ULPSS8B4W/E - Northwest Electric System
Contents
1. Defective start stop control in the transfer switch ATS panel in fault from previous run cycle Blown 3 4 amp fuse on generator control panel Blown 10 amp fuse on generator control panel Defective starter fuel solenoid relay s ENGINE WILL NOT CRANK USING THE AUTO RUN START SWITCH IN GENERATOR 1 Low or dead battery must hold 12 volts during cranking 2 Blown 3 4 amp fuse on generator control panel Blown 10 amp fuse on generator control panel Loose or dirty battery terminals Defective AUTO RUN START switch Defective starter Defective start solenoid Locked up engine generator set Defective starter fuel solenoid relay s 11045 00 ENGINE CRANKS BUT WILL NOT START Improper fuel pressure being delivered to unit Fuel supply shut off Fuel supply 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 Oil in the bottom of air cleaner from crankcase breather 10 Defective starter fuel solenoid relay s ENGINE STARTS AND THEN STOPS AND FAULT LIGHT COMES ON 1 Engine is low on oil 2 No AC output from generator to engage stop crank circuit ENGINE WILL NOT COME UP TO SPEED AFTER IT STARTS 1 Insufficient fuel volume getting to the unit a Fuel line too small2. 27 s lt 27 X 9 lt 77 u 2 9 MAIA LNOYA 3GIS LHOld 11045 00 9 OV SNOILVOO1 93899 14 NI 54108 27 ASN 135 HOLIVH3N39 3NION3 60706 210 20 11045 00 GENERATOR WINDING SPECIFICATIONS RESISTANCES ROTOR 5 67 Ohms STATOR 0 145 Ohms CAPACITOR LEADS 1 31 Ohms 11045 00 21 60706 210 MINECO ING A Division of BTE Dyna Technology nc 12 MONTH LIMITED WARRANTY WINCO Incorporated warrants to the original purchaser for 12 months or 1000 hours which ever occurs first that goods manufactured or supplied by it will be free from de fects 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 de fective in material or workmanship under normal use and service will be repaired or re placed 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 near est WINCO Authorized Service Center or to WINCO Inc at LeCenter Minnesota THERE IS N
3. L3 amp L7 The leads to the load distribution panel are connected to terminals L3 amp L7 The neutral leads from all three locations are con nected to the isolated terminal lugs on the sidewall of the cabinet This terminal block is labeled NEU and the terminal lugs are mounted on red isolation standoffs The ground leads from all locations are connected to the grounded terminal lugs also located on the side wall This set of terminals is labeled GROUND 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 enterance or sub panel protecting the contactor switch All wires should be installed in rigid or flexible con duit 60706 210 Because of the many different types of service feeder and distribution equipment no specific wiring instructions can be provided It is however recom mended that copper wire be used In all cases it is essential that while the load is connected to the gen erator 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 ATS control and safety systems will eliminate all paths for feedback Check with your local electrical inspector on applicable local state and federal cod
4. SERVICE DEPT 507 357 6831 11045 00 24 60706 210
5. TRANSFER SWITCH INSTALLATION AC Electrical Connections DC Electrical Connections PREVENTIVE MAINTENANCE TROUBLESHOOTING INFORMATION WIRING DIAGRAMS AC amp DC Generator Schematics UL ATS Wiring Diagram GENERATOR SET OUTLINE GENERATOR SET PAD LAYOUT GENERATOR WINDING DATA 12 MONTH WARRANTY MAINTENANCE LOG 11045 00 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 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 60706 210 SAFETY INFORMATION 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 installa tion or use Keep these instructions handy for future reference T
6. above the starter there is a small two wire white connector lying loose The wires will be labeled 1 and 21 This connector has to be plugged into the mating two wire white connector coming out of the carburator area on the left side of the unit This connection will engage an orifice in the carbura tor allowing the unit to operate on Liquid Propane vapor fuel NO other adjustments are required If you are reinstalling a unit that has been operating on Liquid Propane vapor and you now want to oper ate it on Natural Gas all that you will need to do is unplug this connector LUBRICATON Before starting the engine check and fill the crank case with the proper weight grade oil as recom mended by the engine manufacturer s maintenance instructions The necessity of using the correct oil and keeping the crankcase full cannot be over em phasized DO NOT OVERFILL THE ENGINE Use the dipstick INSTALLING THE BATTERY kkkk CAUTION kkkk In the following battery installation procedure check to be sure the selector switch remains in the off position This should be your last step before initial start up 11045 00 A customer supplied twelve volt battery is required to complete the installation Installation of the high est CCA rated battery within the correct BCI group size will increase cold weather starting perfor mance Gel batteries should not be used with the battery tender installed in the generator enclosure Mode
7. alter nate source acceptable light comes on the auto matic transfer switch should transfer the load from the utility to the generator At that time the Transfer Switch on generator light should come on 6 The generator will stay connected to the load for about 5 minutes at which time the transfer switch will transfer the load back to the utility At the time it transfers back to utility the Transfer Switch on Utility light should come on and the Transfer Switch on generator light should go out To bypass this five minute time delay you can press and release the Push to Test button again at any time 7 After the load retransfer to the utility the gen erator will continue to run for about 1 minute without a load and then shut down The Generator accept able light will go off indicating the generator set has shut down This completes the functional test of the transfer switch and the generator set If you want to leave the generator in the Automatic Start mode you can leave the left hand toggle switch on the genera tor in the ON position If you have additional work to do or don t want to leave the engine generator set in the automatic position start mode move the toggle switch to the OFF position In the OFF postion the alarm light will come on and the engine generator set will not start or run GENERATOR EXERCISER CIRCUIT The automatic generator exerciser is configured to automatically exercise the generator for 20 minutes on
8. b Low fuel pressure 2 AC short circuit 3 Wiring to the ATS panel crossed or shorted 4 Unit is overloaded Check load amperage ATS PANEL WILL NOT TRANSFER TO EMER GENCY SUPPLY GENERATOR 1 No AC generator output from generator 2 See Automatic Transfer Switch Manual ATS PANEL WILL NOT PULL IN ON NORMAL POWER See Automatic Transfer Switch Manual NO AC OUTPUT FROM GENERATOR 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 16 60706 210 NOILVLIOX3 YOSSJYddNS 39V L10A LN3ISNVHL AMALLV YOLOW YALYVLS MOLOVLNOO LYVLS I YILIN INIL ONINNNY HOLIMS 38i viadWa 110 HOLIMS 334 110 9 0 7 193135 SONNOS 13114 T GION310 1404 TOHL1NOO 3 Lino M3OHVHO 19073 440 W31SAS WHV V YOLVYANAD IOH LNOO NO 310vld3OdH OL SNOLLO3NNOO NOILISOd 6 m B HOLIMS N3JSNVH L 531935 59 OOSV dNIONZ JILVIN3HOS Od ANV OV 60706 210 17 11045 00 WINCO UL ATS Complete installation instructions for WINCO UL Automatic Trans
9. joints Excessive seal ing compound can be drawn into the solenoid regu lator or carburetor causing an engine malfunction FUEL PRESSURE LP amp NG VAPOR FUEL Correct fuel pressure can not be stressed enough The most common cause for inoperative systems is an inadequate or incor rect fuel pressure Performance of the engine is in direct relation to the correctness of the fuel system Shown below is a diagram of a typical LP or NG 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 REGULATOR FUEL SYSTEM 1 2 08 08 LP GAS SUPPLY LEGEND PR PRIMARY REGULATOR Reduces tank pressure to 10 15 PSI pounds per square inch LR LOW PRESSURE REGULATOR Reduces fuel pressure to 4 to 6 oz ounces per square inch FUEL SOLENOID VALVE Positive shut off solenoid DR DEMAND REGULATOR Requires engine vacuum to open 11045 00 GENERATOR DUAL STAGE SINGLE REGULATOR SYSTEM LP GAS SUPPLY GENERATOR LEGEND PR PRIMARY REGULATOR Reduces tank pressure to 4 to 6 oz S FUEL SOLENOID VALVE Positive shut off solenoid DR DEMAND REGU
10. option a prefab pad may be used as long as proper attention is paid to site preparation to insure the unit will not move after installation The transfer switch is mounted next to your electrical entrance or distribu tion panel inside or outside 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 Before beginning the installation process check the rating of the generator set and its transfer switch rating Be certain they can handle the intended load and are compatible with the enterance voltage phase and current ratings Plans for installation should be prepared with proper attention to me chanical and electrical engineering detail to assure a satisfactory system installation The information in this manual is offered only as a guide to finializing your installation plans 60706 210 ENGINE GENERATOR SET MOUNTING WARNING Personal Injury The enclosures on these units can become very hot adjacent to the exhaust areas Special care must be taken when installing these units to insure that the risk of contact by people is mini mized The unit s main frame should be bolted to a four to six inch thick cement pad The engine generator is mounted on a sub frame which is isolated with shock mounts on the main frame This allows the engine generator to vibrate without affecting the control panel on the main
11. the engine control module rendering the unit non operational Remove and fully recharge the battery before attempting to start CONNECTING THE BATTERY CHARGER 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 located be hind an acces cover on the right side of the unit The battery tender receptacle is to be powered by a GFCI circuit and installed in accordane with the United States National Electric Code These AC wires can be run in the same conduit as the the other AC leads from the generator Itis suggested that this circuit be fused for 15 amps Terminal block connections have been provided in the customer connection area of the engine generator set See Page 10 for diagram NOTICE The battery tender is not intended to recharge a bat tery which has become completely discharged It is designed to produce enough current to recharge a slightly low battery maintainging it fully charged MOUNTING THE AUTOMATIC TRANSFER SWITCH ATS kkkkkkkkkkkkkkkkkk kkkkk WARNING kkkkk EQUIPMENT DAMAGE Protect the switch from construction grit and metal chips to prevent mal function
12. LATOR Requires engine vacuum to open Reference numbers 1 through 3 in the diagrams above are system parts supplied by the customer Reference number 4 is on the generator Below are tables of the fuel pressure readings at each reference in the system FUEL PRESSURE TABLES Single Regulator LP Vapor only ReF 1 3 4 UNIT OFF TANK PSI 7 11 IN 7 11 IN 4 6 OZ 4 6 OZ STARTING TANK PSI 7 11 IN 7 11 IN 4 6 OZ 4 6 OZ NOLOAD TANK PSI 7 11 IN 7 11 IN 4 6 OZ 4 6 OZ FULL TANK PSI 7 11 IN 7 11 IN LOAD 4 6 OZ 4 6 OZ Two 2 Regulator System LP Vapor only UNIT OFF TANK 10 15 7 11 IN 7 11 IN PSI LBS 4 6 OZ 4 6 OZ START TANK 10 15 7 11 IN 7 11 IN ING PSI LBS 4 6 OZ 4 6 OZ NO TANK 10 15 7 11 IN 7 11 IN LOAD PSI LBS 4 6 OZ 4 6 OZ FULL TANK 10 15 7 11 IN 7 11 IN LOAD PSI LBS 4 6 OZ 4 6 OZ 60706 210 Natural Gas UNIT OFF LINE PSI 7 11 IN 7 11 IN 4 6 OZ 4 6 OZ STARTING LINE PSI 7 11 IN 7 11 IN 4 6 OZ 4 6 OZ NO LOAD LINE PSI 7 11 IN 4 6 OZ FULL LINE PSI 7 11 IN LOAD 4 6 OZ 7 11 IN 4 6 OZ LP NG FUEL CONVERSION 7 11 IN 4 6 OZ These generator sets are factory tested on Natural Gas and will require no modifications for normal operation on Natural Gas The carburation system has been preset and anti tamper plugs have been installed in the carburator as required by the EPA If you are operating on LP fuel you will have to make the following modifications On the left side of the engine
13. O 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 occurs first from date of purchase In no event is WINCO liable for incidental or conse quential 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 it products without incurring any obliga tions to make such changes or improvements on products purchased previously EXCLUSIONS WINCO does not warrant Engines Engines are covered exclusively by the warranties of their respective manufacturers see enclosed warranties WINCO does not warrant Batteries or Other Component Parts that are warranted by their respective manufacturers WINCO does not warrant modifications or alterations which were not made by WINCO Inc WINCO does not warrant products which have been subjected to misuse and or negli gence or have been involved in an accident 11045 00 22 60706 210 MAINTENANCE LOG x 11045 00 23 60706 210 WINGO ING A Division of DTEs Dyna Technology ne 225 S CORDOVA AVE LECENTER MN 56057 507 357 6821
14. WINGO INC A Division of Dyna Technology nc PACKAGED STANDBY SYSTEM INSTALLATION AND OPERATORS MANUAL ULPSS8B4W E 11045 00 1 60706 210 SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during installation and main tenance of the generator and battery Read and understand all instructions in the manual before starting and operating the generator set USING THE MANUAL Congratulations on your choice of a Winco genera tor 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 Troubleshooting Tables near the end of this manual The warranty listed in the manual describes what you can expect from WINCO should you need service assistance in the future TABLE OF CONTENTS INTRODUCTION GUIDE TO PRODUCT SAFETY BASIC INFORMATION Description Specifications PREPARING THE UNIT Unpacking the Unit ENGINE GENERATOR INSTALLATION Installation Fuel Installation Vapor Fuel Pressure Tables Fuel Conversions Lubrication Battery Installation Connecting Battery Charger
15. ake special note and follow all warnings on the unit labels and in the manuals ANSI SAFETY DEFINITIONS eoe sese se sk se se e eoe KAKA KKK ke e e e ee ok oe eoe ke e e e Ae A A A e e e e e A A E E DANGER DANGER indicates an imminently hazardous situ ation which if not avoided will result in death or serious injury This signal word is to be limited to the most extreme situations KKK KKK KK KKK KAA KKK KR KK KKK KKK KK KR KKK KKK AK KKK RK KK KKK AK KR RRR WARNING WARNING inducates a potentially hazardous situ ation which if not avoided could result in death or serious injury KKK KK KKK KAA KAA KK KK KKK KAKA KERR KK KK KAKA KKK KKK KKK KKK RR RRA KKK KK KKK KAA KKK KKK KAKA KKK KKK KA KK eoe oe RRA se e e ee e oe e RRA CAUTION CAUTION indicates a potentially hazardous situ ation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices A A Ae AE AE KKK KKK KKK KK KK RRR KKK KKK KR RK KEK KK KK KKK RRR KKK KKK KKK RRR NOTE CAUTION is also used on the unit labels and in this manual to indicate a situation that could result in serious damage or destruction of the equipment and possible personal injury 1 ELECTRICAL SHOCK The output voltage pres ent in this equipment can cause fatal electric shock This equipment must be operated by a responsible person a Do not allow anyone to operate the generator without proper in
16. anel you will need to remove the cover over the customer connection box Remove the two bolts using a 7 16 inch open end wrench then remove the panel See pages 19 and 20 for generator set and pad layout Four AC power leads are required between the 11045 00 11 generator and the ATS Two hot leads a neutral and a ground lead You will then need to run both a neutral and ground lead in addition to the two power leads all the way back to your disribution panel The two power leads from the generator are marked G1 and G3 In addition to the power leads you will also need to run a three wire 120 volt 15 amp circuit from your distribution panel to the generator This circuit wll be used to power the battery charger The last four wires you will need are the DC control leads 14 or 16 gauge for the start circuit in the ATS These last two connections will be discussed later in more detail WINCO UL ATS ASCO 165 See the ASCO installation manual for additional details on proper wiring of the Automatic Trans fer Switch The standby generator terminals in the ATS are marked ALTERNATE L2 amp L6 The hot leads G1 and G3 from the generator are connected to the terminals L2 amp L6 The normal line power terminals in the ATS are marked PREFERRED L1 amp L5 The hot line power leads are L1 and L3 from your normal power supply are connected to terminals L1 and L5 The load terminals in the ATS are marked LOAD
17. ce every 14 days 60706 210 In order to set and test the exercise circuit the left hand toggle switch on the generator control panel must be in the ON position SETTING THE EXERCISER CIRCUIT Press and release the Automatic Generator Exer ciser button After about 8 seconds the exerciser light flashes 14 times to indicate that the exerciser circuit has been set The number of flashes indi cates the number of days until the next exercise period This 20 minute period will occur at approxi mately the same time of the day the button was pressed DISABLING THE EXERCISER CIRCUIT Press and hold the Automatic Generator Exerciser button until the light goes off the light flashes then goes off ENABLING THE EXERCISER CIRCUIT Press and hold the Automatic Generator Exerciser button until the light goes off the light flashes then goes off After about 8 seconds the exerciser light flashes fourteen times to indicate that the exerciser circuit has be re enabled kkkkkkkkkkkkkkkkkk WARNING kkkkk kkkkkkkkkkkkkkkkkk WITH A TOTAL POWER FAILURE UTILITY POWER FAILS AND THE GENERATOR FAILS TO START AND RUN THE EXERCISER MUST BE RESET AFTER THE POWER IS RESTORED CLEARING AN ERROR CODE An error codes occurs on the ASCO control board if the generator set fails to start or there is some other malfunction BOTH Transfer Switch lights will be blinking together The Automatic Generator Exer ciser light will be bli
18. e upper right hand corner of the ATS panel The terminal block TB7 11045 00 12 is numbered 1 through 9 These terminals will accept 22 14 AWG stranded wire Itis recom mended that you use 16 AWG for distances up to 200 feet You need to run four 4 wires from the engine gen erator set to the transfer switch see table below PURPOSE RECOMMENDED COLOR es Battery Postive Bie 1 Battery Negative we 28 sm ome You can use any color you want these color codes are just a recommendation The wires terminate on TB7 as follows TB7 TERMINAL COLOR TB7 TERMINALS N O Oo 60706 210 The following is an optional way to interconnect the Fuel line protected and a moisture trap in Generator and the Transfer Switch The wires termi stalled may be required for NG nate on TB7 as follows LP NG pressure OK 4 6 oz 7 11 in WC Battery connections clean and tight Battery fully charged All AC and DC wiring installed and properly protected Refer to engine owners manual for proper levels and types After completing the above checklist the engine generator set is ready for the initial start up test START UP PROCEDURE Engine Generator Set only Move the left hand toggle switch from OFF to the ON position The alarm light should go out N
19. es kkkkkkkkkkkkkkkkkk kkkkk WARNING kkkkkkkkkkkkkkkkkk A service disconnect must be installed in front of the ATS panel as the ATS is not service enterance rated This will alow 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 To wire the automatic transfer switch into the exist ing 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 enterance providing the service enterance ampere rating is within the transfer switch s rated capability If only specific circuits are to be powered under emergency power failure conditions and additional distribution panel designated emergency distribution panel must be installed All selected emergency circuits are removed from main distribution panels and reinstalled in the emer gency distribution panel Suggested circuits freez er refrigerator furnace emergency lights sump pump emergency outlet circuits etc Total running load must not exceed generator rating DC ELECTRICAL INTERCONNECTION kkkk CAUTION kkkk Never run the AC and DC wiring in the same con duit ASCO 165 UL SWITCH Your DC connection points in the ASCO 165 UL ATS are on the terminal block in th
20. ext move the right hand toggle witch from the AUTO to the RUN position You should hear the fuel solenoid engage at this time Next lift the toggle switch to the START position and hold The engine starter should engage and the engine will start As soon as the en gine starts release the toggle switch and it will return to the run position If the engine does not start after 15 seconds release the switch and let the starter rest for 15 seconds and re attempt to start If the unit still will not start consult the troubleshooting guide in the back of this manual 090999909099 N CO Q O d A START INITIAL START UP OFF AUTO kkkkkkkkkkkkkkkkkk kkkkk WARNING kkkkk kkkkkkkkkkkkkkkkkk DO NOT jump start these engine generator sets Starting these units on a low battery of jump start ing them will cause damage to the engine control module With the engine running smoothly check the no load Use the following checklist to verify correct in voltage and frequency at wire 1 and 4 L2 and stallaion before starting the engine L6 in the ASCO ATS on the generator terminal block in the ATS The voltage should be 240 volts plus or Engine oil Check level amp fill as required with minus nominal The frequency should be between proper grade quantity 61 5 to 62 hertz Hz The voltage should also be Unit mounting base properly bolted do
21. fer Switches are contained in the operators manual with each switch Read the complete instructions before installing ASCO 165 SERIES 4 WIRE CONTROL ATS CONNECTION TERMINAL 1 0 NO C START CKT NC NO C RUN IGN CKT NC BATT 9 8 7 6 5 4 3 2 1 59999 999 P Q O CONTACTS SHOWN WITH THE TRANSFER SWITCH IN THE UTILITY POWER FAILED CONDITION THIS DRAWING REPRESENTS THE ASCO 165 SERIES TRANSFER SWITCH WITHOUT THE CONTACTOR ASSEMBLY DRAWN IN CUSTOMER CONNECTION POINT All control wires 18 14 AWG must be torqued to 19 in lbs 11045 00 18 60706 210 LAYOUT ULPSS8B4W E LLI o 2 lt LLI LLI LLI z 34 1441 60706 210 ES wasis nomen EY II V 51708 21 SNOILVOOT 31OH 19 SST emg numen asuma V No
22. frame See page 20 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 The unit should be mounted to allow for ample work ing room around it A general rule to follow is five 5 feet clearance on all sides See NFPA Code 37 for additional clearance requirements FUEL INSTALLATION The fuel supply should be as close as possible to the engine This will reduce the installation cost of fuel runs The information in this manual is offered to as sist 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 mak ing you aware of the decisions you must make In no case should the instructions and information pro vided be interpreted to conflict with any local state or national codes If in doubt always consult your local fire marshal gas supplier or building inspector kkkkkkkkkkkkkkkkkk WARNING kkkkkkkkkkkkkkkkkk FIRE HAZARD All fuel runs should be installed by a licensed fuel supplier To connect the fuel line to the generator set you will connect your incoming fuel line to the 3 4 inch NPT fitting located on the left side of the engine genera tor set This fitting is shipped with a plastic plug installed to insure the fuel system stays clean For all vapor fuel system
23. he ATS as standard equipment The ATS also contains the power failure sensing circuitry necessary to start and stop the engine generator set The transfer switch is also equipped standard with a 3 second start delay and a 15 second transfer delay to allow the engine to warm up before transferring the load to the gen erator When the line power is restored the ATS has a 5 minute retransfer delay to allow the incoming util ity to stabilize before transferring back to line power and then an additional 1 minute engine cool down delay before the engine shuts down Read and understand the ATS owners manual before installing servicing or operating the transfer switch UL Automatic Transfer Switch Sizes UNIT LINE SIDE GENERATOR CONTACTOR SIDE CONTACTOR 100 AMPS 100 AMPS 200 AMPS 200 AMPS ULPSS8BAW Both the 100 amp and the 200 amp UL Switches are available in single phase only 2 ENGINE GENERATOR The engine generator set consists of a Briggs amp Stratton Vanguard twin cylinder four cycle air cooled engine The engine is factory equipped to run on LP or NG 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 generator is a brushless single bearing direct drive rotating field design The generator is connnected to the engine s tapered quill crankshaft extension The engine generator is mounted in a dri
24. kkkkkkkkkkkkkk PERSONAL INJURY HAZARD Install front cover in transfer switch before operation An electrical sys tem fault could cause a flash and severe personal injury utility preferred source acceptable light generator alternate source acceptable light UTILITY GENERATOR exerbiser e Automatic Generator Exerciser transfer switch on utility transfer switch on generator preferred source light alternate source light 11045 00 14 2 Turn on the preferred source utility circuit breaker The utility source acceptable light should now come on as well as the transfer switch on utility light If these lights fail to come on recheck your incoming power to insure you have 240 volts nomi nal If not troubleshoot your utility source before continuing 3 Turn on the altenate source generator curcuit breaker 4 Press and hold the Push to Test button until the generator alternate source acceptable light comes on and stays on Then release the button This will start up your generator set This light indicates that the generator is running and the output voltage and frequency are within accept able limits Under normal conditions this light should come on in 5 to 10 seconds If the light does not come on and stay on a malfunction has occurred Either the unit didn t start or the voltage or frequency is incorrect Correct the problem before continuing 5 About 15 seconds after the generator
25. l MINIMUM CCA Rating 500 Voltage BCI Group ULPSS8B4W 12 26 Installation and servicing of batteries must be per formed or supervised only by personnel knowledge able 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 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 bat posts to be sure they are free of corrosion 4 Always connect the battery positive cable first and then connect the battery negative cable When removing the battery cables from the bat tery reverse the procedure disconnect the nega tive cable first and
26. n engineering tests of typical units and is subject to and limited by the temperature altitude fuel and other condi tions specified by the manufacturer of the applicable engines INTRODUCTION AND DESCRIPTION The package standby system includes all times necessary for a completely automatic standby power System as standard equipment DESCRIPTION The package standby system is designed to au tomatically provide standby power to unattended loads during electrical outages Upon an interruption of normal electrical service the packaged standby System electrical control circuits will automatically start the engine The generator will produce electri cal power and the Automatic Transfer Switch ATS 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 the 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 11045 00 These packaged standby systems consist ot two major components 1 AUTOMATIC TRANSFER SWITCH A wall mounted ASCO 165 Automatic Transfer Switch ATS designed for inside installation The transfer switch is UL1008 approved A fourteen day electronic exerciser circuit is installed in t
27. ne manufacturers manual provided with your new equipment Routinely remove debris and dirt from around the inside generator enclosure Insure that the air intakes are free from leaves and other debris at all times Clean and inspect battery terminals a 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 preventative main tenance required as long as the generator is run biweekly to keep it dry and in good working order COLD WEATHER OPERATION Extreme cold weather operation requires special considerations Higher CCA batteries are required for cold weather starting 650 CCA or larger are rec ommended In addition you should consider install ing an oil heater kit and a battery warmer for reliable starting during cold weather 60706 210 TROUBLESHOOTING TABLES kkkkkkkkkkkkkkkkkkkk xk WARNING kkkkkk kkkkkkkkkkkkkkkkkkkk NEVER JUMP START THESE UNITS JUMP STARTING THESE UNITS WITH LOW OR BAD BATTERIES WILL CAUSE PERMANENT DAMAGE TO THE ENGINE CONTROL MODULE UNIT WILL NOT CRANK WHEN THE POWER FAILS Right generator control toggle switch not in AUTO position Low or dead battery must hold 12 volts during cranking Incorrect wiring between transfer switch and generator Loose or dirty battery terminals Defective ON OFF switch Defective starter Defective start solenoid
28. nking a number of times then pause This number gives the error code reason from page 8 of the ASCO 165 owner s manual To clear this code press and release the Push to Test button once Then troubleshoot the problem accord ing to the ASCO 165 owner s manual This completes your installation and unit testing ALWAYS leave the system in automatic mode unless servicing the unit For automatic operation the left hand toggle switch on the generator control panel must be left in the ON position 11045 00 15 PREVENTIVE MAINTENANCE Reasonable care in preventive maintenance will insure high reliability and a long life for the engine generator set and Automatic Transfer Switch kkkkkkkkkkkkkkkkk WARNING kkkkk kkkkkkkkkkkkkkkkk When performing any type of maintenance on this equipment make sure the selector switch on the en gine generator is in the off position If you are work ing 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 ener gize all power sources both line and engine genera tor set then brush and vacuum away any excessive dust or dirty accumulation You can at this time with the contactor de energized remove the contactor covers and check the contacts Make sure contacts are clean and not burned or pitted ENGINE GENERATOR SET Service the engine in accordance with the engi
29. not be larger than 100 amps If you have a 125 150 200 amp or larger system and want to use a 100 amp transfer switch 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 NOTE THE MAXIMUM OUT PUT OF THE GENERATOR IS 33 AMPS AT 240 VOLTS You must also take into consideration when deciding whether to install an emergency distribution panel AC ELECTRICAL CONNECTIONS NOTICE CLASS 1 WIRING METHODS ARE TO BE USED FOR ALL FIELD WIRING CONNEC TIONS TO TERMINALS OF A CLASS 2 CIRCUIT kkkkkkkkkkkkkkkkkk WARNING kkkkk kkkkkkkkkkkkkkkkkk A main line circuit breaker has been provided inside the generator housing During all wiring installation make sure the breaker is in the off position and the generator operators switch is in the off position always indicates GENERATOR CONNECTIONS Note This symbol ground where used Minimum conductor sizes between the generator and the ATS Based on wire type and temperature rating Wire has been derated for 40 C ambient temperatures WIRE TEMPERATURE RATING saw To gain acces to the customer connections remove the end door panel opposite the muffler end All connections including AC and DC connections to the ATS 120 Volt power connection for battery charger and battery installation are made behind this door panel After removing the door p
30. or shortened life of the switch Contactors returned for warranty consideration with foreign materials inside of them will not be warranted Before installing the ATS you must first ensure that the transfer switch is large enough to handle your complete distribution panel If you are installing a 100 amp transfer switch the main line circuit breaker 60706 210 SNOILOANNOO 304 SNOI1VOIJIO3dS ANDYOL SLNIOd NOILOANNOO Od 8 OV YIWOLSNO SdlAV 98 H3ddOO SAN 597 NI 9L OL NOILOANNOO YAWOLSNO Qqasinodgs SV Q3193NNOO YAWOLSNSD TNSLLOSN SNILVO 14 GROUND ALNILA 1949 AHL HOLIMS H3JSNVH L AON39S3IW3H OL SNOLLO3NNOO LAdLNO HOJVSHSN39 H3NOLS2 98 H3ddOO SMV 0L OL CALVY 91 91 OL ANDYOL 4 H3ON3L AHSLIVS8 H3MOd OL3NITALITLLO LIOA OL LO3NNOO OL YSANOLSND SOfY1HLIM 43ddOO 9L OLVL SS1NI 96 OL SM389S ANDYOL HOLIMS SH3JSNVM L OILVINOLRV OL SNOI LO3NNOO YSAWOLSNSD NO Q3Sf 19000 Q3AON3M SI dl NO LON TIIM NO 5 LON HOLIMS 901 AON3ONS3W3 3 LOIN3 303 YOLOANNOD JAIMZ 5159 dOLS 60706 210 10 11045 00 must
31. p proof en closure for outside installation Connection boxes and terminal blocks are provided for all customer connections both AC output and DC control A customer supplied 12 volt 500 CCA BCI group 26 battery is required to complete the installation NOTICE This unit will automatically transfer if a power outage occurs while running in an exercise mode 60706 210 SPECIFICATIONS GENERATOR esse 120240 1 3600 Derate 10 for Natural Gas operation Derate to 6000 watts when operating on Natural Gas pressure of 4 6 inches water column Derate 3 5 per 1000 feet elevation above sea level FUEL CONSUMPTION 1000 BTU CU FT 2520 BTU CU FT cwm w erum 3200 anum NA 16 Based on full load operation LP TANK SIZING Required LP tank size for LP Vapor withdrawal operating at various outside temperatures given in degrees Fahrenheit Celsius ENGINE SPECIFICATIONS Refer to engine operating and maintenance instruc tions NOTICE When unpacking the generator set be sure to in spect it carefully for freight loss or damage lf 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 segre gate
32. periods of time b Keep your neighbors in mind when permanent ly installing this equipment 5 CLEANLINESS Keep the generator and sur rounding area clean a Remove all grease ice snow or materials that create slippery conditions around the unit b Remove any rags or other materials that could create a potential fire hazard c Carefully clean up any gas or oil spills before starting the unit 6 SERVICING EQUIPMENT All service includ ing the installation or replacement of service parts should be preformed only by a qualified technician a Use only factory approved repair parts b Do not work on this equipment when fatigued c Never remove the protective guards covers or receptacle panels while the engine is running Use exteme caution when working on electri cal components High output voltage from this equipment can cause serious injury or death 60706 210 e Always avoid hot mufflers exhaust manifolds and engine parts They can cause severe burns instantly Installing a generator set is not a Do it your self project Consult a qualified licensed elec trician or contractor The installation must com ply with all national state and local codes 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 o
33. s 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 These fuel pressures are 11045 00 critical failure to provide the proper pressure can cause many problems ranging from a unit that will not start to causing damage to the fuel system These units are normally tested on Natural Gas and will have a tag hanging on the fuel hose indicating on what fuel your unit was factory tested If you are running on LP or have to change fuel types at any time see information on page 8 on LP NG CONVER SION 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 that the unit was set up and tested on 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 or over a two regulator fuel system is recommended This is ac complished 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 second ary regulator mus
34. struction b 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 pronged grounded receptacles and extension cords Be sure the unit is properly grounded to an external gound rod driven into the earth 11045 00 2 FIREHAZARD Natural gas and L P present a hazard of possible explosion and or fire a Do not refuel when the engine is running or hot Allow the engine to cool at least two minutes before refueling Keep fuel containers out of reach of children Do not smoke or use open flame near the gen erator set or fuel tank Keep a fire extinguisher nearby and know its proper use Fire extinguishers rated ABC by are appropriate Store fuel only in an approved container and only in a well ventilated area Follow local codes for closeness to combust ible material 3 DEADLY EXHAUST GAS Exhaust fumes from any gasoline engine contain carbon monoxide an in visible oderless and deadly gas that must be mixed with fresh air a Operate only in well ventilated areas b 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 floors 4 NOISEHAZARD Excessive noise is not only tiring but continual exposure can lead to loss of hearing a Use hearing protection when working around this equipment for long
35. t 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 duel stage regulators it should also be a minimum of 10 feet from the unit If this is not done the demand regula tor on the unit and the pressure regulator in the fuel line will interfere with each other When the two 2 stage regulator system is used on LP 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 you local fuel supplier for your exact requirements The appropriate line size from the table below is then installed from the secondary regulator to the generator set kk k k k kkkkk WARNING kkkkk kkkkkkkkkkkkkkkkkk PERSONAL DANGER Do not use galvanized pipe in fuel line runs The galvanized coating can be come eroded and flake off causing possible obstruc tions in the regulator or fuel valve The results could range from inoperative engine to hazardous fuel leaks 60706 210 NATURAL GAS or LP VAPOR PIPE SIZE Size of pipe nomally required for generators operat ing on NATURAL GAS or LP VAPOR FEET SIZE OF PIPE up to 25 FT 3 4 Pipe 25 100 FT over 100 FT Use a two regulator system Allow an additional 3 feet for each standard elbow Do not use street ells restrictive kkkk CAUTION kkkk Be careful when sealing gas
36. tery 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 elec trolyte following the procedure above BATTERY CHARGING Units equipped with electric start have a small fly wheel charger built into the engine flywheel assem bly for recharging the starting battery This flywheel charger generates a small AC current that passes through a rectifier regulator assembly on the engine to produce a DC charging current This circuit is not designed to be used as a battery charging circuit to recharge dead batteries CAUTION kkkk EQUIPMENT DAMAGE Always connect the posi tive cable first and the negative cable last When disconnecting it is the negative first and the 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 engine starter the negative battery terminal is connected to the negative cable ground from the engine generator 11045 00 assembly All connections must be clean and tight Check the electrolyte fluid in the battery periodi cally to be sure it is above the plates Never allow the battery to remain in a discharged condition CAUTION kkkk EQUIPMENT DAMAGE NEVER JUMP START these units Doing so will destroy
37. the damaged material and contact the carrier for claim procedures Be sure to retain the packag ing material for carrier inspection 11045 00 Concealed Damage is understood to mean dam age to the contents of a package which is not evi dent at the time of delivery by the carrier but wheich is discovered later The carrier or carriers are responsible for merchandise lost or damaged in tran sit 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 Please note most carriers have a time limit for filing concealed damage claims kkkk CAUTION kk These units are shipped with oil Be sure to check oil levels before operating See engine manufactur er s instruction manual for recommended oil require ments before initial starting UNPACKING 1 Carefully remove the carton 2 After inspecting the engine generator and trans fer switch for external physical damage check for the following items packed inside the carton a Owner s manual b Engine manufacturer s instruction manual Remove main frame hold down bolts 4 Unit can now be lifted from shipping pallet INSTALLATION General Information kkkkkkkkkkkkkkkkkk kkkkk WARNING kkkkk 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 As an
38. then the positive cable 5 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 60706 210 Where electrolyte contacts the skin wash off im mediately with water If electrolyte contacts the eyes flush thoroughly and immediately with water and seek immediate medical attention Spilled electrolyte is to be washed down with an acid neutralizing agent A Common practice is to use a solution of one pound of bicarbonate of soda baking soda to one gallon of water The bicarbonate of soda solution is to be added until the evidence of reaction foaming has ceased The resulting liquid is to be flushed with water and the area dried DANGER Explosive Fire Risk Never smoke when near batteries Do not cause a flame or spark in the battery area Always discharge static electricity from your body before touching batteries by first touching a grounded metal surface 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 refill ing the battery with water use only distilled water Tap water will shorten the service life of the bat
39. wn checked between the hot terminals L2 and L6 and Clearance for service and maintenance on all the neutral to be certain of a balanced voltage output sides and a solid neutral connection The voltage should Proper fuel line material and size be about on half of the line to line voltage All fuel line connections tight 11045 00 13 60706 210 NOTICE If for any reason during the check out procedures the voltage and frequency are not correct move the toggle switch to the STOP position and correct the trouble before proceeding After verifying the voltage and frequency are cor rect move the right hand toggle switch to the AUTO position The unit should shut off with no time delay The right hand toggle switch must be left in the AUTO position for proper operation of the gen erator If you leave it in the RUN position the fuel solenoid will remain open and it will not shutdown properly after the next exercise period Transfer Switch amp Engine Generator This procedure checks the electrical operation of the automatic transfer switch If the actual operation does not follow this procedure consult the trou blshooting section in the transfer switch manual 1 Move the left hand toggle switch from the OFF position to the ON position The alarm light should go out The unit is now ready to be operated from the Automatic Transfer Switch kkkkkkkkkkkkkkkkkk kkkkk WARNING kkkk
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