Wanco AB Series User manual

Power & Light
Two-BearingBelt-Drive
Generators
AB-, AR- and EC-Series
Owner’s Manual
March 2011

Owner’s Manual i
Wanco Two-Bearing Belt-Drive Generators
Table of Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Read before using . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Principle of operation . . . . . . . . . . . . . . . . . . . 2
1.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Where to obtain service . . . . . . . . . . . . . . . . . 4
2 Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Operating safety. . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Storage and maintenance safety. . . . . . . . . . 8
3Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Before starting . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1.2 Power requirements . . . . . . . . . . . . 9
3.1.3 Operating speed . . . . . . . . . . . . . . . 10
3.1.4 EC-Series reconfiguration . . . . . . . 11
3.1.5 Installation options. . . . . . . . . . . . . 14
3.1.6 Standby installations . . . . . . . . . . . 18
3.1.7 Safety guards . . . . . . . . . . . . . . . . . . 21
3.1.8 Circuit breakers . . . . . . . . . . . . . . . . 21
3.2 Operating the generator. . . . . . . . . . . . . . . . . 22
3.3 General maintenance . . . . . . . . . . . . . . . . . . . 22
Appendix
A Power requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

iiOwner’s Manual
Wanco Two-Bearing Belt-Drive Generators
List of Figures
Figure 3.1 EC-Series connections, 60 Hz . . . . . . . . . . . . . . 12
Figure 3.2 Sample installation. . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 3.3 Equation for calculating pulley size . . . . . . . . 16
Figure 3.4 Maximum pulley distance from end of
crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 3.5 Slack run side, tensioner and brake . . . . . . . . 17
Figure 3.6 Flexible coupling. . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 3.7 Typical standby installation. . . . . . . . . . . . . . . . 21
Figure A.1 Formula for calculating wattage . . . . . . . . . . . 23
List of Tables
Table 3.1 Minimum horsepower requirements. . . . . . . 10
Table A.1 Approximate current requirements for
electric motors . . . . . . . . . . . . . . . . . . . . . . . 24
Table A.2 Minimum extension cord gauge . . . . . . . . . . . 25
Table A.3 Approximate equipment power
requirements. . . . . . . . . . . . . . . . . . . . . . . . . 26

Owner’s Manual 1
Wanco Two-Bearing Belt-Drive Generators
1 Introduction
1.1 Read before using
This is an industrial-type electric generator. This equipment is
potentially hazardous and could cause physical injury or even death
if improperly used. Before attempting to operate this generator:
■Check to ensure no damage has occurred in transit
■Read this manual thoroughly
■Follow all instructions carefully
■Before using an engine to power the generator, read the engine
manufacturer’s instructions
By following these instructions, you will enjoy safe and trouble-free
operation of your generator.
Installing and wiring a home standby generator is not a do-it-
yourself project. Consult a qualified licensed electrician or
contractor.
WARNING
Improper use of equipment could cause
serious injury or death.
Prior to using this equipment, carefully read,
understand, and observe all instructions.

2 Owner’s Manual
Wanco Two-Bearing Belt-Drive Generators
1.2 Principle of operation
1.2.1 AB- and AR-Series
On AB- and AR-Series generators, the generator stator and the main
phase output winding have an auxiliary phase winding that is
connected to a capacitor.
The resultant current flow creates an alternating armature reaction
that can be considered the combination of two rotating fields. One
field is in the direction of the generator rotation at the same speed;
the other is in the opposite direction, and induces in the rotor field
winding an electromagnetic field that is double the rated
frequency.
By connecting a diode in series with the rotor field winding, the
current is rectified and the necessary excitation is obtained.
The voltage regulation at load is ensured by the field build-up
generated by the armature reactance and the rotating field
windings.
1.2.2 EC-Series
All EC-Series generators are 12-wire brushless generators with an
exciter generator that induces a voltage in the main generator. An
automatic voltage regulator is connected to the main generator
and controls the output voltage of the generator.
EC-Series generators are 3-phase wound generators that are
reconnected for single-phase applications. They can operate at 60
hertz and 1800 RPM or 50 hertz and 1500 RPM with reconnections.
All EC-Series generators can operate in bidirectional rotation
(clockwise or counterclockwise). They can function as prime power
with 24-hour continuous operation.

Owner’s Manual 3
Wanco Two-Bearing Belt-Drive Generators
1.3 Specifications
1.3.1 AB-Series
1.3.2 AR-Series
1.3.3 EC-Series
All AB-Series models
Shaft O.D. 0.875 (7/8) inch
Keyway 0.1875 (3/16) inch
Key Included
Pulley Single pulley, B-size belt
AR100 AR250M
Shaft O.D. 1.0 inch 35mm
Keyway 0.25 (1/4) inch 10mm
Key Included Included
Pulley Double pulley Double pulley
Single-phase
EC7-1
EC11-1
EC12.5-1
EC24-1
EC30-1
EC40-1
EC50-1
EC67-1
EC83-1
EC100-1
EC120-1
EC145-1
EC180-1
EC200-1
EC270-1
Shaft O.D. 35mm 42mm 55mm 65mm 85mm
Keyway 10mm 12mm 16mm 18mm 22mm
Key Included Included Included Included Included
Three-phase
EC8-3
EC13-3
EC15-3
EC29-3
EC40-3
EC50-3
EC65-3
EC80-3
EC100-3
EC120-3
EC145-3
EC176-3
EC215-3
EC240-3
EC325-3
Shaft O.D. 35mm 42mm 55mm 65mm 85mm
Keyway 10mm 12mm 16mm 18mm 22mm
Key Included Included Included Included Included

4 Owner’s Manual
Wanco Two-Bearing Belt-Drive Generators
1.4 Where to obtain service
Before calling for service, please have the generator model and
serial number ready. This information is displayed on the serial
number tag, which is adhered to the generator.
Contact our service department using the following information:
Wanco Inc.
5870 Tennyson Street
Arvada, Colorado 80003
800-730-3927
fax [phone]
www.wanco.com
[e-mail]

Owner’s Manual 5
Wanco Two-Bearing Belt-Drive Generators
2 Safety
2.1 Operating safety
DANGER
Explosion hazard.
■NEVER operate generator in an explosive
atmosphere or near combustible materials.
■Keep generator, engine, fuel, and other
combustibles away from sparks, open flame,
and burning objects.
■Before using an engine to power the generator,
read engine manufacturer’s instructions.

6 Owner’s Manual
Wanco Two-Bearing Belt-Drive Generators
■Before using this equipment, carefully read, understand, and
observe all instructions in this manual.
■If using an engine to power the generator, read the engine
manufacturer’s instructions.
■Before using this equipment for the first time, inspect it for loose or
missing parts and damage that may have occurred in shipment.
■This equipment should not be operated by persons under 18 years
of age.
■ALWAYS wear appropriate protective clothing, shoes, and other
protective devices, as required by the job.
■When working on or around this equipment, do not wear neckties,
loose-fitting shirts or jackets, or sleeves that may become caught in
moving parts.
■ALWAYS wear appropriate respiratory, hearing, and eye protection.
■NEVER operate this equipment when not feeling well due to fatigue,
illness, or medication.
WARNING
Shock hazard.
■Use extreme caution when working on or with
electrical components.
■Avoid contact with live terminals and
receptacles.
■The generator must be properly grounded
according to all applicable electrical codes.
■Do not operate generator in rain, snow, or wet
conditions.
■Use only 3-prong grounded receptacles and
extension cords.
■On construction sites, use a GFCI (ground fault
circuit interrupter) to protect 120-volt
receptacles.
■Installation as a standby generator must
comply with all applicable electrical codes, and
requires a suitable power-transfer device to
isolate generator from power utility.

Owner’s Manual 7
Wanco Two-Bearing Belt-Drive Generators
■NEVER operate this equipment under the influence of drugs or
alcohol.
■Before operating, know the location of the nearest fire extinguisher,
first aid kit, and emergency telephone.
■Keep a fire extinguisher nearby and know its proper use.
Extinguishers rated ABC by the NFPA are appropriate for all
applications. For more information, consult your local fire
department.
■Ensure the generator is well ventilated on all four sides.
■Do not operate this equipment in an enclosed area, such as a
recreational vehicle, marine vehicle, under the hood of a car or
truck, or inside a truck or van with only the rear door open. All
warranties are voided if the unit is operated in such an area.
■Keep generator and surrounding areas clean. Remove oily rags and
other material that could create a fire hazard.
■NEVER use generator with any safety guards removed. Keep all
safety guards and power shields in position and secured.
■NEVER use the generator with a cover over the unit. The generator
must operate in an open-air environment.
■NEVER service generator or its components while generator is
running. Do not perform service or maintenance while generator is
hot.
■Only a qualified technician should perform repairs on this
equipment, including the installation or replacement of parts and
accessories.
■Use ONLY accessories or attachments that are recommended by the
manufacturer. Unauthorized equipment modifications will void all
warranties.

8 Owner’s Manual
Wanco Two-Bearing Belt-Drive Generators
2.2 Storage and maintenance
safety
■When not in use, store equipment in a clean, dry location, out of the
reach of children.
■ALWAYS keep the generator in proper running condition.
■Before servicing, ensure the power unit cannot be inadvertently
started during service.
■ALWAYS fix damage to the generator immediately. Repair or replace
broken or worn parts. Only use parts from original manufacturer.
■Replace operation and safety decals when they become difficult to
read.

Owner’s Manual 9
Wanco Two-Bearing Belt-Drive Generators
3 Operation
3.1 Before starting
3.1.1 Safety
Before operating the Wanco Generator:
■Read and be familiar with this instruction manual.
■Read and follow all safety instructions (see Section 2, page 5).
■If using an engine to power the generator, read the engine
manufacturer’s instructions.
3.1.2 Power requirements
You must supply the power source—usually an engine—for use
with your generator. The factory does not supply engines.
All engines have a horsepower curve. Always operate the engine at
a speed that develops the required horsepower, as listed in
Table 3-1.
If you do not have enough horsepower from the engine, you will
not obtain the full electrical output from the generator. If you
attempt to draw full power from the generator without enough
horsepower, the result will be low voltage and higher amperage,
which will damage the generator and the equipment you are
powering with the generator.
The generator will not operate properly if powered by a tractor (as a
PTO generator). The RPMs from a tractor engine are too low. If a PTO
generator is required, contact the factory.
CAUTION
Insufficient horsepower will damage generator and other
connected equipment.
Use a power source that is properly sized for the generator.

10 Owner’s Manual
Wanco Two-Bearing Belt-Drive Generators
Operating the generator with insufficient horsepower is considered
improper use of the generator and will void the warranty.
Although AB- and AR-Series generators have circuit breakers, they
are thermal-type breakers, which take some time to heat up on
overload before tripping. With insufficient horsepower, they may
not trip soon enough to protect connected equipment.
EC-Series generators do not have circuit breakers. To protect
equipment, you MUST supply your own circuit breaker between the
generator and load.
3.1.3 Operating speed
■Operate AB- and AR-Series generators at a constant speed of 3600
RPM for 60 Hz models or 3000 RPM for 50 Hz models.
❑All AB25 and AB30 generators are running at the correct speed
when their voltmeters read 120V.
❑All other AB- and AR-Series generators are operating at the
correct speed when their voltmeters read 240V.
Table 3-1 Minimum horsepower requirements
Generator model Minimum horsepower
AB25, AB25-Hydro,
AB30-Hydro
5 HP
AB50 8 HP
AB60 11 HP
AR100 18 HP
AR250M 50 HP
EC-Series Approximately 2 HP per 1000 watts
CAUTION
Low RPMs will create high amperage demands. High RPMs will
create high voltage.
■Always operate at the required speed.
■Use a tachometer when needed.
■Maximum allowable RPM variation is ±10%.

Owner’s Manual 11
Wanco Two-Bearing Belt-Drive Generators
■All AB- and AR-Series generators are inherently regulated. By
maintaining the appropriate speed as described above, the proper
voltage of 120 or 240 volts will be delivered by the generator.
Lowering the generator shaft speed decreases the voltage;
increasing the shaft speed increases the voltage.
■Operate EC-Series generators at a constant speed of 1800 RPM for
60 Hz models or 1500 RPM for 50 Hz models.
❑For 60 Hz models, EC-Series generators are operating at 1800
RPM when the frequency meter reads 60 Hz.
❑For 50 Hz models, EC-Series generators are operating at 1500
RPM when the frequency meter reads 50 Hz.
3.1.4 EC-Series reconfiguration
To change phase or voltages on 60-Hertz EC-Series generators, see
Figure 3-1. For 50-Hertz generators, consult the factory.
This is not a do-it-yourself project and should only be done by a
certified electrician or electrical contractor.
The generator must be operating at the proper speed (see
Section 3.1.3) before and while adjusting the voltage regulator.
All EC-Series generators feature an automatic voltage regulator that
maintains ±1.5% voltage regulation. If a change in voltage is
required, the frequency meter MUST be connected to one line (hot)
wire and to the neutral connection for the meter to function.
To adjust voltage, refer to Figure 3-1 and follow the instructions on
page 14.
DANGER
Shock hazard.
Live wires carry a voltage and amperage that are
lethal.
NEVER touch the generator’s main power terminals.

12 Owner’s Manual
Wanco Two-Bearing Belt-Drive Generators
Figure 3-1 EC-Series connections, 60 Hz
Single phase, 120/240 volts
Parallel zigzag
8
7
12
43
11
12
10-12 2-4 6-8
9-115713
10
9
6
5
NL1 L2
LLN
Single phase, 120/240 volts
Double delta
8
7
2-3
512
8-11
110
6-9
74
12
11
34
L1 NL2
L
N
9
10
6
2
5
1
L
Three phase, 120/208 volts
Parallel star
13
24
10 8
12
9
11
6
7
5
L
L
L
N
2-410-12 6-8
5-71-3 9-11
L1 L2 L3 N
Three phase, 277/460/480 volts
Series star
10-11 2-3 6-7
4-8-12
159
L1 L2 L3 N
8
6
7
5
12
10
11
9
LL
L
N
4
2
3
1
L1 = Line
L2 = Line
L3 = Line
N = Neutral
Connections for 60Hz
generators only. Consult
factory for 50Hz
connections.
Do not use other
connection terminals

Owner’s Manual 13
Wanco Two-Bearing Belt-Drive Generators
12 34567891011
AMP HZ VOLT
REG. TYPE. SR7-2G
REG. TYPE. SR7-2G
6
5
4
3
2
1
0
B
+
–
REG TYPE UVR 6
3
2
4
1
REG TYPE UVR 6
AMPHZ VOLT
Three phase, 240 volts
Series delta (no neutral)
CT center tap
10-11 2-3 6-7
1-12 5-4 9-8
L1 L2 L3
8675
LL
L
CT
CT CT
9
11
10
12
4
2
3
1
Voltage regulators
S.R.7/2-G
U.V.R.6/1-F
L1 = Line
L2 = Line
L3 = Line
CT = Center tap
Connections for 60Hz generators only.
Consult factory for 50Hz connections.
Do not use other connection
terminals.
For neutral connection, you must use the
center tap adjacent to the line connection
you choose.
Voltage adjustment
screw
Voltage adjustment
screw

14 Owner’s Manual
Wanco Two-Bearing Belt-Drive Generators
This is not a do-it-yourself project and should only be done by a
certified electrician or electrical contractor.
1. Remove the top cover of the control box.
2. Before adjusting the voltage, establish the proper speed using a
frequency meter:
■For 60-hertz models, the generator shaft is turning at 1800
RPM when the frequency meter reads 60 Hz.
■For 50-hertz models, the generator shaft is turning at 1500
RPM when the frequency meter reads 50 Hz.
3. The generator has several automatic voltage regulators. Locate the
Phillips adjusting screw marked “VOLTS”in small print. DO NOT touch
any other adjusting screws.
4. With no load on the generator, and the generator operating at
either 60 hertz and 1800 RPM, or 50 hertz and 1500 RPM, turn the
“VOLTS”adjusting screw very slowly, wait a few seconds, then
monitor the voltage from one line (hot wire) to neutral (or center
tap on 240V delta connections). The voltage will increase or
decrease depending on the direction you turn the screw.
5. When you have established the proper voltage, stop the generator
and reinstall the top cover of the control box.
3.1.5 Installation options
Belt and pulleys
The most common installation connects the generator and engine
using a belt and pulleys, available from industrial supply sources.
■All engines vibrate and shake while running. The generator must
move with the engine or the belt that connects them will slip. The
engine and generator must therefore be mounted on a common
base, such as a steel plate. Installing rubber mounts on the bottom
of the baseplate prevents it from shifting during operation. See
Figure 3-2.
CAUTION
Improper installation can result in equipment damage and
severe injury.
To prevent the engine and generator from lifting off the baseplate,
ensure they are both securely fastened.

Owner’s Manual 15
Wanco Two-Bearing Belt-Drive Generators
Figure 3-2 Sample installation
■When mounting the engine and generator, remember that most
engine crankshafts turn counterclockwise (when viewing the
engine shaft straight on).
■Smaller pulleys require more belt tension to deliver sufficient
horsepower. To reduce the belt’s load on the crankshaft and
bearings, determine the correct pulley size based on the equation
in Figure 3-3.
■Altitude affects the horsepower performance of all engines. For
every 1000 feet above sea level, engine horsepower is reduced by
3.5%, consequently reducing the generator wattage by 3.5%.
■If the exact pulley size is not available, you must slightly adjust the
engine speed to compensate for the pulley diameter. It is important
to note that slower engine speed will result in less horsepower. The
result may be a lack of power sufficient to carry the full electrical
load of the generator.
■Most one- and two-cylinder engines have horsepower rated at 3600
RPM. If the engine and generator both operate at 3600 RPM, the
pulley diameter for the engine and generator will be the same.
Pulleys
Common
baseplate
Rubber mounts
Engine
Generator
Belt

16 Owner’s Manual
Wanco Two-Bearing Belt-Drive Generators
Figure 3-3 Equation for calculating pulley size
■Keep the pulley close to the engine. The outer edge of the pulley
should not extend more than 2 inches (50mm) past the end of the
crankshaft (see Figure 3-4). Greater distances will stress the shaft
and bearings.
■If a belt tensioner is used, it should be installed on the slack side run
of the belt (see Figure 3-5). If the tensioner is used as a drive clutch,
you may need to install a brake at the driven pulley to prevent
driven pulley rotation while belt tension is released.
■Avoid using an idler pulley whenever possible. If an idler must be
used, install it on the slack side of the belt (see Figure 3-5).
The equation for determining pulley diameter is:
The equation can be solved for any variable using simple algebra.
EXAMPLE: You want to operate an engine at 2400 RPM. You have an AR-Series
generator, which must always operate at 3600 RPM. You have a pulley on the
engine that is 7.0 inches in diameter. What diameter pulley should you use on
the generator?
Engine Speed
Generator Speed
----------------------------------------- Generator Pulley Diameter
Engine Pulley Diameter
----------------------------------------------------------------
=
2400
3600
------------Generator Pulley Diameter
7
----------------------------------------------------------------
=
2400 7
3600
---------------------Generator Pulley Diameter=
16800
3600
---------------4.67 Generator Pulley Diameter==