Winco  PSS8000 User Manual
PACKAGED
STANDBY
SYSTEM
INSTALLATION AND OPERATORS MANUAL
PSS8000/P
PSS12000/C
PSS20000/C
Automatic Transfer
Switch
Model PSS8000
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 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.
TROUBLESHOOTING INFORMATION
WIRING DIAGRAMS
NON-UL ATS Wiring Diagram
PSS8000 AC & DC Schematic
PSS12000 AC Schematic
PSS12000 DC Schematic
PSS20000 AC Schematic
PSS20000 DC Schematic
ATS Dimensions
PSS8000 Layout
PSS12000 Layout
PSS20000 Layout
UL ATS Wiring Diagram
12 MONTH WARRANTY
MAINTENANCE LOG
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PROPER USE AND INSTALLATION
You must be sure your new engine generator set is:
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TABLE OF CONTENTS
INTRODUCTION
GUIDE TO PRODUCT SAFETY
BASIC INFORMATION
Description
Specification Table
PREPARING THE UNIT
Unpacking the Unit
ENGINE GENERATOR INSTALLATION
Installation
Fuel Installation
Vapor Fuel Pressure Tables
Liquid Withdrawal
Fuel Adjustments
Fuel Conversions
Lubrication
Battery Installation
Connecting Battery Charge &
Blockheater
TRANSFER SWITCH INSTALLATION
AC Electrical Connections
DC Electrical Connections
Exerciser Clock Set Up
INITIAL START-UP
13
Properly serviced before starting
Operated in a well ventilated area
Properly exhausted and gases safely dispersed
Wired by a qualified electrician
Operated only for its designed purposes
Used only by operators who understand its operation
Properly maintained
COPY YOUR MODEL AND SERIAL
NUMBER HERE
No other WINCO generator has the same serial number
as yours. It is important that you record the number and
other vital information here. If you should ever need to
contact us on this unit it will help us to respond to your
needs faster.
MODEL____________________________________
SERIAL NUMBER____________________________
PURCHASE DATE____________________________
DEALER___________________________________
DEALER PHONE # ___________________________
PAGE i
SAFETY INFORMATION
b.
c.
This engine generator set has been designed and
manufactured to allow safe, reliable performance.
Poor maintenance, improper or careless use can
result in potential deadly hazards; from electrical
shock, exhaust gas asphyxiation, or fire. Please read
all safety instructions carefully before installation or
use. Keep these instructions handy for future
reference. Take special note and follow all warnings
on the unit labels and in the manuals.
ANSI SAFETY DEFINITIONS
************************************************************
DANGER:
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in death or
serious injury. This signal word is to be limited to the
most extreme situations.
***********************************************************
************************************************************
WARNING:
WARNING indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
***********************************************************
***********************************************************
CAUTION:
CAUTION indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe
practices.
************************************************************
NOTE:
d.
e.
f.
3. 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.
a.
b.
c.
d.
e.
f.
a.
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.
5. CLEANLINESS - Keep the generator and surrounding
area clean.
a.
b.
c.
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 clean up any gas or oil spills before
starting the unit.
Never allow leaves or other flammable material
to build up around the engine intake or exhaust
area.
6. SERVICING EQUIPMENT - All service, including the
installation or replacement of service parts, should be
performed only by a qualified technician.
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.
2. FIRE HAZARD - Natural gas and L.P. present a hazard
of possible explosion and/or fire.
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).
4. NOISE HAZARD - Excessive noise is not only tiring,
but continual exposure can lead to loss of hearing.
CAUTION is also used on the unit labels and in this
manual to indicate a situation that could result in
serious damage or destruction of the equipment and
possible personal injury.
1. ELECTRIC SHOCK - The output voltage present in this
equipment can cause a fatal electric shock. This
equipment must be operated by a responsible
person.
before refueling.
Keep fuel containers out of reach of children.
Do not smoke or use open flame near the
generator set or fuel tank.
Keep a fire extinguisher nearby and know its
proper use. Fire extinguishers rated ABC by
NFPA are appropriate.
Store fuel only in an approved container, and only
in a well-ventilated area.
Follow local codes for closeness to combustible
material.
Do not refuel when the engine is running or hot.
Allow the engine to cool at least two minutes
PAGE 1
a.
b.
c.
d.
e.
f.
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.
Optional UL Automatic Transfer Switch Sizes
UNIT
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 system includes all items
necessary for a completely automatic standby power
system as standard equipment.
This packaged standby system is designed to automatically provide standby power to unattended loads
during electrical outages. Upon an interruption of
normal electrical service the packaged standby
systems 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 emergency transfer switch will
sense return of the normal commercial power. The
Automatic Transfer Switch will retransfer the load
back to normal commercial power source. The
engine control circuits will begin a cool-down cycle,
after which the fuel supply will be shut off and the
engine ignition system disabled.
These packaged standby systems consist of two major
components:
1) AUTOMATIC TRANSFER SWITCH
A wall mounted Automatic Transfer Switch (A.T.S.)
designed for inside installation. The A.T.S. consists of a
line side contactor and a generator side contactor. The
contactors are both electrically and mechanically
interlocked. A seven day electronic exerciser clock 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.
UNIT
PSS8000
PSS12000
PSS20000
LINE SIDE
CONTACTOR
110 AMPS
110 AMPS
230 AMPS
GENERATOR
SIDE CONTACTOR
60 AMPS
60 AMPS
150 AMPS
GENERATOR
SIDE CONTACTOR
PSS8000
100 AMPS
100 AMPS
PSS12000
100 AMPS
100 AMPS
PSS20000
100 AMPS
100 AMPS
or
200 AMPS
200 AMPS
Both the 100 amps and the 200 amps UL Switches are
available in single and three phase.
Additional optional A.T.S. sizes are available to meet
specific needs. Contact your local WINCO Rep. or the
WINCO Sales Department for a quote.
2) ENGINE/GENERATOR
DESCRIPTION
Standard Automatic Transfer Switch Sizes
(NON-UL)
LINE SIDE
CONTACTOR
PSS8000 - The engine generator set consists of a
Briggs & Stratton Vanguard, two cylinder, air cooled
engine equipped to run on L.P. or N.G. fuel. The engine
operates at 3600 rpm and frequency regulation is
maintained by the engine governor within 4 cycles
variation (62.5 Hz - 58.5 Hz) from no load to rated load.
The 8000 watt (8kW) generator is a brushless, single
bearing, direct drive, rotating field design. The generator
is connected to the engine’s tapered (quill) crankshaft
extension. The engine generator is mounted in a NEMA
3R enclosure for outside installation. Connection boxes
are provided for all customer connections (both AC
output and DC control). A customer supplied 235 CCA
(BCI group U1) battery is required to complete the
installation. Engine operation is controlled by an Electronic Engine Control Module (E.C.M.) mounted in the
engine generator enclosure. The E.C.M. is equipped
standard with a 10 second start delay, 90 second cool
down delay and cycle cranking.
PSS12000 - The engine generator set consists of a
Onan Performer, two cylinder, air cooled engine equipped
to run on L.P. or N.G. fuel. The engine operates at 3600
rpm and frequency regulation is maintained by the
engine governor within 4 cycles variation (62.5 Hz - 58.5
Hz) from no load to rated load. The 12000 watt (12kW)
generator is a single bearing, direct drive, rotating
armature design with external voltage regulation. The
generator is connected to the engine’s tapered (quill)
crankshaft extension. The engine generator is mounted
in a NEMA 3R enclosure for outside installation. Connection boxes are provided for all customer connections
(both AC output and DC control). A customer supplied
450 CCA (BCI group 26/70) battery is required to complete the installation. Engine operation is controlled by an
Electronic Engine Control Module (E.C.M.) mounted in
the engine generator enclosure. The E.C.M. is equipped
standard with a 10 second start delay, 90 second cool
down delay and cycle cranking.
PSS20000 - The engine generator set consists of a
Ford Industrial, four cylinder, water cooled engine
equipped to run on L.P. or N.G. fuel. The engine operates
at 3600 rpm and frequency regulation is maintained at 60
Hz, by an electronic governor mounted on the engine.
The 20,000 watt (20kW) generator is a single bearing,
PAGE 2
direct drive, rotating armature design. The generator is
connected to the engine flywheel via a flexible drive disk.
The engine generator is mounted in a water tight
enclosure for outside installation. Connection boxes are
provided for all customer connections (both AC output
and DC control). A customer supplied 500 CCA (BCI
group 24) battery is required to complete the installation.
Engine operation is controlled by an Electronic Engine
Control Module (E.C.M.) mounted in the engine generator
enclosure. The E.C.M. is equipped standard with a 3
second start delay, 3 minute cool down delay and cycle
cranking consisting of five, 12 second on/12 second off
cycles. The ECM has both oil pressure and high water
temperature delays build into the starting circuit. During
initial start up the oil pressure delay is 12 seconds, to
allow the engine time to build oil pressure, before a
shutdown will occur. The high water temperature
shutdown has a 60 to 90 second lockout, allowing the
engine time to clear the hot water out of the block in case
of a hot restart. In addition if the generator should loss
output during a run cycle the engine will continue to run
for about 60 seconds and then shutdown and display
and overcrank light, the starter will not reengage during
this time or until the generator selector switch has been
cycled off and back on. This is the only way to clear a
fault light.
** NOTICE **
This unit will automatically transfer if a power outage
occurs while running in an exercise mode.
GENERATOR
PSS8000
PSS12000
PSS20000
PSS20000-4
PSS20000-17
WATTS* VOLTS
8,000
12,000
20,000
20,000
20,000
120/240
120/240
120/240
120/208
120/240
AMPS*
HZ
pH
RPM
33.3
50.0
83.0
55.6
48.1
60
60
60
60
60
1
1
1
3
3
3600
3600
3600
3600
3600
*Derate 10% for Natural Gas operation. Derate 3.5%
per 1000 feet elevation above sea level.
FUEL CONSUMPTION
NG
1000 BTU/CU FT
MODEL CF/HR BTU/HR
PSS8000
200 200,000
PSS12000 245 245,000
PSS20000 325 325,000
L.P. VAPOR
2520 BTU/CUFT
#/HR* GAL/HR CF/HR
11.4
2.7
97.6
13.9
3.3
119
16.8
4.0
142
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 **
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.
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.
SPECIFICATIONS
MODEL
TANK TEMPERATURE
MODEL
60 f(16 c) 32 f(0 c) 0 f(-18 c) -20 f(-29 c)
PSS8000
150 Gal. 150 Gal. 250 Gal. 500 Gal.
PSS12000 150 Gal. 250 Gal. 500 Gal. 1000 Gal.
PSS20000* 250 Gal. 500 Gal. 500 Gal. 1000 Gal.
* Fuel tank sizes for PSS20000 on liquid withdrawal are
considerably smaller consult your local fuel supplier.
BTU/HR*
246,000
301,000
366,000
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 consignor’s
memo of the loss or damage. Contact the carrier for
claim procedures.
When loss or damage is noted after delivery, segregate
the damaged material, and contact the carrier for claim
procedures. Be sure to retain the packaging material for
carrier inspection.
*Based on full load operation
L.P. TANK SIZING
Required L.P. Tank size for L.P. Vapor withdrawal
operating at various outside temperatures given in
degrees Fahrenheit (Celsius)
“Concealed Damage” is understood to mean damage
to the contents of a package which is not in evident 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
F.O.B. factory, and only the consignee can legally file a
claim.
PAGE 3
**** CAUTION ****
ENGINE GENERATOR SET MOUNTING
The PSS8000 and PSS12000 are shipped without oil.
The PSS20000 is 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.
The unit’s main frame should be bolted solid to a four to
six inch thick cement pad. The engine-generator is
mounted on a sub-frame which is isolated with special
shock mounts on the main frame. This allows the
engine-generator to vibrate without affecting the control
panel on the main frame.
UNPACKING:
Do not install any shock mounts between the base
frame and the concrete pad. Engine vibration will be
transmitted to the control panel causing erroneous start/
stop cycles and premature control failure.
1. Carefully remove the carton.
2. After inspecting the engine-generator and transfer
switch for external physical damage, check for the
following items packed inside the carton.
4. Unit can now be lifted from shipping pallet.
The unit should be mounted to allow for ample working
room around it. A general rule to follow is three (3) feet
clearance on all sides. Particular attention should be
paid to the direction of the hot air discharge and exhaust
discharge. Unit location should be such that these
discharges are not allowed to be drawn back in through
an open window or door.
INSTALLATION
FUEL INSTALLATION
a. Owner’s manual, wiring diagram and parts list.
b. Engine manufacturer’s instruction manual.
c. USDA approved spark arrestor (PSS8000 only)
3. Remove main frame hold down bolts, (4).
General Information
*************
***** WARNING ****
*************
Before proceeding with the installation, be sure the
operation selector switch is in the stop position.
These engine/generator sets are designed to be
mounted on a concrete pad outdoors only. The transfer
switch is mounted next to your electrical entrance or
distribution panel inside the building. Consult a qualified, licensed electrician or contractor to install and wire
the transfer switch. The installation must comply with all
national, state and local codes.
***** CAUTION ****
EQUIPMENT DAMAGE - The PSS20000 must be
mounted on a full length 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.
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.
*************
***** WARNING ****
*************
FIRE HAZARD - All fuel runs should be installed by a
licensed fuel supplier.
Connect the fuel supply to the inlet of the fuel solenoid
(see table for recommended line size). For all vapor fuel
systems the delivery pressure of the fuel to the fuel
solenoid on the unit must be four to six ounces psi (per
square inch) or 7 to 11 inches W.C. (Water column).
PSS20000 equipped with liquid withdrawal kits must be
connected to the liquid withdraw valve on the tank. Full
tank pressure must be delivered to the 3/8” fuel fitting on
the fuel lock strainer at the generator. These fuel
pressures are critical, failure to provide the proper fuel
pressure can cause many problems ranging from a unit
that will not start to causing damage to the fuel system.
INSTALLING THE FUEL LINE
** NOTICE **
The engine generator sets are properly adjusted before
they leave the factory. A tag is attached to the unit that
specifies the fuel, natural gas (NG) or propane vapor (LP)
PAGE 4
that the unit was set up and tested on. A slight adjustment may be necessary on NG depending on local BTU
content. This adjustment will be discussed later.
Line Size
Unit location will determine the size of fuel line that is
required to supply the engine with a constant fuel
pressure and volume. Refer to the tables below for fuel
line size, fuel consumption and recommended tank size.
For distances of 50 feet 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 four (4) to 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. This is also true for the single dual stage regulators, they should also be minimum of 10 feet form the
unit. If this is not done the demand regulator on the unit
and the pressure regulator in the fuel line will interfere
with each other. When this two (2) stage regulator
system is used, a fuel line size of 1/2 to 5/8 inch is
generally adequate for distances up to 300 feet from the
primary to the secondary regulator. (Consult your local
fuel supplier for your exact requirements.) The appropriate line size from the table below is then installed from
the second regulator to the generator set.
*************
***** 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.
FUEL PRESSURE
L.P. & N.G. VAPOR FUEL
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. vapor fuel installation.
Notice the following tables give two (2) different units of
measuring fuel pressure. The first and most accurate is
the use of a simple water manometer. A manometer is
calibrated in inches of water column. The second is with
a pressure gauge calibrated in ounces per square inch.
TWO (2) REGULATOR FUEL SYSTEM
Supply
Primary
Secondary
Tank
Regulator
Regulator
1
2
3
SINGLE REGULATOR FUEL SYSTEM
Supply
Tank
1
Primary
Regulator
3
up to 25 feet* 25 - 100 feet*
PSS8000
3/4" pipe
1" pipe
PSS12000 3/4” pipe
1” pipe
PSS20000 1" pipe
1.25" pipe
*Allow an additional 3 feet for each standard
‘street ells’ (restrictive)*
over 100 feet*
not recommended
use a two
regulator system
elbow. Do not use
Reference number 4 is the engine generator set.
Below is a table of the fuel pressure reading at each
reference in the system.
Fuel Pressure Table
Single Regulator (L.P. Vapor only)
UNIT OFF
1
TANK PSI
STARTING
TANK PSI
NO LOAD
TANK PSI
FULL LOAD TANK PSI
UNIT OFF
TANK PSI
Size of pipe normally required for generators operating
on LP LIQUID WITHDRAWAL
STARTING
TANK PSI
PSS20000 -
NO LOAD
TANK PSI
3/8” line for all distances.
**** CAUTION ****
Be careful when sealing gas joints. Excessive sealing
compound can be drawn into the solenoid, regulator or
carburetor causing an engine malfunction.
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
4-6 oz
7-11 in
4-6 oz
7-11 in
4-6 oz
7-11 in
4-6 oz
Two (2) Regulator System (L.P. Vapor only)
1
LP LIQUID WITHDRAWAL (ONLY)
Generator
Set
4
Reference numbers 1 through 3 in the block diagrams
above are system parts supplied by customer.
NATURAL GAS or LP VAPOR
Size of pipe normally required for generators operating
on NATURAL GAS or LP VAPOR
Generator
Set
4
FULL LOAD TANK PSI
PAGE 5
2
3
10-15 lbs 7-11 in
4-6 oz
10-15 lbs 7-11 in
4-6 oz
10-15 lbs 7-11 in
4-6 oz
10-15 lbs 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
Note: The fuel mixture adjustment on the PSS8000 is
the brass load block located on top of the demand
regulator. This load block is a multi-turn needle
valve. On the PSS20000 & PSS12000 it is located on
the carburetor just behind the fuel inlet hose. This
mixture adjustment is a partial turn, lean to rich, load
block.
Natural Gas
1
UNIT OFF
LINE PSI
STARTING
LINE PSI
NO LOAD
LINE PSI
FULL LOAD LINE PSI
3
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
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. Begin making a mixture adjustment, observing the Hz
meter. If the meter begins to drop you have the mixture
set too lean or to rich . Adjust the valve in the opposite
direction. Adjustments should be made very slowly.
Adjust back and forth until the highest Hz is achieved. Do
not turn the valve richer after the Hz quits rising, this
would cause the engine to run rich. If the Hz is out of
upper or lower limits, a governor adjustment will be
necessary.
LP LIQUID WITHDRAWAL
The following is a block diagram of a typical L/P Liquid
Withdrawal fuel system for the PSS20000.
Tank
1
Fuel Solenoid
2
Converter
3
Engine
4
Reference number 1 is the fuel tank. No regulator is
required but the tank must have a liquid withdrawal drop
tube installed in it and a liquid valve on the tank.
Reference number 2 through 4 are installed on the
engine generator set.
4. On the PSS8000 & PSS12000 see your engine
manual for governor adjustment procedures. The
PSS20000 is equipped with an electronic governor which
requires no adjustment.
**** CAUTION ****
Under full load do not adjust the Hz above 60. If a higher
Hz reading is used, as the load is decreased the Hz will
go out of upper limits (61 to 62 Hz).
PROPANE (LP)
Liquid fuel is delivered from the tank directly to the fuel
solenoid on the generator at full tank pressure. This
system requires no pressure regulator be installed any
where in the system. The converter mounted on the
engine generator set will take the liquid fuel at tank
pressure and convert it to vapor at the proper delivery
rate.
A generator set factory tested on LP will normally
require no adjustment. If for some unforeseen reason
the machine should require adjustment, follow the NG
procedure.
FUEL TYPE CONVERSION
If it should be necessary to change the type of fuel used
after a unit is received, the following procedures are
provided.
LP/NG FUEL ADJUSTMENTS
**** CAUTION ****
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).
PSS8000
These units require no changes to the regulator. After
plumbing in the fuel lines the only thing necessary is to
reset your mixture as detailed in the adjustment section
above.
NATURAL GAS (NG)
PSS12000 & PSS20000
Due to variations in NG fuel characteristics and BTU
levels throughout the country, it may be necessary to
readjust the fuel mixture once the engine has been
installed and serviced.
NATURAL GAS TO PROPANE
1. Turn off fuel supply.
**** CAUTION ****
Never make a fuel mixture adjustment on a unit when it is
stopped or running no load. A mixture adjustment is only
effective when the engine is operating under load.
ADJUSTMENT PROCEDURE
1. Insure the unit is operating with an 80 to 100% load
or at the highest anticipated load.
2. Attach a frequency meter to monitor Hz.
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
PAGE 6
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).
cold weather starting performance. Use only Maintenance Free batteries, this will reduce the need to refill the
battery with water. Gel batteries should not be used with
the battery tender installed in the generator enclosure.
7. If the pressure is correct, remove the meter and
reinstall the pipe plug.
Model
8. You are now ready to make the final fuel mixture
adjustment. Refer to adjustment section in this manual.
PSS8000
PSS12000
PSS20000
PROPANE TO NATURAL GAS
BCI Group
MINIMUM
CCA Rating
U1
26/70
24
235
450
500
*****CAUTION*****
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. 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.
4. Reconnect the fuel line at the regulator.
5. 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).
6. 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 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.
7. You are now ready to make the final fuel mixture
adjustment. Refer to adjustment section in this manual.
LUBRICATION
Before starting the engine, fill the crankcase 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.
EQUIPMENT DAMAGE - Always connect the positive
cable first and the negative cable last, when disconnecting it is negative cable first and positive last. Failure to
connect and disconnect in the proper sequence can
cause equipment damage.
Observe polarities: connect the positive (+) battery
terminal to the (+) cable from the control panel; the
negative (-) battery terminal is connected to the negative
cable (ground) from the engine generator assembly.
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.
*****CAUTION*****
EQUIPMENT DAMAGE - NEVER jump start these units.
Doing so will destroy the engine control module rendering the unit non-operational. Remove and fully recharge
the battery before attempting to start.
CONNECTING THE BATTERY CHARGER &
BLOCKHEATER
A two-stage battery tender is provided on all PSS series
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 in the same location as the other AC and DC
connections.
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.
This battery tender requires a circuit breaker protected
AC circuit from your distribution panel be run out to the
engine generator set. These AC wires can be run in the
same conduit as the other AC leads from the generator.
It is suggest that this circuit be fused for 15 amps, then
both the battery charger and the block heater can be
connected to the same circuit. The block heater is
optional on the PSS8000 and is installed standard on the
PSS20000. At this time there is no block heater available
for the PSS12000.
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
The PSS8000 and PSS12000 have a 120 volt receptacle mounted in the generator connection box. The
receptacle is prewired with black, white and green leads
INSTALLING THE BATTERY
**** CAUTION ****
PAGE 7
attached to it, this is where you will connect your 120 volt
fused power feed. If you are installing the optional block
heater on the PSS8000, you should also connect the
power feed for the block heater here. The PSS20000 has
a duplex receptacle mounted on the rear engine support
bracket. The wires for this receptacle have been routed
up into the generator connection box for your convenience. You will make your connection from your 120 volt
power feed in the connection box. The block heater can
then be plugged into the extra receptacle on the duplex.
FIGURE 3
NOTE:
The PSS12000
generator
connections are
numbered
differently. Use
extreme caution
when connecting
generator to the
transfer switch.
See installation
paragraph for
proper wire
connections.
** NOTICE **
The battery tender is not intended to recharge a battery
which has become completely discharged. It is designed to produce enough current to recharge a slightly
low battery, maintaining it fully charged.
MOUNTING THE AUTOMATIC
TRANSFER SWITCH (A.T.S.)
*************
***** WARNING *****
*************
EQUIPMENT DAMAGE- Protect the switch from construction grit and metal chips to prevent a malfunction or
shortened life of the switch. Contactors returned for
warranty consideration wilth foreign material inside of
them will not be warranted.
FIGURE 4
The Automatic Transfer Switch connects the load
(lights, furnace, outlets, etc.) to the normal power line
during standby. When normal power fails, the A.T.S.
starts the engine generator set, disconnects the power
line and then connects the load to the standby generator
set. When normal power is restored, the automatic
switch retransfers the electrical load to the normal
service and stops the engine. The A.T.S. panel should
be mounted as close to the distribution panel as
possible.
*****NOTE*****
EQUIPMENT DAMAGE- The standard NON-UL Winco
ATS does not protect against undervoltage. If you are in
an area that is suspectibly to brown outs (low voltage)
you may want to consider adding an undervoltage sensor
to standard ATS panel.
FIGURE 5
*************
***** WARNING *****
*************
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
your electrical inspectors before proceeding!
PSS8000 - The Automatic Transfer Switch shipped with
the PSS8000 system has a 110 Amp line side contactor
installed to handle your normal power needs and a 60
Amp generator side contactor to handle the emergency
generator output. Before installing the A.T.S. you must
first ensure that the 110 Amp line side contactor will be
sufficient to handle your complete service. See Figure 3.
PAGE 8
(i.e. the main line breaker must not be larger than 110
Amps) If you have a 125, 150 , 200 Amp or larger
system, you will not be able to transfer the complete
electrical system. In this case it will be necessary to
install a secondary emergency distribution panel. See
Figure 4. NOTE: THE MAXIMUM OUTPUT OF THE
GENERATOR IS 33.3 AMPS AT 240 VOLTS. You must
also take this into consideration when deciding whether
to install an emergency distribution panel.
PSS12000 - The Automatic Transfer Switch shipped
with the PSS12000 system has a 110 Amp line side
contactor installed to handle your normal power needs
and a 60 Amp generator side contactor to handle the
emergency generator output. Before installing the A.T.S.
you must first ensure that the 110 Amp line side contactor
will be sufficient to handle your complete service. See
Figure 3. (i.e. the main line breaker must not be larger
than 110 Amps) If you have a 125, 150 , 200 Amp or
larger system, you will not be able to transfer the complete electrical system. In this case it will be necessary
to install a secondary emergency distribution panel. See
Figure 4. NOTE: THE MAXIMUM OUTPUT OF THE
GENERATOR IS 50.0 AMPS AT 240 VOLTS. You must
also take this into consideration when deciding whether
to install an emergency distribution panel.
PSS20000 - The Automatic Transfer Switch shipped
with the PSS20000 system has a 230 Amp line side
contactor installed to handle your normal power needs
and a 150 Amp generator side contactor to handle the
emergency generator output. Before installing the A.T.S.
you must first ensure that the 230 Amp line side contactor will be sufficient to handle your complete service. See
Figure 5. (i.e. the main line breaker must not be larger
than 230 Amps). If you have a larger main line breaker,
you will not be able to transfer the complete electrical
system. In this case it will be necessary to install a
secondary emergency distribution panel. See Figure 4.
NOTE: THE MAXIMUM OUTPUT OF THE GENERATOR IS
83 AMPS AT 240 VOLTS SINGLE PHASE, 56 AMPS AT
208 VOLTS AND 48 AMPS AT 240 VOLTS THREE PHASE.
You must also take this into consideration when deciding
whether to install an emergency distribution panel.
*************
***** DANGER *****
*************
Be certain the operation selector switch on the front of the
A.T.S. Control is in the “stop” position and the main power
switch “off”. For your own protection, verify these important safety precautions yourself with reliable instruments
before proceeding.
A.C. ELECTRICAL CONNECTIONS
*************
***** WARNING *****
*************
A FUSED DISCONNECT OR CIRCUIT BREAKER
MUST BE INSTALLED BETWEEN THE GENERATOR
AND THE A.T.S. PANEL TO PREVENT OVERLOADING
AND BURNING OUT THE GENERATOR. FAILURE TO
PROVIDE A FUSED DISCONNECT OR CIRCUIT
BREAKER, RATED AT GENERATOR RATING WILL VOID
YOUR WARRANTY IN CASE OF GENERATOR FAILURE.
PSS8000
Generator Connections
To gain access to the customer connections remove
the end panel opposite the muffler. Both AC and DC
connections are made behind this panel. Three AC
power leads are required between the generator and the
A.T.S. The two power leads are marked G1 and G3, the
neutral lead is shipped bonded to the ground lug. If your
local code requires the generator to be wired with an
isolated neutral, remove this neutral to ground bond.
This will require you to run four AC leads from the
generator to the A.T.S. as you will need to run both a
neutral and a ground lead. All wires must be sized to
handle 33 Amps minimum, the type of wire you use will
determine the gauge required. Consult your local wire
supplier for proper gauge and type for your area.
A.T.S .Connections
The standby generator terminals in the A.T.S are
marked “GENERATOR - G1, G-N, G3”. The “hot” leads G1
and G3 from the generator are wired to the generator
side contactor, terminals G1 and G3.
The line terminals in the A.T.S. are marked “LINE - L1,
L-N, L3”. The “hot” line leads L1 and L3 are wired to the
line side contactor, terminals L1 and L3.
The load terminals in the A.T.S. are marked “LOAD - T1,
T-N, T3”. The “hot” leads T1 and T3 are wired to the
bottom side of both the line side and the generator side
contactor.
If you are using a separate ground lead it is routed to
the ground lug in the A.T.S.
PSS12000 SINGLE PHASE
Generator Connections
To gain access to the customer connections remove
the end panel opposite the muffler. Both AC and DC
connections are made behind this panel. Three AC
power leads are required between the generator and the
A.T.S. The power leads coming into this connection box
from the generator end are run in parallel. (i.e. G1-A and
G1-B are both connected to the G1 lead and G2-A and
G2-B are both connected to the G3 lead going to the
A.T.S.) CAUTION THE G3-A AND G3-B LEADS ARE
NOT USED IN THE SINGLE PHASE INSTALLATION,
JUST LEAVE THEM CAPPED IN THE BOX. The voltage
regulator leads are currently connected to some of the
generator leads. These leads must remain with the
generator leads they are connected to. The neutral lead
(GN-A & GN-B) are shipped bonded to the ground lug. If
your local code requires the generator to be wired with an
isolated neutral, remove this neutral to ground bond.
This will require you to run four AC leads from the
PAGE 9
T-N, T3”. The “hot” leads T1 and T3 will wire directly to
the lugs on bottom the generator side contactor. Copper
jumper straps have already been installed between the
lower lugs on the generator contactor and the upper
terminals on the line side contactors. The T-N connection will be made on the stand-off just to the left of the
contactor.
generator to the A.T.S. as you will need to run both a
neutral and a ground lead. All wires must be sized to
handle 50 amps minimum, the type of wire you use will
determine the gauge required. Consult your local wire
supplier for proper gauge and type for your area.
A.T.S .Connections
The standby generator terminals in the A.T.S are
marked “GENERATOR - G1, G-N, G3”. The “hot” leads G1
and G3 from the generator are wired to the generator
side contactor, terminals G1 and G3.
The line terminals in the A.T.S. are marked “LINE - L1,
L-N, L3”. The “hot” line leads L1 and L3 are wired to the
line side contactor, terminals L1 and L3.
The load terminals in the A.T.S. are marked “LOAD - T1,
T-N, T3”. The “hot” leads T1 and T3 are prewired to the
bottom side of both the line side and the generator side
contactor.
If you are using a separate ground lead it is routed to
the ground lug in the A.T.S.
PSS20000 Single Phase
Generator Connections
To gain access to the customer connections, remove
the panel the warning light and the selector switch are
mounted on, inside the left hand access door. Both AC
and DC connections are made behind this panel. Three
AC power leads are required between the generator and
the A.T.S. The power leads coming into this connection
box from the generator end are run in parallel. (i.e. G1-A
and G1-B are both connected to the G1 lead and G3-A
and G3-B are both connected to the G3 lead going to the
A.T.S.) The engine control leads are currently connected
to some of the generator leads. These leads must
remain with the generator leads they are connected to.
The neutral lead (GN-A & GN-B) are shipped bonded to
the ground lug. If your local code requires the generator
to be wired with an isolated neutral, remove this neutral
to ground bond. This will require you to run four AC leads
from the generator to the A.T.S. as you will need to run
both a neutral and a ground lead. All wires must be sized
to handle 83 amps minimum, the type of wire you use
will determine the gauge required. Consult your local
wire supplier for proper gauge and type for your area.
A.T.S. Connections
The standby generator terminals in the A.T.S are
marked “GENERATOR - G1, G-N, G3”. The “hot” leads
G1 and G3 from the generator are wired to the generator
side contactor, terminals G1 and G3.
The line terminals in the A.T.S. are marked “LINE - L1,
L-N, L3”. The “hot” load leads L1 and L3 are wired line
side contactor, terminals L1 and L3. The L-N connection
will be made on the stand-off just to the left of the
contactor.
PSS12000 & PSS20000 Three Phase
The three phase units are installed the same as the
single phase units above, except a third power lead is
added, (i.e. a G2 from the generator, L2 on the line side
and a T2 on the load side). In the 120/240 volt configuration the G3, L3 and T3 will be the high voltage (wild) leg.
The other difference is a three phase power monitor
has been installed in the A.T.S. to monitor each phase for
low voltage. This three phase monitor is phase rotation
sensitive and comes from the factory set up for A-B-C
phase rotation. If you have trouble getting the A.T.S. to
pick-up the line power on initial installation, try switching
the A and B phase on the monitor. Your rotation may be
C-B-A. If so, be sure to match the generator rotation to
your current line rotation or your three phase motors will
try to turn backwards.
*************
***** WARNING *****
*************
When installing a Three Phase 240 Volt Delta system be
sure you know which lead is the high voltage leg (208
Volt line to neutral). The generator has the high voltage
lead connected at G3.
INSTALLATION NOTES
The load current carrying wires (L) and (T) must be
sized to handle the maximum load current without
excessive voltage drop. 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.
All wires should be installed in rigid or flexible conduit.
(Knockouts are provided in the control box)
Because of the many different types of service, feeder,
and distribution equipment, no specific wiring instructions can be provided. It is, however, 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. Check with your
local electrical inspector on applicable local, state and
federal codes.
NOTE:
The load terminals in the A.T.S. are marked “LOAD - T1,
PAGE 10
It is an excellent idea to install a disconnect in the
incoming power line wiring directly in front of the A.T.S.
panel. This will allow you to test the generator under
load. Should you ever have to work on the switch, you
will be able to disconnect the power and work on the
switch cold without having the power company pull your
meter.
control terminal box and in the A.T.S. to small terminal
blocks. Both are labeled “Start 1” and “Start 23”. The
wire are run between identical terminals, i.e. “Start 1” to
“Start 1” etc.
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 or main entrance providing the service
entrance ampere rating is within the transfer switch’s
rated capability.
The only significant difference when make your DC
connections in the UL ATS is the terminal makings in the
UL ATS. Instead of being marked “Start 1” and Start 23”
the are marked start contacts “11” and “12”. The wire
labeled “Start 1” is routed to start contact “11” and the
wire labeled “Start 23” is routed to start contact “12”
WINCO UL ATS
SETTING THE EXERCISER CLOCK
If only specific circuits are to be powered under
emergency power failure conditions, an additional
distribution panel designated “emergency distribution
panel” must be installed.
Setting the current time and date.
1. Position the top right hand (RUN) slide switch to the
left position.
All selected emergency circuits are removed from main
distribution panels and reinstalled in 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.
D.C. ELECTRICAL INTERCONNECTION
Never run the AC and DC wiring in the same conduit.
5. Position the top right hand (RUN) slide switch to the
center position. The correct time and date should now
be displayed.
WINCO NON-UL ATS
PSS8000
Two control wires are required to be installed 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 will be labeled “Bat -”, and
“Start”.
The control wires will be connected as follows in the
generator control terminal box:
Start 23
to
3. Push the “Hour Select Button” until the display
indicates the correct time in hours. Note: In the afternoon
you should push the button until a “P” is displayed
beside the correct hour.
4. Push the “Minute Select Button” until the display
indicates the correct time in minutes.
*******CAUTION******
ATS Panel
Start 1
to
2. Push the clock’s “Day Select Button” until the clock
displays a triangle under the number corresponding to
the current day of the week. (Monday is day 1, Sunday is
day 7)
Setting the Exerciser Program:
1. Position the top right hand (RUN) slide switch to the
right hand position.
2. Position the top left hand (AUTO) slide switch to the
center position.
3. Press the “Program Select Button” until No 1 is
displayed on the clock to the right of the time.
Generator Control Panel
Wire # 1, Fuel Solenoid Wire #1and
Neg lead from charger wire #1.
Wire #23
Wire #21 & Fuel Solenoid Wire #21
are just left capped together.
Wire #4 and the Charger Lead Wire
#4 are just left capped together.
4. Push the “Day Select Button” to select the day you
want the engine generator set to start up and run. Note:
You can get more than one triangle displayed on the
clock. If this happens just keep pressing the button and it
will work back through the cycle and display only one
triangle under whichever day you desire.
5. With the “Hour” and “Minute” buttons select the time
of day you want the engine to start up.
6. Press the “Program Select Button” until No. 2 is
displayed on the clock.
PSS12000 and PSS20000
Two control wires are required to be installed 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 will be labeled “Start 1”,
and “Start 23”.
7. Push the “Day Select Button” to select the day you
want the engine to stop. This must be the same day you
selected in step 4 above.
8. With the “Hour” and “Minute” buttons, select the time
The control wires will be connected in the generator
PAGE 11
you want the engine to stop. It is recommended you let
the engine run at least 15 minutes during any exercise
period.
PROCEDURE
Move the selector switch on the engine generator to the
“RUN” position. The engine-generator will crank and
start automatically. If the engine fails to start, return
selector switch to the “stop” position and correct the
trouble before proceeding.
9. Position the top right hand (RUN) slide switch to the
center (RUN) position.
CLOCK NOTES:
This seven day exerciser clock has seven additional
program cycles available. Always keep in mind the odd
number turns the unit on and the even number shuts the
unit off. (i.e. (3 on, 4 off) (5 on, 6 off) etc.)
The relay in the clock will not work unless the transfer
switch is installed and powered up. The relay needs 120
volts AC to operate.
If, when you finish programming the clock, you get an
“EEEE” on the display, it stands for error. The most
common error is that the day of operation has not been
properly set at each step or a program has been turned
on and not turned off. (i.e. programs not properly grouped
1& 2, 3 & 4, 5 & 6, etc.)
On the face of clock is a small button marked “R”, this
is a reset switch. Depressing this switch will remove all
programming in the clock including the time, Use a
small screwdriver or the tip of a pencil to depress this
button. This should be used only as a last resort.
INITIAL START UP
*************
***** WARNING *****
*************
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:
" Engine oil.* Check level & fill as required with
proper grade/qty.
" Engine coolant.* Check level & 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.).
" LP/NG pressure O.K. 4-6 Oz. (7-11" WC).
" Battery connections clean and tight.
" Battery fully charged.
" All A.C. and D.C. wiring installed and properly
protected.
* Refer to engine owners manual for proper
levels and type.
After completing the above checklist, the enginegenerator set is ready for the initial start-up test.
With the engine running smooth, check the no load
voltage and frequency at terminals G1 and G3 on the
generator terminal block in the A.T.S. The voltage
between G1 and G3 should be between 238-240 volts on
the PSS8000 & PSS12000 and 255-264 volts on the
PSS20000. The frequency on the PSS8000 and
PSS12000 should be betweeen 61.5 To 62 hertz (Hz), on
the PSS20000 it should be between 60.0 to 60.5 hertz.
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 one
half of the line to line (G1 to G3) voltage or approximately
118 to 132 volts AC. The same approximate voltage
should be found between terminals G3 and G-N (118 to
132 volts AC).
** Notice **
If for any reason during the check out procedure the
voltage and frequency are not correct, turn the selector
switch to the “STOP” position and correct the trouble
before proceeding.
After verifying the voltage and frequency are correct, turn
the selector switch to the “STOP” position. The unit
should shut off with no time delay. You are now ready to
test the automatic start function.
Move the selector switch on the engine generator set to
the “AUTOMATIC” position. Next move the selector switch
on the A.T.S. panel to the “START” position. The unit will
go into a 3 to 10 second start delay and then start up. If it
fails to start at this time, check your DC inter connection
wiring. When the selector switch on the A.T.S. is moved to
the “DISABLE” position the unit will go into a cool down
period and then shut off. The cool down period for the
PSS8 & PSS12 is 90 seconds on the PSS20 it is 3
minutes. As long as line power is still applied to the
transfer switch during this test period the A.T.S. will not
transfer the load to the generator.
Next you need to test the complete system. To accomplish this you will have to fail the incoming line power to
the A.T.S. panel. First move both selector switches to the
automatic position. Then fail the incoming power. All the
loads connected to the A.T.S. should now be dead. The
engine generator set will go into a 3 to 10 second start
delay. At the end of the start delay the unit will start up. A
soon as the engine generator set reaches operating
speed the generator side contactor will close and the
load will be applied to the engine generator.
Restoring the line power will cause the generator side
PAGE 12
contactor in the A.T.S. to open. The line side contactor will
close as soon as the generator side contactor clears the
mechanical interlock and closes the electrical interlock.
These interlocks ensure that you get a clean ‘break
before make’ action in the transfer switch.
ENGINE CRANKS BUT WILL NOT START.
1.
2.
3.
4.
5.
6.
7.
8.
The restoration of line power also sends a stop signal
to the engine generator set. This stop signal will activate
a cool down timer circuit. The engine generator will shut
down 90 seconds later on the PSS8000 & PSS12000, 3
minutes later on the PSS20000.
This completes your installation and unit testing.
ALWAYS leave the system in automatic mode unless
servicing the unit. For automatic operation, keep both the
generator set and transfer selector switches in the
“AUTOMATIC” position.
TROUBLESHOOTING TABLES
ENGINE STARTS AND THEN STOPS AND
FAULT LIGHT COMES ON.
1.
2.
1.
UNIT WILL NOT CRANK WHEN THE
POWER FAILS.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Alarm light on, from previous run cycle
Generator control switch not in “AUTOMATIC”
position.
Transfer control switch not in “AUTOMATIC”
position.
Low or dead battery, must hold 12 volts during
cranking
Incorrect wiring between transfer switch and
generator.
Defective start/stop relay in the transfer switch.
Circuit breaker tripped on engine control.
3/4 amp fuse blown inside engine control.
Defective engine control module.
Loose or dirty battery terminals
Defective “Run/Auto” switch
Defective starter.
Defective start solenoid.
2.
3.
4.
5.
1.
2.
3.
4.
5.
2.
3.
4.
5.
6.
7.
8.
9.
No AC generator output from generator.
Broken or defective mechanical/electrical inter
locks.
Defective holding coil in the generator side
contactor.
Wiring error between generator set and transfer
switch
Defective start/stop relay in ATS.
ATS PANEL WILL NOT PULL IN ON
NORMAL POWER.
1.
2.
3.
4.
Low or dead battery, must hold 12 volts during
cranking
DC circuit breaker on control module tripped.
3/4 amp fuse blown inside control module.
Defective engine controller.
Loose or dirty battery terminals
Defective “Run/Auto” switch
Defective starter.
Defective start solenoid.
Locked up engine generator set.
Insufficient fuel volume getting to the unit.
a. Fuel line too small.
b. Low fuel pressure.
Fuel load block needs to be adjusted.
AC short circuit.
Wiring to the A.T.S. panel crossed or shorted.
Unit is overloaded, check load amperage.
ATS PANEL WILL NOT TRANSFER TO
EMERGENCY SUPPLY (GENERATOR).
ENGINE WILL NOT CRANK WITH GENERATOR
SELECTOR SWITCH IN THE RUN POSITION.
1.
Engine is low on oil.
No AC output from generator to engage stop
crank circuit.
ENGINE WILL NOT COME UP TO SPEED
AFTER IT STARTS.
PSS8000
1.
2.
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 voltage from battery to fuel solenoid, must
hold 12 volts during cranking.
Proper normal line power not available at line
terminals in ATS panel.
Defective holding coil in line side contactor.
Broken or defective mechanical/electrical inter
locks.
Defective Start/stop relay in ATS.
NO AC OUTPUT FROM GENERATOR.
1.
2.
3.
4.
5.
6.
7.
8.
9.
PAGE 13
Diodes on rotor blown.
Defective capacitor(s).
Defective rotor.
Defective stator.
AC short in the output leads,
Unit has lost its residual voltage.
Rotor loose on engine crankshaft.
Low engine speed, must be 3600 RPM
AC short on output leads.
PSS12000
UNIT WILL NOT CRANK WHEN THE
POWER FAILS.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Alarm light is on from pervious run cycle.
Generator control switch not in “AUTOMATIC”
position.
Transfer control switch not in “AUTOMATIC”
position.
Low or dead battery must hold 12 volts during
cranking.
Incorrect wiring between transfer switch and
generator.
Defective start/stop relay in the transfer switch.
Circuit breaker tripped on engine control.
3/4 amp fuse blown inside engine control.
Defective engine control module.
Loose or dirty battery terminals.
Defective “Run/Auto” switch.
Defective starter.
Defective start solenoid.
ENGINE WILL NOT CRANK WITH GENERATOR
SELECTOR SWITCH IN THE RUN POSITION.
3.
4.
5.
AC short circuit
Wiring to the A.T.S. panel crossed or shorted.
Unit is overloaded, check load amperage.
ATS PANEL WILL NOT TRANSFER TO
EMERGENCY SUPPLY(GENERATOR).
1.
2.
3.
4.
5.
No AC generator output from generator.
Broken or defective mechanical/electrical inter
locks.
Defective holding coil in the generator side
contactor.
Wiring error between generator set and transfer
switch.
Defective start/stop relay in the ATS
ATS PANEL WILL NOT PULL IN ON
NORMAL POWER
1.
2.
3.
4.
Proper normal line power not available at line
terminals in ATS panel.
Defective holding coil in line side contactor.
Broken or defective mechanical/electrical inter
locks.
Defective strat/stop relay in ATS.
NO AC OUTPUT FROM GENERATOR .
1.
2.
3.
4.
5.
6.
7.
8.
9.
Battery dead.
DC circuit breaker on control module tripped.
3/4 amp fuse blown inside control module.
Defective engine controller.
Loose or dirty battery terminals.
Defective “Run/Auto” switch.
Defective starter.
Defective start solenoid.
Locked up engine generator set.
1.
2.
3.
4.
5.
6.
7.
AC short in the output leads.
Defective voltage regulator.
Defective armature.
Defective coils.
Unit has lost its residual voltage.
Rotor loose on engine crankshaft.
Low engine speed, must be 3600 RPM
PSS20000
ENGINE CRANKS BUT WILL NOT START.
1.
2.
3.
4.
5.
6.
7.
8.
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 voltage from battery to fuel solenoid, must
hold 12 volts during cranking.
ENGINE STARTS AND THEN STOPS AND
FAULT LIGHT COMES ON.
1.
2.
Engine is low on oil.
No AC output from generator to engage stop
crank circuit.
ENGINE WILL NOT COME UP TO SPEED
AFTER IT STARTS.
1.
2.
UNIT WILL NOT CRANK WHEN THE
POWER FAILS.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Insufficient fuel volume getting to the unit.
a. Fuel line too small.
b. Fuel pressure too low.
Fuel load block needs to be adjusted.
PAGE 14
Alarm light on from previous run cycle.
Generator control switch not in “AUTOMATIC”
position.
Transfer control switch not in “AUTOMATIC”
position.
Low or dead battery.
Incorrect wiring between transfer switch and
generator.
Defective start stop relay in the transfer switch.
Circuit breaker tripped on engine control panel.
3/4 amp fuse blown inside engine control.
Defective engine control module.
Loose or dirty battery terminals.
Defective “Run/Auto” switch on generator or
transfer switch.
Defective starter.
Defective start solenoid.
Defective remote start solenoid
ATS PANEL WILL NOT PULL IN ON
NORMAL POWER.
ENGINE WILL NOT CRANK WITH GENERATOR
SELECTOR SWITCH IN THE RUN POSITION.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
1.
Battery dead.
DC circuit breaker on control module tripped.
3/4 amp fuse blown inside control module.
Defective engine controller.
Loose or dirty battery terminals
Defective “Run/Auto” switch on generator.
Defective starter.
Defective start solenoid.
Defective remote start solenoid.
Locked up engine generator set.
2.
3.
4.
5.
NO AC OUTPUT FROM GENERATOR
1.
2.
3.
4.
5.
6.
7.
ENGINE CRANKS BUT WILL NOT START.
1.
2.
3.
4.
5.
6.
7.
8.
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 voltage from battery to fuel solenoid, must
hold 12 volts during cranking.
Reasonable care in preventive maintenance will insure
high reliability and a long life for the engine generator set
and the Automatic Transfer Switch.
Engine is low on oil.
Engine has high water temperature.
Engine has gone into overspeed.
Engine has gone into overcrank.
No output signal from engine ignition module to
engine control module.
ENGINE WILL NOT COME UP TO SPEED
AFTER IT STARTS.
1.
2.
3.
4.
5.
6.
Insufficient fuel volume getting to the unit.
a. Fuel line too small.
b. Fuel pressure to low.
Fuel load block needs to be adjusted.
Governor is out of adjustment.
AC short in generator components.
Wiring to the A.T.S. panel crossed or shorted.
Unit is overloaded, check load amperage.
ATS PANEL WILL NOT TRANSFER TO
EMERGENCY SUPPLY(GENERATOR).
1.
2.
3.
4.
5.
No AC generator output from generator.
Broken or defective mechanical/electrical inter
locks.
Defective holding coil in the generator side
contactor.
Wiring error between generator and transfer
switch.
Defective start/stop relay in ATS.
Defective rectifier.
Defective capacitor.
Defective armature.
Defective field coils.
AC short in the output leads.
Unit has lost its residual voltage.
Low engine speed, must be 3600 RPM.
PREVENTIVE MAINTENANCE
ENGINE STARTS AND THEN STOPS AND
A FAULT 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 in ATS.
Three phase AC is wrong rotation for three phase
power monitor. (Three phase units only)
*************
***** WARNING ****
*************
When performing any type of maintenance on this
equipment make sure the selector switch on the engine
generator is in the off position. If you are working in the
Automatic Transfer Switch, confirm with a reliable meter
that all power has been disconnected.
AUTOMATIC TRANSFER SWITCH
Clean and inspect the switch once a year. De-energize
all power sources, both line and engine generator set,
then brush and vacuum away any excessive dust and
dirty accumulation. You can at this time with the contactor
de-energized remove the contactor covers and check the
contacts. Make sure the contacts are clean and not
burned or pitted.
ENGINE GENERATOR SET
Service the engine in accordance with the engine
manufacture manual provided with your new equipment.
Routinely remove debris and dirt from around and inside
generator enclosure. Insure that the air intakes are free
from leaves and other debris at all times.
Clean and inspect battery terminals at least twice a
year. Check the battery water level at least twice a year
also.
Other than keeping the generator clean and free of
debris there is no other routine or preventive maintenance required, as long as the generator is run once a
week to keep it dry and in good working order.
PAGE 15
110/60ATS-3/C
230/150ATS-3/C
NON-UL ATS SCHEMATIC
230/150ATS-4/D
230/150ATS-17/D
NON-UL ATS SCHEMATIC
LEGEND
LTS
GTS
SSR
EC
Line Side Contactor
Generator Side Contactor
Start/Stop Relay
Exerciser Clock
Indicates Wire Number
GTS/AUX
LTS/AUX
UVR
SSS
PAGE 16
Generator Side Auxiliary
Line Side Auxiliary
Under Voltage Relay
Start/Stop Switch
PSS8000 AC AND DC SCHEMATIC
PAGE 17
PSS120000 AC CONNECTIONS
PSS12000 AUTOMATIC VOLTAGE REGULATOR
PAGE 18
PAGE 19
PSS120000 DC CONNECTIONS
PSS20000 AC SCHEMATIC
120/240 VOLT SINGLE PHASE
120/240 VOLT THREE PHASE
120/208 VOLT THREE PHASE
PAGE 20
PSS20000 DC SCHEMATIC
PAGE 21
NON-UL ATS PANEL
OUTLINE DIMENSIONS
ATS SIZE
100/100 ATS
225/100 ATS
225/225 ATS
400/225 ATS
400/300 ATS
110/60 ATS
230/150 ATS
400/320 ATS
REF A
22.88”
22.88”
22.88”
28.00”
28.00”
17.00”
22.90”
28.00”
REF B
14.00”
14.00”
14.00”
16.00”
16.00”
8.00”
14.00”
16.00”
REF C
10.63”
10.63”
10.63”
12.68”
12.68”
8.10”
10.63”
12.68”
PSS8000 LAYOUT
PAGE 22
REF D
28.25”
28.25”
28.25”
36.00”
36.00”
20.00”
28.00”
36.00”
REF E
18.375”
18.375”
18.375”
23.88”
23.88”
12.375”
18.375”
23.875”
PSS12000 LAYOUT
PSS20000 LAYOUT
PAGE 23
WINCO UL ATS
Complete installation instructions for WINCO UL Automatic Transfer Switches are contained in
the operator manual with each switch. Read the complete instructions before installing.
ULATS100-3 120/240 1 Phase
ULATS100-17 120/240 3 Phase
ULATS100-4 120/208 3 Phase
ULATS200-3 120/240 1 Phase
ULATS200-17 120/240 3 Phase
ULATS200-4 120/240 3 Phase
CUSTOMER DC CONNECTION POINT
All control wires (18-12 AWG) must be torques to 19 in-lbs.
PAGE 24
WINCO, Incorporated warrants to the original purchaser for 12 months 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 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 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, 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
have been involved in an accident.
225 SOUTH CORDOVA AVE
LE CENTER MN 56057
Phone: 507-357-6831
PAGE 25
MAINTENANCE LOG
DATE
P/N 60706-143-0-0053
ITEM
WORK PERFORMED
225 SOUTH CORDOVA AVE
LE CENTER MN 56057
Phone: 507-357-6831
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