Winco TB4000 User manual

BRUSHLESS
TWO-BEARING
A Div~sion of Technology Znc GENERATORS
INSTALLATION,OPERATION, and MAINTENANCEINSTRUC-
TIONS
OWNERS MANUAL
-- -
A Division of -Dy& Techno/oogy fnc

Read and understand all instructions inthemanual
beforestarting and operating thegeneratorset.
USING THIS MANUAL
Congratulations on your choice of a Wnco generator
set. You have selected a high-quality, precision-engi-
neered generator set designed and tested to give you
years of satisfactory portable 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 WlNCO should you needservice assistance
inthe future.
TABLE OF CONTENTS
INTRODUCTION
12 MONTH WARRANTY
GUIDETOPRODUCTSAFETY
BASICINFORMATION
Specification Table
Unit Capabilities
Unpackingthe unit
lNSTALLATIONlOPERATlON
Assembly
Plan The Installation
Connecting The Load
Common Problems
PROPER USE AND INSTALLATION
You must be sure your new generator set is:
* Properlyserviced before starting
* 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 WlNCO generator has the same serial number as
yours. Itisimportantthatyou recordthenumberandothervital
informationhere. Ifyoushouldeverneedtocontactusonthis
unit it will help us to respondto your needs faster.
MODEL
SERIAL NUMBER
i PURCHASE DATE
i
1 DEALER
WINCO, Inc. 12 MonthLimited Warranty
WINCO, Incorporatedwarrantstotheoriginalpurchaser for 12 monthsthatgoodsmanufactured orsuppliedbyitwill
be free from defects in workmanship and material,provided such goods are installed, operated and maintained in
accordance withWinco written instructions.
WINCO'ssoleliability,andPurchaser'ssoleremedyforafailureunderthiswarranty,shallbelimitedtotherepairofthe
product. At WINCO'soption,material foundtobe defectiveinmaterialor workmanship undernormal useandservice
will be repaired or replaced. For warranty service, return theproduct within
12 months from thedate of purchase,
transportation charges prepaid, toyour nearest WlNCOAuthorized Service Center or to WINCO, Inc. at Le Center
Minnesota.
THEREIS NO OTHER EXPRESS WARRANTY.
Totheextentpermitted bylaw, any and all warranties,including those of merchantabilityand fitnessforaparticular
purpose, arelimitedto
12 months from dateof purchase. Inno eventis WINCOliable forincidental or consequential
damages.
Note:Somestatesdonotallowlimitation onthedurationofimpliedwarrantyandsomestates donotallowtheexclusion
orlimitation of incidental or consequential damages,so theabovelimitations may notapply in every instance. This
warranty gives you specific legal rights whichmay vary from state tostate.
WlNCOreserves therighttochangeor improveitsproducts withoutincurringany obligations tomakesuch changes
orimprovementonproducts purchased previously.
EXCLUSIONS:
WlNCO does not warrant engines, batteries, or other component parts that are warranted by their respective
manufacturers.
WlNCOdoes not warrant modifications oralterations whichwerenotmade by WINCO,Inc.

GUIDE TO PRODUCT SAFETY
This engine generator set has been designed and manu-
factured to allow safe, reliableperformance. Poor mainte-
L nance, improper or careless use can result in potential
deadlyhazards; fromelectricalshock,exhaustgasasphyxi-
ation, or fire. Please read all safety instructions carefully
beforeinstallationoruse. Keeptheseinstructionshandyfor
future reference. Takespecial note andfollow allwarnings
on the unit labels and inthe manuals.
ANSI SAFETY DEFINITIONS
2. FIREHAZARD-Gasolineandotherfuelsalwayspresent
a hazardofpossibleexplosionandlorfire.
a. Do not refuelwhen the engineisrunningor hot. Allow
theenginetocoolat leasttwominutesbeforerefueling.
b.Keep fuel containers out of reachof children.
c. Donotsmokeor useopenflame nearthegeneratorset
orfueltank.
d. Keep a fire extinguisher nearby and know its proper
use. FireextinguishersratedABC byNFPAareappro-
priate.
e.Storefuelonly inan approved container, andonly ina
well-ventilated area.
DANGER:
DANGERindicates animminentlyhazard-
oussituationwhich,
if notavoided, will
result
in death w serious injury. This
signalwordistobelimitedtothemost
extremesituations.
WARNING:
WARNING indicates a potentially hazard-
oussituationwhich, if notavoided, could
result
in deathorseriousinjury.
CAUTION:
CAUTIONindicatesapotentiallyhazardous
situationwhich,
if notavoided, mayre-
sult in minorormoderateinjury. Itmay
also be used to alert against unsafe
practices.
NOTE:
CAUTION is alsousedontheunitlabelsand
in this manualtoindicateasituationthat
couldresult
in serious damage orde-
structionoftheequipmentandpossible
personalinjury.
1. ELECTRICSHOCK- Theoutputvoltage presentinthis
equipmentcancauseafatalelectric shock. Thisequip-
mentmustbe operated bya responsibleperson.
a. Do not allow anyone to operate the generator without
proper instruction.
b.Guard against electric shock.
c.Avoid contact with liveterminals or receptacles.
d. Useextreme care if operatingthis unit in rainor snow.
e.Useonlythree-pronggroundedreceptaclesandexten-
L sion cords.
f. Be sure the unit is properly grounded to an external
ground rod driven intothe earth.
3. DEADLYEXHAUSTGAS-Exhaustfumesfromanygaso-
lineenginecontaincarbonmonoxide,aninvisible, odor-
lessanddeadly gasthatmustbemixedwithfreshair.
a.Operateonly inwell ventilated areas.
b.Never operate indoors.
c. Neveroperatetheunitinsuch
a way astoallowexhaust
gases to seep back into closed rooms (i.e. through
windows, walls or floors).
4. NOISEHAZARD - Excessivenoiseisnotonlytiring, but
continualexposurecanleadtolossofhearing.
a.Use hearing protection equipment when working
around this equipment for long periodsof time.
b.Keep your neighbors in mind when permanently in-
stalling this equipment.
5. CLEANLINESS-Keepthegenerator andsurrounding
area clean.
a. Removeall grease, ice, snow or materialsthat create
slippery conditions around the unit.
b. Remove any rags or other materialthat could create
potentialfire hazards.
c. Carefullywipeupanygasoroilspillsbeforestartingthe
unit.
d. Neverallow leavesorotherflammablematerialto build
up around the engine exhaust area.
6. SERVICINGEQUIPMENT-Allservice, includingthe in-
stallation or replacement ofservice parts, should be
performedonlybyaqualifiedtechnician.
a. Use only factory approved repair parts.
b. Do not work on this equipment when fatigued.
c. All belts, pullies andlor drive shafts must have protec-
tiveguardsandlor covers permanentlyinstalledbythe
assembler.
d.Never removethe protective guards, cover, or recep-
tacle panels while the engine is running.
e.Use extreme caution when working on electricalcom-
ponents. Highoutputvoltagesfromthisequipmentcan
cause serious injury or death.
f. Always avoid hot mufflers, exhaust manifolds, and
engine parts. They all can cause severe burns in-
stantly.
Page 1
TB SERIES

BASIC INFORMATION
TESTING POLICY:
Beforeany generator is shipped from thefactory, it is
fully checked for performance. The generator is
loadedto itsfull capacity, and the voltage, current, and
frequency arecarefully checked.
Ratedoutput of generators is basedon factory tests of
typical units, and is subject to, and limited by the
ambient operating temperature. The generatorwill
not providefull power output unless driven by a prime
mover of adequate horsepower. The prime mover
(engine or other input power source) horsepower is
also affected by temperature as well as a number of
other factors such as: fuel, altitude, and all other
conditions specified by the prime mover manufacturer.
INTRODUCTIONAND DESCRIPTION
The generator is a 3600 rpmtwo bearing, belt driven,
brushless, revolvingfield design. The generator is self
excited and inherently regulatedto
+I- (plus or minus)
7%
- no loadto full rated load. Itcan be operated
under any load within its rating without being dam-
aged. The frequency regulationis determinedby the
sensitivity of the customer supplied prime movers'
governor. It is desirable to maintainthis speed to
within 3 cyclesvariation (61.5 Hz
- 58.5 Hz) no loadto
full rated load (3690 rpm
- 3510 rprn).
GeneratorSpecifications
MODEL WATS VOLTS AMPS HZ PH RPM
UNIT CAPABILITIES
1. GeneratorConi-lections - The diagrambelow represents
atypicalordinary4000wattgenerator. Only2000watts at
120volts(16.7Amps) canbetakenfromthegeneratorat
receptacle A and up to 2000 watts at 120 volts from
receptacleC. Onanordinarygenerator,CAUTIONMUST
BEEXERCISEDTOPREVENTOVERLOADINGEITHER
OFTHE 120VOLT CIRCUITS (A OR C).
CONVENTIONAL DUAL VOLTAGE
120/240 VOLT SCHEMATIC -
Neutral A A
--
E 120 Volts Gro~nd~k'2$ocles r\
TYPICAL 4000 WATT GENERATOR
The following currents (measuredin amps) are producedat
120
& 240 volts for typical wattage shown.
AMPSAT 120 VOLT 240 VOLT
RECEPTACLEID
MODEL A C B
TB1500C 12.5 NIA NIA
TB2400C 20 NIA NIA
TB4000C 16.7 16.7 16.7
TB4000* 16.7 16.7 16.7
TB6000C 2 5 25 25
TB6000* 25 2 5 25
TB7200** 30 30 30
'Customer connectionsare made on the back side
of the circuit breaker
** This unit has a junction box rather than recep-
tacles. Ref."amistheGIlead, Ref."c" isthe G3 lead
and Ref.
"b" isGIto G3 rating
2. Starting Electric Motors - Electric motors require much
morecurrent(amps)to startthemthanto runthem. Some
motors, particularly low cost split-phase motors, are very
hardtostartandrequire5to7timesasmuchcurrenttostart
them as to runthem. Capacitor motorsare easier to start
and usually require 2 to 4 times as much current to start
them as to runthem. Repulsion Induction motors are the
easiestto start and usually require 1-112to 2-112 times as
much to start them as to run them.
Most fractional horsepower motors take about the same
amount of current to run themwhether they are of Repul-
sion-Induction (RI), Capacitor (Cap), or Split-Phase (SP)
type. The chart below shows the approximate current
requiredto start and runvarious types of sizes of 120volt
-
60 cycle electric motors under average load conditions.
TB SERIES
Page 2 60706-098

BASIC INFORMATION
RUNNING STARINGAMPS
HP AMPS SP CAP RI
-
116 3.2 16T022 6 TO13 ST0 8
114 4.5 22TO32 9T018 7T012
113 5.2 26TO35 10T02 18T017
112 7.2 NOTMADE 14TO2911TO18
1 13.0 NOTMADE 26 TO 52 20 TO 33
The figures given above are for average load such as a
bloweror fan. Iftheelectric motorisconnectedto a hard
starting load such as an air compressor, it will require
morestartingcurrent. Ifit isconnectedto a light load, or
no load such as a power saw, it will require less starting
current. The exact requirement will also vary with the
brand or design of the motor.
For240 volt motors,the"running"current ishalfas much
as shownfor the 120volt motorsofthe samesize. Some
dual voltage 1201240volt motors are difficult to start on
240 voltswhen driven by enginelgeneratorsand can be
started more easily when connectedto operate on 120
volts. Thisisparticularlytrueof"capacitorstart-induction
run" motors. Sometimes a 240 volt motor which cannot
bestartedonthe240voltcircuitofa1201240voltgenerator
can be started on a 120 volt circuit and then auicklv
Generator
Model MotorSize
(code
"G" capacitorstart)
Tryingto starta largermotor or highercode (ie. J or K)
motormayresultindamagetoboththegeneratorandthe
electricmotorespecially
120 volt motors.
UNPACKING INSTRUCTIONS
** NOTICE **
When unpackingthe generator, be sure to inspectit
carefully for freight loss or damage. If loss or damage
is noted at the time of delivery, requirethat the person
makingthe delivery make a note of the loss or damage
on the freight bill, or affix his signature under the
consigner's memo of the loss or damage. Contact the
carrier for claim procedures.
switchedto the240voltcircuitafter it isstarted. c his cai
be done in applications where the motor is manually When lossor damage is noted afterdelivery, segre-
controlled and is started under "no load" conditions. gate the damaged material, and contact the carrier for
claim procedures.
A self-excited generator responds differently to severe
overloading than the power line. To illustrate, suppose
-, that a 240 volt 10 H.P. "capacitor start-Induction Run"
motor is connected to the generator. The engine would
not be ableto supply enough power to bring the electric
motor up to operating speed. The generator would re-
spond with high initial starting current, but the engine
would be very severely overloaded. The speed would
probably drop sharply and possibly stall the engine. If
allowedto operate at very low speeds, the electric motor
startwindingwouldburnout inashorttime. Thegenerator
winding might also be damaged.
Onthe other hand, supposea smallerelectric motorthat
requiresjust a little more output than the generator can
produceisconnectedtoit. Itwilltrytorunbutwillnotreach
a highenough speedfor the internalcentrifugalswitchto
disconnect the starting winding. The generator output,
instead of being 120volts, may drop to 70 or 80 volts.
RUNNING THE GENERATORSET UN-
DER EITHER OF THESE CONDITIONS
"CONCEALEDDAMAGE" is understoodto mean
damage to the contents of a package which is not in
evidenceat the time of delivery bythe carrier, butwhich
is discovered later. The carrier or carriersare respon-
sible for merchandise lost or damaged in transit. The
title to goods rests with the consignee when genera-
tors are shippedfob factory, and only the consignee
can legally file claims.
1. Carefullyopen carton.
2. After inspectingthe generatorfor externalphysical
damage, check for the owner's manual (operating
instructions, wiring diagram, parts list) inside the
carton.
2. Removegenerator hold down bolts.
4. Unit can now be lifted from shipping base.
**** CAUTION ****
COULD RESULT IN DAMAGE TO THE
Before proceedingwith the installation, be sure that you
GENERATORSTATORASWELLASTHE
have completely read and understand the assembly
MOTOR WINDING. and installation instructions.
Because the heavy surge of current requiredfor starting
motors is required for only an instant, the generator will
ASSEMBLY
not bedamaged ifit can bringthe motorup to speed ina
few secondsoftime. Ifdifficulty isexperiencedinstarting 1.An engine with adequate horsepower and a close
motors, turn all other electrical loads off and if possible regulating (fixed speed) governor is requiredfor
L
reducethe load on the electric motor. satisfactory operation of any alternatingcurrent
3. Motor Starting Ca~acitv - listedbelow vou will find the generator.
motor starting ~>~al;ilit~bf your engine ienerator set.
60706-098 Page 3 TB SERIES

INSTALLATION
These units require approximatelytwo (2) horsepower
for every 1000watts of generatoroutput. Theoretically
you should be able to produce 1000watts with
1.4
Horsepower, but this is only possiblewith 100%
efficiencies in boththe engine and the generator.
Betweenengine and generator efficiencies of only
80%
to 90% and the lossesthrough the drive systemthe two
horsepower requirement is more realistic.
For example, this 1,500 watt generator output will
require a 3 or 4 h.p. Enginefor full output, good speed
I
voltage regulation, and satisfactory load performance.
2. When determining the prime mover I generator pulley
ratioto drivethe generator at the correct operating
speed, bear in mind that the power ratingof most prime
movers (usually an engine) varies with the speed-that
is, it produces more power at higher speeds, less when
slowed. The prime mover must be run fast enoughto
reachthe desired horsepower for good generator set
operation.
The drive belt system must beof adequate size and
must be tight enough to powerthe generator without
slippage. Becarefulnotto overtightento the extentthat
it puts excessive strain on the bearings--doing so can
cause bearingfailure and other possibledamage to the
generator.
Alignment ofthe generator to the prime mover is
important. Misalignment of the pullieswill cause
excessive belt and pulleywear and unnecessary stress
on the prime mover.
3. The following table shows the effect of various operating
speeds and electrical loads on a typical generator when
matched and mounted to an adequate prime mover
togetherwith the natural "voltage drop" withinthe
generator itselfdue to loadcurrent and heatingof the
windings, results in a slightly lower voltage than when
--
the generator is running idle.
The normal, slight variations in speed also directly affect
thefrequencyof the output current. Thisfrequency
variation has no appreciable effect in the operation of
most loads (such as motors, lights and most small
appliances). However, timing devices and clocks will
not keep perfect time unless the engine can keepthe
generator running at exactly 3600 rpm at all times.
Since this is not usually possible, minor time errors in
clocks occur.
The speed of the engine is usually adjusted so that the
generator produces proper voltage. Ifthe adjustment is
made "cold", set the voltage a little higher than normal
since itwill drop a few volts as the generator warms up.
**" CAUTION ****
When operating continuously at full load the generator
shell becomesvery warm. Itwill be uncomfortableto
the touch-this is normalfor any high performance
inherently regulated generator.
Outputvoltageshouldbecheckedperiodicallyto
insureproperoperationofthegeneratingplantand
appliances.
**** CAUTION "**
-
Low voltage may damage any motors or appliances
connectedto it. Runningthe generator at excessively
high speeds results in too high voltage which will also
damage electrical devices connectedto it. Excessively
high speed may also cause damage to the generator
stator windings.
Although individualunits and models may vary slightly,
the normalvoltage andfrequencyoftypical60 cycle
generators described in this book are approximatelyas
follows when powered by a typical prime mover (engine)
runfirst with no load applied, then at halfthe generator
capacity and finally when loadedto itsfull capacity as
rated on the nameplate:
GENERATOR
LOAD SPEED FREQUENCY VOLTAGE
NONE 3690RPM 61112 HZ 129VOLTS
HALF 3600RPM 60HZ 120VOLTS
FULL 3510RPM 58 112 HZ 115VOLTS
**** CAUTION ****
Required generator speed must be maintained at 3600
+I- 90 rpm under all load conditions.
4.All engines havea tendency to slow down when a load
is applied. The governor on the engine is designedto
holdthe enginespeed nearly constant. When the
electrical load connected to the generator is increased,
the engine is more heavily loaded and as a result the
speed drops slightly. This slight decrease in speed
PLAN THE INSTALLATION
Plans for installation should be prepared with proper
attention to mechanical and electrical engineering detail
to assure a satisfactory system installation. The
informationin this manual is offered as a guide to
finalizing your installation plans. The installation
sequence is summarized below:
Generally these two bearing generators are used on
portable equipment. For best service consider the
following
:
1.All electrical equipment should be protected from
excessive moisture. Failure to do so will result in
deteriorationof the insulation and will result in short
circuits and grounds.
2. The generator should be installed in a sheltered area. If
the unit must be left in the open, it should always be
protectedwith a weather cover such as a tarp or large
-
piece of canvas after each useto keep out water and
dust.
TB SERIES P
'age 4 60706-098

BASIC OPERATION
"* CAUTION ****
Always allow the generator and prime mover to cool
-
before coveringwith a flammableweather covering.
**** CAUTION *"*
The generator must be mountedwith the engine to a
common rigid base to prevent stress on the engine
and generator shafts and bearings due to
vibration displacement. For permanent installations,
the engine-generator is usually mounted on a sub-
frame which can be shock mounted with special
neoprene pads on the main frame.
CONNECTING THE LOADS
1. ApplyingTheLoad - Ashortwarm-uptimewillpermitthe
engineto work more efficiently when the load is applied
and will reducethewear and extend its life.
a. Rece~tacleshavebeenDrovided on the control Dane1
pump and other itemsto bepowereddirectlyinto
the generator receptacles. Before plugginginall
the tools and cord sets, recheck the rating of the
generator set. Be sure itcan handlethe intended load
and iscompatiblewiththevoltage, phase, and current
ratings.
f. 'HardWiring'thisunitdirectlyintoatemporaryconstruc-
tion site electrical system is NOT A SIMPLE DO-IT-
YOURSELF JOB. For your safety all wiring must be
done by a qualified electrician and conform to the
National Electric Code and comply with all state and
localcodes and regulations. Check with localauthori-
ties before proceeding.
****WARNING""
PERSONAL DANGER A fully isolated, double pole
double throw manualtransfer switch must be installed
anytime a generatorisbeingconnectedto an existing
distribution system.
tocohecttheloadsonthemodels, TBI ~OOC, TB~~OOC,
TB4000C,TB6000C. OnthemodelsTB2400,TB4000,
**"CAUTION"*
TB6000the connectionsare made onthe backside of EQUIPMENTDAMAGE
- Failureto properlylimitandbal-
the circuit breakers. The TB7200 has a junction box ance the load applied to the generator will cause the
mountedonthetopofthe generator.The loads should generator to produce low voltage and may damage the
be applied gradually. If a large motor is being started enginegeneratorset. Itmay also cause severe damage
or multiple motors are being started, they should be to the loads connected to the generator at that time.
started individually and the largest should be started Improper loading of the generator set constitutesabuse
first. andwill not be covered bywarranty.
L
**" CAUTION ****
EQUIPMENTOVERLOAD-Keepthegeneratorloadwithin
the generator and receptacle nameplate rating. Over-
loading may cause damage to the generator andlor the
loads
b.Mostelectrictools andapplianceswill havethevoltage
and amperagerequirementson their individual name-
plates. When in doubt consult the manufacturer or a
local electrician. The nameplateamperage rating for
electric motorscan be misleading. See "StartingElec-
tric Motors"in SpecificationSection.
c. These engine generator sets are inherently self regu-
lating based on engine speed. The engine governor
will automatically adjust itselfto the load. No harmto
the generator will result if it is operated with no load
connected.
d.Proper.utilization amperage is necessary to prevent
damage to eitherthe receptacleslbreakersor the gen-
erator. The generator is a limited source of electrical
power,therefore payspecialattentiontothe receptacle
and generator ratings. The nameplate rating can be
obtained through a combination of receptacles or a
single receptacle as long as the receptacleamperage
ratingisnotexceeded. Boththe 120and240voltoutput
can be utilized at the same time. See Specification
Section for proper load separation.
e. Plug your tools such as drills, saws, blowers, sump
COMMON PROBLEMS
Sometimes problems can be easily solved by checking
a few basicthings. Check below before you call or take
your unitto a servicecenter. Itcouldsaveyou time and
money.
Voltagetoolow *Engine speed is too low.
*Generator overloaded.
*Defectivestator.
*Defective rotor (field).
Circuit BreakerTrips 'Defective load.
*Defective receptacle.
Voltagetoohigh *Engine speed is too high.
Generatoroverheating *Overloaded.
*Insufficient ventilation.
Nooutputvoltage *Short in load (disconnect).
*Broken or loose wire.
*Defective receptacle.
*Defective capacitor.
*Defective diode.
*No residual magnetism in
generator.
*Defective stator.
"Defective rotor (field).
60706-098 Page 5 TB SERIES

UNMARKED
WIRINGDIAGRAMS
EXClTATlON
WINDING
(STATOR)
LEADS EXCITATION
FIELD RECTIFIERS
COILS
(ROTOR)
CIRCUIT
BREAKERS
A.C. OUTPUT
WINDING
(STATOR) 1
EXClTATlON WINDING
CIRCUIT BREAKER RECEPTACLES
7 *--
CAPACITOR
UNMARKED RECTIFIERS
LEADS COILS
(ROTOR)
EXCITATION WINDING
EXCITATION
UNMARKED RECTIFIERS
LEADS COILS
(ROTOR)
CIRCUIT BREAKER
wd , rn
A.C. OUTPUT f
WlNDlNG 120
VOLTS
VOLTS
120 1
kr_, BREAKER vOrl
A Division of DTL DpTechno/ogyfnc
225 SouthCordovaAvenue
Le Center,Minnesota
56057