4-D
DR175I4-J
DR175I4-L
175,000
175,000
175,000
175,000
120/240
120/208
120/240
277/480
1.0
0.8
0.8
0.8
729
607
526
263
60
60
60
60
1
3
3
3
IVECO NEF67 TE2
IVECO NEF67 TE2
IVECO NEF67 TE2
IVECO NEF67 TE2
12 VOLTS
12 VOLTS
12 VOLTS
12 VOLTS
4D/1100
4D/1100
4D/1100
4D/1100
12.4 GAL
12.4 GAL
12.4 GAL
12.4 GAL
DR200D4-D
DR200D4-J
DR200D4-L
200,000
200,000
200,000
120/208
120/240
277/480
0.8
0.8
0.8
607
526
263
60
60
60
3
3
3
DEUTZ BF6M1013FC
DEUTZ BF6M1013FC
DEUTZ BF6M1013FC
12 VOLTS
12 VOLTS
12 VOLTS
4D/1100
4D/1100
4D/1100
13.0 GAL
13.0 GAL
13.0 GAL
DR250I4-D
DR250I4-J
DR250I4-L
250,000
250,000
250,000
120/208
120/240
277/480
0.8
0.8
0.8
867
751
375
60
60
60
3
3
3
IVECO CURSOR 87 TE1D
IVECO CURSOR 87 TE1D
IVECO CURSOR 87 TE1D
24 VOLTS (2) 4D/1100
24 VOLTS (2) 4D/1100
24 VOLTS (2) 4D/1100
17.0 GAL
17.0 GAL
17.0 GAL
DR300I4-D
DR300I4-J
DR300I4-L
300,000
300,000
300,000
120/208
120/240
277/480
0.8
0.8
0.8
1040
902
451
60
60
60
3
3
3
IVECO CURSOR 10 TE1D
IVECO CURSOR 10 TE1D
IVECO CURSOR 10 TE1D
24 VOLTS (2) 4D/1100
24 VOLTS (2) 4D/1100
24 VOLTS (2) 4D/1100
20.2 GAL
20.2 GAL
20.2 GAL
DR350I4-D
DR350I4-J
DR350I4-L
350,000
350,000
350,000
120/208
120/240
277/480
0.8
0.8
0.8
1214
1052
526
60
60
60
3
3
3
IVECO CURSOR 13 TE3X
IVECO CURSOR 13 TE3X
IVECO CURSOR 13 TE3X
24 VOLTS (2) 4D/1100
24 VOLTS (2) 4D/1100
24 VOLTS (2) 4D/1100
24.5 GAL
24.5 GAL
24.5 GAL
4LE1T
4LE1T
4LE1T
4LE1T
BATTERY FULL LOAD
Note: De-rate unit power ratings by 3-1/2 % per 1000 feet elevation above sea level.
60708-160
Page 15
2170-00
APPENDIX 2
The table below is based on Table 310.16 in the National Electric Code 2008 Edition
Allowable ampacitier of insulated condutors rated 0 through 2000 volts, 750 C through 900C. Not more than
three current-carrying conductors in Raceway, Cable or Earth (Direct Buried). Adjusted for 400C (1040F)
ambient temperature.
Copper
Copper
Aluminum
Copper Clad Aluminum
750C
Aluminum
Copper Clad Aluminum
900C
750C
900C
Wire Type:
RHW
THHW, THW
THWN, XHHW
USE,ZW
Wire Type:
TBS,SA.SIS
FEP,FEPB,MI,RHH
RHW-2,THHN
THHW, THW-2
XHH, XHHW
XHHW-2, ZW-2
SIZE AWG
OR kcmil
Wire Type:
RHW
THHW, THW
THWN, XHHW
USE
Wire Type:
TBS,SA.
SIS, THHN
THHW, THW-2
THWN-2,RHH
RHW-2, USE-2
XHH, XHHW
XHHW-2, ZW-2
44
57
75
50
68
86
8
6
4
35
44
57
41
55
68
88
101
114
100
118
137
3
2
1
66
79
88
77
91
105
132
154
176
202
155
177
205
237
1/0
2/0
3/0
4/0
106
119
136
158
123
137
159
187
224
251
273
295
264
291
319
346
250
300
350
400
180
202
220
238
209
232
255
278
334
370
405
418
391
432
473
487
500
600
700
750
273
299
330
339
319
350
382
396
431
458
480
519
505
532
560
605
800
900
1000
1250
348
374
392
427
410
437
455
496
550
572
585
642
669
683
1500
1750
2000
458
480
493
532
560
573
For addition information see table 310.16 of the National Electric Code
2170-00
Page 16
60708-160
APPENDIX 3
WIRING DIAGRAMS CROSS REFERENCE
MODEL
WATTS
VOLTS
PHASE
AC CONNECTION
DIAGRAM
DC ENGINE
CONTROL
ENGINE
CONNECTIONS
DR30I4-A
DR30I4-D
DR30I4-J
DR30I4-L
30,000
30,000
30,000
30,000
120/240
120/208
120/240
277/480
SINGLE
THREE
THREE
THREE
PAGE 18
PAGE 19
PAGE 18
PAGE 19
PAGE 20
PAGE 20
PAGE 20
PAGE 20
PAGE 22
PAGE 22
PAGE 22
PAGE 22
DR45I4-A
DR45I4-D
DR45I4-J
DR45I4-L
45,000
45,000
45,000
45,000
120/240
120/208
120/240
277/480
SINGLE
THREE
THREE
THREE
PAGE 18
PAGE 19
PAGE 18
PAGE 19
PAGE 20
PAGE 20
PAGE 20
PAGE 20
PAGE 21
PAGE 21
PAGE 21
PAGE 21
DR65I4-A
DR65I4-D
DR65I4-J
DR65I4-L
65,000
65,000
65,000
65,000
120/240
120/208
120/240
277/480
SINGLE
THREE
THREE
THREE
PAGE 18
PAGE 19
PAGE 18
PAGE 19
PAGE 20
PAGE 20
PAGE 20
PAGE 20
PAGE 21
PAGE 21
PAGE 21
PAGE 21
DR90I4-A
DR90I4-D
DR90I4-J
DR90I4-L
90,000
90,000
90,000
90,000
120/240
120/208
120/240
277/480
SINGLE
THREE
THREE
THREE
PAGE 18
PAGE 19
PAGE 18
PAGE 19
PAGE 20
PAGE 20
PAGE 20
PAGE 20
PAGE 21
PAGE 21
PAGE 21
PAGE 21
DR100I4-A
DR100I4-D
DR100I4-J
DR100I4-L
100,000
105,000
105,000
110,000
120/240
120/208
120/240
277/480
SINGLE
THREE
THREE
THREE
PAGE 18
PAGE 19
PAGE 18
PAGE 19
PAGE 20
PAGE 20
PAGE 20
PAGE 20
PAGE 21
PAGE 21
PAGE 21
PAGE 21
DR130I4-A
DR130I4-D
DR130I4-J
DR130I4-L
130,000
130,000
130,000
130,000
120/240
120/208
120/240
277/480
SINGLE
THREE
THREE
THREE
PAGE 18
PAGE 19
PAGE 18
PAGE 19
PAGE 20
PAGE 20
PAGE 20
PAGE 20
PAGE 21
PAGE 21
PAGE 21
PAGE 21
DR175I4-A
DR175I4-D
DR175I4-J
DR175I4-L
175,000
175,000
175,000
175,000
120/240
120/208
120/240
277/480
SINGLE
THREE
THREE
THREE
PAGE 18
PAGE 19
PAGE 18
PAGE 19
PAGE 20
PAGE 20
PAGE 20
PAGE 20
PAGE 21
PAGE 21
PAGE 21
PAGE 21
DR200D4-D
DR200D4-J
DR200D4-L
200,000
200,000
200,000
120/208
120/240
277/480
THREE
THREE
THREE
PAGE 19
PAGE 18
PAGE 19
PAGE 20
PAGE 20
PAGE 20
PAGE 21
PAGE 21
PAGE 21
DR250I4-D
DR250I4-J
DR250I4-L
250,000
250,000
250,000
120/208
120/240
277/480
THREE
THREE
THREE
PAGE 19
PAGE 18
PAGE 19
PAGE 20
PAGE 20
PAGE 20
PAGE 21
PAGE 21
PAGE 21
DR300I4-D
DR300I4-J
DR300I4-L
300,000
300,000
300,000
120/208
120/240
277/480
THREE
THREE
THREE
PAGE 19
PAGE 18
PAGE 19
PAGE 20
PAGE 20
PAGE 20
PAGE 21
PAGE 21
PAGE 21
DR350I4-D
DR350I4-J
DR350I4-L
350,000
350,000
350,000
120/208
120/240
277/480
THREE
THREE
THREE
PAGE 19
PAGE 18
PAGE 19
PAGE 20
PAGE 20
PAGE 20
PAGE 21
PAGE 21
PAGE 21
60708-160
Page 17
2170-00
THREE PHASE -DELTA
120/240 VOLTS
THREE PHASE AC WIRING - DELTA
SINGLE PHASE AC WIRING
SINGLE PHASE
120/240 VOLTS
60708-160
Page 18
2170
60708-160
Page 19
2170-00
THREE PHASE-HIGH WYE
277/480 VOLTS
THREE PHASE-LOW WYE
120/208 VOLTS
THREE PHASE AC WIRING
HIGH AND LOW WYE
DSE 7X10 ENGINE CONTROL WIRING DIAGRAM ALL MODELS
60708-160
Page 20
2170-00
ENGINE SCHEMATIC DR45I4, DR65I4, DR100I4, DR130I4
ENGINE SCHEMATIC DR100D4 & DR200D4
ENGINE SCHEMATIC DR175I4, DR250I4, DR300I4, DR350I44M
60708-160
Page 21
2170-00
ENGINE SCHEMATIC DR30I4
ACCESSING THE FRONT PANEL
CONFIGURATION
EDITING A PARAMETER
2170-00
Page 22
60708-160
PAGE LEFT BLANK
FOR FUTURE USE
60708-160
Page 23
2170-00
APPENDIX 4
2170
GENERATOR CROSS REFERENCE
MODEL
BASE
P/N
VOLTS
PHASE
WINCO P/N
NEWAGE
MODEL #
WINDING
GROUP
GENERATOR
LEADS
DR30I4-A
DR30I4-D
DR30I4-J
DR30I4-L
455030-041
455030-042
455030-043
455030-044
120/240
120/208
120/240
277/480
SINGLE
THREE
THREE
THREE
350003-731
350003-702
350003-702
350003-702
PI144G1J
PI144H1L
PI144H1L
PI144H1L
6
311
311
311
4
12
12
12
DR45I4-A
DR45I4-D
DR45I4-J
DR45I4-L
351907-1
351907-2
351907-2
351907-2
120/240
120/208
120/240
277/480
SINGLE
THREE
THREE
THREE
350003-731
350003-702
350003-702
350003-702
UCI224E
UCI224D
UCI224D
UCI224D
6
311
311
311
4
12
12
12
DR65I4-A
DR65I4-D
DR65I4-J
DR65I4-L
351924-1
351924-2
351924-2
351924-2
120/240
120/208
120/240
277/480
SINGLE
THREE
THREE
THREE
350003-751
35000-704
35000-704
35000-704
UCI224G
UCI224F
UCI224F
UCI224F
6
311
311
311
4
12
12
12
DR90I4-A
DR90I4-D
DR90I4-J
DR90I4-L
351914-1
351914-2
351914-2
351914-2
120/240
120/208
120/240
277/480
SINGLE
THREE
THREE
THREE
350004-711
350004-701
350004-701
350004-701
UCI274C
UCI274C
UCI274C
UCI274C
6
311
311
311
4
12
12
12
DR100I4-A
DR100I4-D
DR100I4-J
DR100I4-L
455100-100
455100-100
455100-100
455100-100
120/240
120/208
120/240
277/480
SINGLE
THREE
THREE
THREE
350004-721
350004-702
350004-702
350004-702
UCI274D
UCI274D
UCI274D
UCI274D
6
311
311
311
4
12
12
12
DR130I4-A
DR130I4-D
DR130I4-J
DR130I4-L
351949-1
351949-0
351949-0
351949-0
120/240
120/208
120/240
277/480
SINGLE
THREE
THREE
THREE
350004-101
350004-710
350004-710
350004-710
UCI274F
UCI274F
UCI274F
UCI274F
6
311
311
311
4
12
12
12
DR175I4-A
DR175I4-D
DR175I4-J
DR175I4-L
351955-1
351955-0
351955-0
351955-0
120/240
120/208
120/240
277/480
SINGLE
THREE
THREE
THREE
350004-106
350004-105
350004-105
350004-105
UCI274H
UCI274H
UCI274H
UCI274H
6
311
311
311
4
12
12
12
DR200D4-D
DR200D4-J
DR200D4-L
351973-1
351973-1
351973-1
120/208
120/240
277/480
THREE
THREE
THREE
350004-117
350004-117
350004-117
UCI274J
UCI274J
UCI274J
311
311
311
12
12
12
DR250I4-D
DR250I4-J
DR250I4-L
351937-1
351937-1
351937-1
120/208
120/240
277/480
THREE
THREE
THREE
350031-2
350031-2
350031-2
HCI434D
HCI434D
HCI434D
311
311
311
12
12
12
DR300I4-D
DR300I4-J
DR300I4-L
351943-1
351943-1
351943-1
120/208
120/240
277/480
THREE
THREE
THREE
350031-3
350031-3
350031-3
HCI434E
HCI434E
HCI434E
311
311
311
12
12
12
DR350I4-D
DR350I4-J
DR350I4-L
351957-2
351957-2
351957-1
120/208
120/240
277/480
THREE
THREE
THREE
350037-7
350037-7
350031-3
HCI434F
HCI434F
HCI343E
311
311
311
12
12
12
Page 24
60708-160
Limited Warranty
WINPOWER, 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 WINPOWER written instructions.
WINPOWER’s sole liability, and Purchaser’s sole remedy for a failure under this warranty, shall be
limited to the repair of the product. At WINPOWER’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 WINPOWER Authorized Service Center or to WINPOWER, 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 WINPOWER 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.
WINPOWER reserves the right to change or improve its products without incurring any obligations to
make such changes or improvement on products purchased previously.
EXCLUSIONS:
WINPOWER does not warrant Engines. Engines are covered exclusively by the warranties of their
respective manufacturers, see enclosed warranties.
WINPOWER does not warrant Batteries, or Other Component Parts that are warranted by their respective
manufacturers.
WINPOWER does not warrant modifications or alterations which were not made by WINPOWER, Inc.
WINPOWER does not warrant products which have been subjected to misuse and/or negligence or
have been involved in an accident.
60708-160
Page 25
2170-00
60708-160- 2170-00
225 S. Cordova
Le Center MN 56057
Phone - 507-357-6707
www:winpowerinc.com
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